description
stringlengths 2.98k
3.35M
| abstract
stringlengths 94
10.6k
| cpc
int64 0
8
|
|---|---|---|
FIELD OF THE DISCLOSURE
The present disclosure relates to safety systems and methods for a vehicle, and in particular to a system and method for determining if a driver of a vehicle is using an electronic device.
BACKGROUND
Driving while using an electronic device, for example a smartphone, is one of the leading causes of traffic accidents in the United States. The United States Department of Transportation notes that cell phones contribute to 1.6 million auto accidents each year which cause 500,000 injuries and take 6,000 lives. Many states require that electronic devices only be used in a hands-free mode while driving a vehicle, and have taken other steps to discourage use of electronic devices while driving a vehicle.
There are several approaches to solving the problem of detecting when an electronic device is being used in a vehicle. Some of these approaches are simplistic, for example assuming that if the device is moving above walking speed, then the device must be in a moving vehicle. These approaches use the GPS sensor on the device to determine the speed of the device. However, these approaches do not distinguish between the driver of the vehicle and the passenger(s), thereby providing inaccurate results at best. Other approaches attempt to solve the driver versus passenger dilemma by asking the user of the device a question that requires intense concentration. For the passenger, this is no problem at all. For the driver, answering a question that requires intense concentration violates the very reason for the vehicle safety system: preventing distracted driving of a vehicle. A few approaches use the accelerometer and gyroscope sensors to detect movement of the mobile device; but these approaches also cannot distinguish who is causing the movement of the mobile device: the driver or a passenger.
Prior solutions have attempted to solve the driver versus passenger identification problem by challenging the electronic device user with a simple “unlock” test. This approach works by placing a test on the device screen when the vehicle is in motion, such as a math problem. The theory is that solving the test requires the device user to focus on the screen. Unfortunately, this approach requires additional driver attention on the device screen to solve the test, which presents the unintended consequence of actually making the problem worse since solving the test requires the driver to focus on the test, further distracting the driver from actually driving the vehicle.
It would be desirable to have a system and method to perform one or more of the following: to determine if a driver of a vehicle was using an electronic device while the vehicle was moving, to distinguish between driver and passenger usage of the electronic device, and to disable certain features of the device for driver usage while the vehicle is moving.
SUMMARY
An electronic beacon, for example a Bluetooth beacon, can be used to locate an electronic device, for example a mobile device or cell phone, within a vehicle and to determine if the device is being used in hands free mode. Accelerometers, gyroscopes or other sensors in the electronic device or the vehicle can be used to determine if the electronic device is being used. Global Positioning System (GPS) or other sensors in the electronic device or the vehicle can be used to determine if the vehicle is moving. From this information, the system can determine if the driver is using an electronic device while the vehicle is moving. The system can distinguish driver mobile device usage from passenger mobile device usage.
In some embodiments, the system can disable certain features on the device when the system determines that the device is in a vehicle that is moving and the device is in close proximity to the driver. The device features that can be disabled can include, but are not limited to sending and receiving text messages, sending and receiving e-mails, accessing the Internet via Web browser, and placing and receiving telephone calls.
A vehicle safety system is disclosed that controls usage of a mobile device in a vehicle. The vehicle safety system includes an electronic beacon, a proximity sensor, a movement sensor and a processor. The electronic beacon is located in the vehicle, and the electronic beacon transmits a location signal. The proximity sensor generates device location data using the location signal. The device location data monitors the location of the mobile device in the vehicle. The movement sensor detects movement of the vehicle or the mobile device, and generates movement data. The processor receives the device location data and the movement data, determines whether the mobile device is being used by a driver of the vehicle using the device location data, and determines whether the vehicle is moving using the movement data. The processor monitors usage of the mobile device based on whether the mobile device is being used by the driver of the vehicle while the vehicle is moving. On some mobile platforms, the processor can also limit usage of the mobile device while the vehicle is moving.
The electronic beacon can be a Bluetooth beacon that transmits a Bluetooth signal, and the proximity sensor can be a Bluetooth component on the mobile device that detects the Bluetooth signal of the electronic beacon. The motion sensor can be a GPS sensor on the mobile device that detects movement of the mobile device. The electronic beacon can be located in the vehicle between a steering column and a driver-side doorjamb.
The vehicle safety system can also include a device usage monitor and an enforcement list of mobile device functionality. The device usage monitor detects functionality of the mobile device being used, and generates functionality data that indicates what functionality of the mobile device is currently being used. The enforcement list indicates mobile device functionality to be limited by the vehicle safety system when the mobile device is being used by the driver of the vehicle while the vehicle is moving. The processor can receive the functionality data, determine if any functionality of the mobile device currently being used is on the enforcement list, and if any functionality of the mobile device currently being used is on the enforcement list then the processor can limit that functionality of the mobile device according to the enforcement list.
The vehicle safety system can also include device motion sensors that detect motion of the mobile device in the vehicle, and that generate device motion data. The processor can receive the device motion data and determine whether the driver of the vehicle is moving the mobile device using the device location data and the device motion data. The processor can limit usage of the mobile device based on whether the mobile device is being used by the driver of the vehicle while the vehicle is moving and whether the driver of the vehicle is moving the mobile device while the vehicle is moving. The device motion sensors can be an accelerometer sensor and a gyroscope sensor on the mobile device.
The processor can determine a device motion/usage profile using the device motion data and the functionality data. At selected upload times, the processor can transmit the device location data, the movement data, the functionality data, the device motion data and the device motion/usage profile to a server.
A vehicle safety method for controlling usage of a mobile device in a vehicle is disclosed that includes generating device location data indicating the location of the mobile device in the vehicle; generating vehicle movement data indicating whether the vehicle is moving; determining whether the mobile device is being used by a driver of the vehicle based on the device location data; and limiting usage of the mobile device based on whether the mobile device is being used by the driver of the vehicle while the vehicle is moving.
Generating device location data and determining whether the mobile device is being used by the driver can include using a wireless receiver on the mobile device to receive a location signal from an electronic beacon located in the vehicle; determining a distance between the mobile device and the electronic beacon using the location signal; and determining whether the distance between the mobile device and the electronic beacon locates the mobile device at a driver's seat or at a passenger seat in the vehicle. Alternatively, generating device location data and determining whether the mobile device is being used by a driver of the vehicle can include using a wireless receiver on the mobile device to receive location signals from one or more electronic beacons located in the vehicle; determining a distance between the mobile device and each of the one or more electronic beacons using the location signals; determining a device location using the one or more distances between the mobile device and each of the one or more electronic beacons; and determining whether the device location locates the mobile device at a driver's seat or at a passenger seat in the vehicle.
The vehicle safety method can also include monitoring activation and usage of functionality of the mobile device; generating device functionality data indicating activation and usage of functionality of the mobile device; maintaining an enforcement list of mobile device functionality to be limited when the mobile device is being used by the driver of the vehicle while the vehicle is moving; determining if any functionality of the mobile device that is on the enforcement list is attempting to activate, and if any functionality of the mobile device on the enforcement list is attempting to activate, limiting or disabling activation of that functionality of the mobile device according to the enforcement list. In an embodiment where text messaging is on the enforcement list, the vehicle safety method can include allowing a user to edit a default response text message to be sent in response to any text message received by the user while the user is driving the vehicle and the vehicle is moving; detecting receipt of a text message on the mobile device of the user; and automatically sending the default response text message in response to the received text message received by the user if the user is driving the vehicle and the vehicle is moving.
The vehicle safety method can also include generating device motion data indicating motion of the mobile device in the vehicle; determining whether the driver of the vehicle is moving the mobile device; and generating a device motion/usage profile indicating usage of the mobile device by the driver based on the functionality data and the device motion data. Generating device motion data can include monitoring accelerometer outputs of an accelerometer sensor on the mobile device; monitoring gyroscope outputs of a gyroscope sensor on the mobile device; computing a gross movement vector based on the accelerometer outputs and the gyroscope outputs; and determining motion of the mobile device in the vehicle based on the difference between the gross movement vector and a minimum movement threshold.
The vehicle safety method can also include scoring the driver of the vehicle based on the device motion/usage profile while the driver is driving the vehicle. The vehicle safety method can also include uploading the device location data, the vehicle movement data, the functionality data, the device motion data and the device motion/usage profile to a server. The vehicle safety method can also include allowing an administrator to customize the enforcement list of mobile device functionality to be limited when the mobile device is being used by the driver of the vehicle while the vehicle is moving.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned aspects of the present disclosure and the manner of obtaining them will become more apparent and the disclosure itself will be better understood by reference to the following description of the embodiments of the disclosure, taken in conjunction with the accompanying drawings, wherein:
FIG. 1 shows an exemplary vehicle interior with one or more electronic beacons;
FIG. 2 shows an exemplary electronic device that includes a screen and control buttons;
FIG. 3 illustrates example components for an example electronic device;
FIG. 4 illustrates an exemplary method for a vehicle safety system;
FIG. 5 shows the sensor data for a scenario where the device is in a vehicle that is moving but has not been picked up;
FIG. 6 shows the sensor data for a scenario where the device is in a vehicle that is moving and has been picked up once; and
FIG. 7 illustrates an example of the driver safety system storing and forwarding sensor and/or motion profile data from the device to a server.
Corresponding reference numerals are used to indicate corresponding parts throughout the several views.
DETAILED DESCRIPTION
The embodiments of the present disclosure described below are not intended to be exhaustive or to limit the disclosure to the precise forms in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present disclosure.
FIG. 1 shows the interior of an exemplary vehicle 100 with electronic beacons 110 , 112 . The interior of the vehicle 100 also includes a steering wheel 102 , a steering column 104 , a driver-side door jamb 106 , a driver seat 108 , a passenger seat 118 and a center console 120 . One electronic beacon 110 is located in the interior of the vehicle 100 near the driver seat 108 . In FIG. 1 , the beacon 110 is located in front of the driver seat 108 between the steering column 104 and the driver-side door jamb 106 . Placing the beacon 110 on the driver's side of the vehicle 100 in close proximity to the steering column 104 can help differentiate between driver and passenger usage of an electronic device. Additionally or alternatively, the electronic beacon 112 can be placed in the vehicle 100 , for example near or on the center console 120 and the system could differentiate between driver and passenger usage of an electronic device based on distance and direction from the beacon 112 . The locations of the one or more beacons 110 , 112 shown in FIG. 1 are exemplary, and other locations can be selected in different system embodiments and vehicle layouts.
FIG. 2 shows an exemplary electronic device 200 that includes a screen 202 and control buttons. The control buttons include touchscreen controls 204 and physical controls 206 . The control buttons 204 , 206 allow a user to perform various functions using the electronic device 200 including, for example, making a telephone call, typing, texting, checking messages, etc. The electronic device 200 also includes various electronic components, for example processors, sensors, memories, transmitters, receivers, etc. FIG. 3 illustrates possible components for an example electronic device 200 , including an operating system 300 , a driver safety component 302 , a user interface component 310 , a WiFi (Wireless Fidelity) wireless networking component 312 , an accelerometer sensor 320 , a gyroscope sensor 322 , a GPS sensor 330 , a Bluetooth wireless component 332 , a telephone component 340 and a camera 342 . The device 200 can have more or less components or different components than those shown in FIG. 3 . The driver safety component 302 can be resident on the electronic device 200 , the vehicle 100 , one of the beacons 110 , 112 , or divided between two or more of these locations.
One or both of the beacons 110 , 112 and the components of the electronic device 200 can be used to precisely locate the electronic device 200 within the vehicle 100 and to determine if the electronic device 200 is being used in hands free mode. A component of the electronic device 200 can be used to determine the distance of the electronic device 200 from the beacon 110 . For example, if the beacon 110 is a Bluetooth beacon, the Bluetooth component 332 of the electronic device 200 can be used to determine the distance to the beacon 110 . The accelerometer sensor 320 and the gyroscope sensor 322 of the electronic device 200 can be used to determine if the electronic device 200 is being moved within the vehicle 100 . The GPS sensor 330 of the electronic device 200 can be used to determine if the vehicle 100 is moving. The operating system 300 can report to the driver safety component 302 , or the driver safety system 302 can directly determine, these sensor readings and if other functionality of the device 200 is being activated. Combining this information, the driver safety system 302 can determine if the driver is using the electronic device 200 while the vehicle 100 is moving and what functionality of the device 200 is being used. The placement of the beacon 110 near the driver's seat 108 and away from the passenger seat 118 enables the system to separate driver mobile device usage from passenger mobile device usage using the single beacon 110 .
An exemplary control method 400 for a vehicle safety system is illustrated in FIG. 4 . The following description will use the vehicle and devices illustrated in FIGS. 1-3 by way of example and not limitation. The driver safety component 302 and control flow 400 can be resident on the electronic device 200 , the vehicle 100 , one of the beacons 110 , 112 or divided between two or more of these locations. The following exemplary description uses the beacon 110 of FIG. 1 , but can easily be expanded to include one or more additional beacons, such as beacon 112 , or a beacon in another location.
The beacon 110 can be registered with the device 200 and the driver safety method can be manually or automatically activated when the device 200 comes into close proximity of the beacon 110 . This can take place similar to how an electronic device can be registered with an automobile Bluetooth system, and then will be recognized for hands free functions when in close proximity of the automobile.
At block 402 , the driver safety system determines the location of the electronic device 200 in the vehicle 100 . The beacon 110 can be a Bluetooth Low Energy (BLE) beacon that is located near the driver seat 108 between the driver side door jamb 106 and the steering column 104 of the vehicle 100 . The Bluetooth component 322 on the electronic device 200 can calculate the distance to the beacon 110 . The driver safety system can separate distances into multiple categories: for example, immediate, near, far and unknown. As an example, the immediate category can include distances of less than 1 meter, the near category can include distances from 1 to 10 meters, the far category can include distances from 10 to 50 meters, and the unknown category can include distances greater than 50 meters. The distance between the device 200 and the beacon 110 can be used to determine the location of the device 200 in the vehicle 100 . Based on this location and/or category, the user of the device 200 can be classified as either Driver or Passenger. The immediate category can be used to represent the Driver and the near category can be used to represent a Passenger.
At block 404 , the driver safety system determines if the device 200 is in a vehicle 100 that is moving. Many electronic devices and vehicles come equipped with GPS (Global Positioning System) sensors that can be used to determine current location as well as speed. The GPS sensor 330 of the device 200 can be used to determine if the device 200 is in a moving vehicle. The GPS sensor data indicates the speed at which the device 200 is traveling. Any speed above zero indicates that the device 200 is moving. When combined with the beacon detection determined at block 402 , the driver safety system can determine where the device 200 is in the vehicle 100 and whether that vehicle 100 is moving.
At block 406 , the driver safety system determines if the device 200 is being moved within the vehicle 100 . Many electronic devices come equipped with three-dimensional accelerometer and gyroscope sensors that can be used to determine if the device is being moved. The accelerometer and gyroscope sensors 320 , 322 of the device 200 can be used to determine if the device 200 is being moved. An exemplary method for detecting motion is to use six data points: Accelerometer X value (A x ), Accelerometer Y value (A y ), and Accelerometer Z value (A z ) from the accelerometer sensor 320 ; and Gyroscope X value (G x ), Gyroscope Y value (G y ), and Gyroscope Z value (G z ) from the gyroscope sensor 322 . The individual sensor readings fluctuate slightly over time; however, when treated as a vector, large changes indicate movement of the device 200 . A gross movement vector (v) for the device 200 can be calculated as:
v =Square Root ( A x 2 +A y 2 +A z 2 +G x 2 +G y 2 +G z 2 )
The device accelerometer and gyroscope sensors 320 , 322 typically report these values several times per second and indicate changes in acceleration and rotation of the device 200 . A MINIMUM_THRESHOLD value can be used to eliminate minor fluctuations in the gross movement vector v. When the calculated value of the vector v is above the MINIMUM_THRESHOLD, the driver safety system can determine that the device 200 is being moved.
At block 408 , the driver safety system characterizes a motion and/or usage profile of the device 200 . The motion detection of device 200 at block 406 detects gross movement of the device 200 , and each of these device movements can be further classified by examining the trends in the sensor data and other information. For example, when the accelerometer vector (A x , A y , A z ) shows large changes, but the gyroscope vector (G x , G y , G z ) shows little or no changes, the system could determine that the device 200 is being picked up, as evidenced by the rapid acceleration. Whereas, if the accelerometer vector shows little or no changes, but the gyroscope vector shows large changes, the system could determine that the device 200 is being tapped on, as evidenced by the slight twisting motion caused by the tapping. The driver safety system can categorize and catalog the motions and usages of the device 200 into a “motion/usage profile”. This motion/usage profile can include but is not limited to the following types of device motions and usages, which are each described with an example of how they can be detected:
Picking up—The device was picked up from a resting position
accelerometer vector shows large changes, gyroscope vector shows small changes, altitude increases
Putting down—the device was put down after being in use
accelerometer vector shows large changes, gyroscope vector shows small changes, altitude decreases
Typing—the device is being used to type in an application (Email, notes, etc.)
accelerometer vector shows small changes, gyroscope vector shows large changes and/or detection by operating system 300
Swiping—user is using his/her finger to swipe content on the screen 202 of the mobile device 200 . The swiping motion is typically either left-to-right or right-to-left, but could also be top-to-bottom or bottom-to-top or combinations thereof.
swiping motion can be detected by the operating system 300 of the mobile device 200 . For example, the user interface component 310 can detect and report activation of a screen touch subsystem monitoring user touching the screen 202 ; these events can include tap, double-tap, pinch-zoom, scroll up/down and others.
Zooming—user is using his/her fingers to zoom in or out content on the screen 202 .
zoom motion can be detected and reported by the operating system 300 and/or user interface component 310 , as explained above.
Taking picture—user is taking a picture using the camera 342 on the device 200 .
if the device 200 has a camera 342 , activation of the camera 342 can be detected and reported by the operating system 300 and/or camera component 342 .
Making phone call—user is making a call using the telephone 340 on the device 200 .
if the device 200 has a telephone 340 , activation of the telephone 340 can be detected and reported by the operating system 300 and/or telephone component 340 .
Making phone call with in hands-free mode—user is making a telephone call with the device using a hands-free mode/device
hands-free mode can be detected by the operating system 300 on the mobile device 200 ; for example, the Bluetooth component 332 and accessibility subsystems on the device 200 and vehicle 100 can report when a Bluetooth hands-free device is in use.
The sensor readings, detected functionality activation or usage, and other relevant information of the device 200 can be received directly by the driver safety system or reported to the driver safety system by the operating system 300 or other component of the device 200 .
The types of motions characterized by the system can be customized by using a combination of sensor values and rules. This extensible system allows operators of the system to change the motion and usage profile settings based on the policies being enforced. For example, if the system is deployed using devices that utilize a bar-code scanner, the operator could define a motion profile for the scanning motion. This profile could be used for monitoring package delivery drivers who are scanning packages while driving. Each motion profile can define which sensors and applications are being used and which values are required to satisfy the motion/usage profile.
FIG. 5 shows example sensor data for a scenario where the device is in a vehicle that is moving but has not been picked up. In FIG. 5 , the speed of the vehicle is indicated by a speed line 510 , and the forward movement of the vehicle shows some movement of the gyroscope X value (G x ) indicated on a gyroscope-X line 520 . FIG. 5 also shows the gyroscope Y and Z values (G y and G z ), the roll, pitch and yaw values, and the gross movement vector v which all remain fairly stable around a zero Y-value. The roll, pitch and yaw values can be computed from the gyroscope and accelerometer values used in computing the gross movement vector v. Random jitter of these values over time can be due to vibration in the car due to road conditions, i.e. bumps, uneven pavement, turns, etc.
FIG. 6 shows example sensor data for a scenario where the device is in a vehicle that is moving and has been picked up once. In FIG. 6 , the speed of the vehicle is indicated by a speed line 610 , and the forward movement of the vehicle shows some movement of the gyroscope X value (G x ) indicated on a gyroscope-X line 620 . FIG. 6 also shows the gyroscope Y and Z values, the roll, pitch and yaw values, and the gross movement vector v which all remain fairly stable around a zero Y-value except during the pick-up event. The gyroscope and accelerometer values and the gross movement vector v, which is a function of those values, all move simultaneously during the pick-up event which occurs just before time 400 on the x-axis. The simultaneous movement of the gyroscope and accelerometer values due to the pickup of the mobile device causes the gross movement vector v (defined above) to exceed a threshold amount, which can indicate to the system that a mobile device pick-up event has occurred.
At block 410 , the driver safety system can disable one or more features on the device 200 . On some device platforms, application developers are permitted to customize and even disable certain features of the platform. For example, on Google's Android operating system, a developer can implement code that listens for incoming text messages and prevents the user from seeing those messages while in a moving vehicle. This may be beneficial for a driver, but not for a passenger of the vehicle. Feature disablement can include, but is not limited to, sending and receiving text messages, sending and receiving e-mails, accessing the Internet via Web browser, and placing and receiving telephone calls.
Feature disablement can be accomplished by monitoring the list of current applications that are running on the device 200 , and comparing this list against all applications that the system is authorized to block (text messaging, e-mail, web browser, phone, etc.). If the system has determined the device 200 is in a moving vehicle 100 (Block 404 ), and the device 200 is in close proximity to the driver (Block 402 ), then the driver safety system can intercept any attempts to access an application that the system is authorized to block. The driver safety system can also allow a user to predetermine a reply message, for example a predetermined voice message for an incoming telephone call or a predetermined text reply to an incoming text message. This predetermined reply message can be sent by the driver safety system when it determines that the requested application should be blocked because the user is driving. For example, if the user of the device is driving and receives a text message, the driver safety system can send a predetermined text reply message back to the sender of the message such as “Sorry, I can't reply to you right now since I am driving.”
At block 412 , the driver safety system can award points or score a driver based on his/her historical motion/usage profile data. As motion/usage data is captured over time, a pattern of a user's behavior with his/her mobile device starts to emerge. By assigning points or scores to each of the motion/usage profile categories, a user's behavior can be quantified. For example, Typing on the device 200 might be given a relatively high score compared to Picking Up the device 200 , since Typing may be considered “worse” than Picking Up. The driver safety system can have a scoring system that allows a user's motion/usage profile to be scored over several time periods: for example one day, one week, one month, one year, etc. These scores can be used to track a user's behavior and compare against other users. In aggregate, these scores can also be used to create a safe driving guideline. For example, a score of 5 Typing in one day might indicate an unsafe motion/usage profile. The table below illustrates one possible implementation of a driver safety scoring system:
Event
Description
Points
Pick up
user picked up device
5
Phone call
user made phone call with device
10
Typing
user typed on device
25
E-mail
user accessed E-mail app on device
50
Text Messaging
user accessed Text Messaging app on
50
device
Browser
user accessed Web Browser app on
25
device
Camera
user accessed Camera app on device
25
The table above shows an exemplary implementation of a driver safety scoring system. The scoring system for the motion data can be customized by an administrator or operator based on the policies being enforced. The points assigned for each violation can be defined accordingly. For example, if an administrator determines that using E-mail while driving is an important action to prevent, relatively more points can be assigned to the E-mail motion. Likewise, if using the Camera is considered less important, then relatively fewer points can be assigned to the Camera motion. By adjusting this scoring system, the administrator or operator can configure the system to match the policies being enforced.
At block 414 , the driver safety system stores and/or forwards driver safety data from the mobile device 200 or the other device where the driver safety system is resident, for example the vehicle 100 or beacon 110 . Driver safety data from the sensors and other components of the device 200 can be captured continuously while the device 200 is in the immediate proximity of the beacon 110 in the vehicle 100 . This data can be cataloged and stored to properly detect device usage, detect motion, classify the motion/usage profile, and calculate the motion/usage profile score. A data collection system can cache this data locally and transmit the driver safety data to a remote server. The driver safety data can be captured in real-time in a local database. As an example, the driver safety data can include sensor data that is captured several times per second, and the captured sensor data can include:
Date/Time—a timestamp for the data User ID—a unique identifier for the user AccelerometerX—the X value of the accelerometer AccelerometerY—the Y value of the accelerometer AccelerometerZ—the Z value of the accelerometer GyroscopeX—the X value of the gyroscope GyroscopeY—the Y value of the gyroscope GyroscopeZ—the Z value of the gyroscope GPSLatitude—the latitude value of the GPS sensor GPSLongitude—the longitude value of the GPS sensor GPSAltitude—the altitude value of the GPS sensor Speed—the velocity value of any number of sensors on the device (GPS, Cell Network calculated, Accelerometer, or Gyroscope) Direction—the compass direction of the device
If the device 200 allows monitoring and reporting of information regarding device usage and other relevant information, then this information can also be captured by the data collection system and transmitted to the remote server. At discreet times, the driver safety system can transmit the database containing the driver safety data to a remote server. Transmission of the driver safety data can be performed using industry standard practices such as web services and secure hypertext transport protocol (HTTPS) in order to keep the data secure.
FIG. 7 illustrates an example of the driver safety system storing and forwarding driver safety data from the device 200 to a server. The driver safety data can include, for example, sensor data, motion/usage profile data and/or other relevant driver safety information. In this embodiment, the device 200 stores the driver safety data 710 locally in memory on the device 200 . Then at some predetermined, periodic or other time basis, the device 200 transmits the driver safety data 710 over a network 720 to a server 730 or other computing system. The network 720 can be a local area network (LAN), wide area network (WAN), the Internet or other network. The server 730 stores the historical driver safety data in a database 740 that can be accessed locally or remotely by a computer system 750 , or possibly the electronic device 200 .
While the disclosure has been illustrated and described in detail in the drawings and foregoing description, such illustration and description is to be considered as exemplary and not restrictive in character, it being understood that illustrative embodiment(s) have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected. It will be noted that alternative embodiments of the present disclosure may not include all of the features described yet still benefit from at least some of the advantages of such features. Those of ordinary skill in the art may readily devise their own implementations that incorporate one or more of the features of the present disclosure and fall within the spirit and scope of the present invention as defined by the appended claims.
|
A vehicle safety system and method for controlling usage of mobile devices in a vehicle is disclosed that includes determining mobile device location in the vehicle; determining vehicle movement; determining whether device is being used by the driver based on device location; and monitoring or limiting usage of the device based on whether its being used by the driver while the vehicle is moving. An electronic beacon located in the vehicle can be used in determining device location. The method can include monitoring activation and usage of device functionality; maintaining an enforcement list of functionality to be limited when used by the driver; determining if any functionality on the enforcement list is attempting to activate, and if so limiting or disabling activation of that functionality. The method can include generating a device motion/usage profile for the driver while driving, and scoring the driver based on the device motion/usage profile.
| 7
|
This application is a division of application Ser. No. 06/632,733 filed July 20, 1984, now U.S. Pat. No. 4,790,736.
This application relates generally to pressure extrusion, and more particularly to pressure extrusion coupled with centrifugal fiber spinning for producing continuous and nonwoven fabrics.
One of the constraints of conventional fiber extrusion is the cost and inherent limitation of the mechanical roll systems which are required to pull fibers out of spinnerets at economical speeds. In other systems, the mechanical roll system has been by-passed by using air to pull fibers out of spinnerets at high speed. The air process is difficult to control. It suffers from spinline instability and lack of fiber uniformity. In addition, the use of compressed air is very energy intensive and costly.
Known centrifugal fiber spinning systems also offer very limited utility for fiber production, especially for viscous, thermoplastic polymers, because of low productivity and poor process and product controls. In these systems, fiber forming material is fed by gravity into the interior of a rapidly rotating open cup or die. The fiber forming fluid flows by virtue of the centrifugal force to the interior wall of the cup or die from whence it is spun into fibers from the outlet passages which pass through the wall of the cup or die. The generated centrifugal energy forces the fluid to extrude through the die. The rate of extrusion is relatively low, since the outlet passages have to be relatively small to assure fiber quality and filament stability. The use of large passages to increase productivity is not suitable for fiber extrusion, however. It is mainly for this reason that centrifugal extrusion of this type offers more utility for the production of larger diameter pellets than for the production of fibers, especially when considering thermoplastic polymers.
Only those polymers which are heat resistant and relatively fluid above their melting points may have any practical use for fiber conversion by the above described known spinning process. The literature mentions polypropylene, polyester, ureaformaldehyde and glass for use in such systems. Most thermoplastic polymers are too viscous and chemically unstable at the temperature required to reduce the viscosity sufficiently for centrifugal fiber spinning by this method. This is primarily due to the fact that the molten polymer is fed into an open cup. Except for the effects of rotation, the pressure inside the cup is virtually the same as the pressure outside the cup. Accordingly, if the holes in the cup are small, the polymer will move up the side of the cup and over the rim.
The above mentioned systems are illustrated by U.S. Pat. No. 4,288,397, issued Sept. 8, 1981, U.S. Pat. No. 4,294,783, issued Oct. 13, 1981, U.S. Pat. No. 4,408,972 issued Oct. 11, 1983 and U.S. Pat. No. 4,412,964 issued Nov. 1, 1983. These patents disclose a gravity feed system using a rotating cup wherein gas flows with the melt through the holes in the cup and the fiber producing condition is caused by the centrifugal force generated by the spinning of the cup and the included gas. U.S. Pat. No. 4,277,436 issued July 7, 1981 discloses a similar device using a stream of gravity fed molten material and a spinning cup so as to extrude the filaments by means of centrifugal force only.
Accordingly, an object of this invention is to provide a pressurized rotating fiber extrusion system.
A further object of the invention is to provide a rotating fiber extrusion system which is not limited to centrifugal spinning speed for controlling the extrusion rate or fiber denier.
Another object of the invention is to provide a rotating fiber extrusion system wherein it is not necessary to reduce polymer viscosity for increasing extrusion rate to improve process economics.
Yet another object of the invention is to provide a rotating fiber extrusion system wherein extrusion rate is controlled by a pumping system independent of die rotation, extrusion temperature and melt viscosity.
A further object of this invention is to provide a rotational fiber extrusion system including take-up means for producing fabric.
Yet another object of the invention is to provide a rotational fiber extrusion system including a take-up system for providing fibrous tow and yarn.
These and other objects of the invention will be obvious from the following discussion when taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the fiber producing system of the present invention;
FIG. 2 is a sectional view taken along lines 2--2 of FIG. 1;
FIG. 3 is a sectional view taken along the lines 3--3 of FIG. 2;
FIG. 4 is a sectional view taken along the lines 4--4 of FIG. 2;
FIG. 5 is a graphical illustration of the relationship between extrusion rate, die rotation, filament orbit diameter and filament speed;
FIG. 6 is a graphical illustration of denier as a function of die rotation.
FIG. 7 illustrates a modification of FIG. 2;
FIG. 8 is a schematic illustration of a system for producing a fabric;
FIG. 9 is a schematic illustration of a system producing a stretched web of FIG. 8;
FIG. 10 is a side view of the system of FIG. 9; and
FIG. 11 is a schematic illustration of a system for producing yarn.
BRIEF DESCRIPTION OF THE INVENTION
The present invention relates to a method and apparatus wherein there is provided a source of liquid fiber forming material, with said liquid fiber forming material being pumped into a die having a plurality of spinnerets about its periphery. The die is rotated at a predetermined adjustable speed, whereby the liquid is expelled from the die so as to form fibers. It is preferred that the fiber forming material be cooled as it is leaving the holes of the spinnerets during drawdown. The fibers may be used to produce fabrics, fibrous tow and yarn through appropriate collection and take-up systems. The pumping system provides a pumping action whereby a volumetric quantity of liquid is forced into the rotational system independent of viscosity or the back pressure generated by the spinnerets and the manifold system of the spinning head, thus creating positive displacement feeding. Positive displacement feeding may be accomplished by the extruder alone or with an additional pump of the type generally employed for this purpose. A rotary union is provided for positive sealing purposes during the pressure feeding of the fiber forming material into the rotating die.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings, there is schematically shown in FIG. 1 a system according to the present invention for producing fibers. The system includes an extruder 11 which extrudes fiber forming material such as liquid polymer through feed pipe 13 to a rotary union 21. A pump 14 may be located in the feed line if the pumping action provided by the extruder is not sufficiently accurate for particular operating conditions. Electrical control 12 is provided for selecting the pumping rate of extrusion and displacement of the extrudate through feed pipe 13. Rotary union 21 is attached to spindle 19. Rotary drive shaft 15 is driven by motor 16 at a speed selected by means of control 18 and passes through spindle 19 and rotary union 21 and is coupled to die 23. Die 23 has a plurality of spinnerets about its circumference so that, as it is rotated by drive shaft 15 driven by motor 16 and, as the liquid polymer extrudate is supplied through melt flow channels in shaft 15 to die 23 under positive displacement, the polymer is expelled from the spinnerets and produces fibers 25 which form an orbit as shown. When used, air currents around the die will distort the circular pattern of the fibers.
FIGS. 2-4 illustrate one embodiment of the present invention. FIG. 2 is a cross-sectional view taken through spindle 19, rotary union 21, die 23 and drive shaft 15 of FIG. 1. FIGS. 3 and 4 are cross sectional views taken along lines 3--3 and 4--4 of FIG. 2 respectively. Bearings 31 and 33 are maintained within the spindle by bearing retainer 34, lock nut 35 and cylinder 36. These bearings retain rotating shaft 15. Rotating shaft 15 has two melt flow channels 41 and 43. Surrounding the shaft adjacent the melt flow channels is a stationary part of rotary union 21. Extrudate feed channel 47 is connected to feed pipe 13, FIG. 1, and passes through rotary union 21 and terminates in an inner circumferential groove 49. Groove 49 mates with individual feed channels 50 and 52, FIG. 3, which interconnect groove 49 with melt flow channels 41 and 43.
The rotary union may be sealed by means such as carbon seals 51 and 53 which are maintained in place by means such as carbon seal retainers 54,56. Adjacent lower carbon seal 53 is a pressure adjustable nut 55 which, by rotation, may move the two carbon seal assemblies upwardly or downwardly. This movement causes an opposite reaction from belleville washers 59 and 60 so as to spring-load each sliding carbon seal assembly individually against the rotary union.
Lower washer 60 rests on spacer 61 which in turn rests on die 23. Die 23 has a plurality of replaceable spinnerets 67 which are interconnected with flow channels such as flow channel 41 by means of feed channel 69 and shaft port 71 which extends through shaft 15 between channel 41 and circumferential groove 70, FIG. 4 so as to provide a constant source of extrudate. The apparatus is secured in place by means such as plate 73 secured to shaft 15.
If desired, a means for cooling the extrudate as it leaves the spinnerets may be provided, such as stationary ring 77 having outlet ports which pass air under pressure in the direction of arrows A. Ring 77 is secured in the position shown by support structure, not shown.
Further, electrical heaters 20 and 22, FIG. 3, are preferably provided in stationary segment 20 of rotary union 21 so as to maintain extrudate temperature.
As can be seen, the apparatus as described provides a system which is closed between the extruder and the die with the liquid extrudate being extruded through a rotary union surrounding the rotating shaft. Accordingly, as the shaft is rotated, the liquid extrudate is pumped downwardly through the melt flow channels in the rotating shaft and into the center of the circular die. The die, having a plurality of spinnerets 67, FIG. 4, about the circumference thereof, will cause a drawdown of the discharging extrudate when rotated by expelling the extrudate from the spinneret so as to form fibers 25 as schematically illustrated in FIG. 1. Die rotation therefore, is essential for drawdown and fiber formation, but it does not control extrusion rate through the die. The extrusion rate through the die is controlled by the pumping action of extruder 11 and/or pump 14.
In order to provide a long lasting high pressure seal between rotary union 21 and die 23, shaft 15 includes helical grooves 101 and 103 about its circumference on opposite sides of feed channels 50 and 52. Helical grooves 101 and 103 have opposite pitch so that, as the shaft is rotated in the direction as indicated by the arrow, any extrudate leaking between the mating surfaces of shaft 15 and rotary union 21, will be driven back into groove 49 and associated channels 50 and 52. Accordingly, leakage is substantially eliminated even under high pressure through the use of this dynamic seal.
The major variables involved in this system, besides the choice of polymer, are the pumping rate of the liquid polymer from the extruder and/or pump, the temperature of the polymer and the speed of rotation of the die. Of course, various size orifices may be used in the interchangeable spinnerets for controlling fiber formation without affecting extrusion rate. The rate of extrusion from the die, such as grams per minute per hole, is exclusively controlled by the amount of the extrudate being pumped into the system by the extruder and/or pump.
When the system is in operation, fibers are expelled from the circumference of the die and assume a helical orbit as they begin to fall below the rotating die. While the fibers are moving at a speed dependent upon the speed of rotation of the die as they are drawn down, by the time they reach the outer diameter of the orbit, they are not moving circumferentially, but are merely being laid down in that particular orbit basically one on top of the other. The orbit may change depending upon variation of rotational speed, extrudate input, temperature, etc. External forces such as electrostatic or air pressure may be employed to deform the orbit and, therefore, deflect the fibers into different patterns.
FIGS. 5 and 6 are derived from the following data.
TABLE 1__________________________________________________________________________DENIER VERSUS PROCESS CONDITIONSEXTRUSION FIL. ORBITRATE DIE ROTATION DIAMETER FIL. SPEED FILAMENT(g/min/hole) (r.p.m.) (INCHES) M/MIN DENIER__________________________________________________________________________1.9 500 16 640 272.0 1,000 14 1,120 162.0 1,500 15 1,800 102.1 2,000 14.5 2,300 82.1 3,000 15 3,600 53* 1,000 16 1,300 213* 1,500 19.5 2,300 123* 2,000 20.5 3,300 83* 2,500 21.5 4,300 63.8 1,000 19.0 1,500 23 3.8* 3,000 24.5 5,900 6__________________________________________________________________________ *Extrusion rate was extrapolated from screw r.p.m. Note: Line speed = orbit circumference × die rotation Denier is based on line speed and extrusion rate
FIG. 5 illustrates the relationship of the various parameters of the system for a specific polymer (Example I below) which includes the controlling parameters, pumping rate and die rotation, and their affect on filament spinning speed and filament orbit diameter. In the graph of FIG. 5, there are illustrated three different pumping rates of extrudate, which controls the extrusion rate from the die, in grams per minute per hole. In the illustration, the number inside the symbols indicates averaged pumping rate from which the graph was developed. In FIG. 6, the graph illustrates denier as a function of die rotation. As can be seen from the graphs, as the die rotational speed is increased, the filament speed and drawdown is also increased.
It is to be understood that the following examples are illustrative only and do not limit the scope of the invention.
EXAMPLE I
Polypropylene resin, Hercules type PC-973, was extruded at constant, predetermined extrusion rates into and through a rotary union, passages of the rotating shaft, the manifold system of the die and the spinnerets. Except for the extruder, the apparatus is as shown in the cross-section of FIG. 2.
Upon extrusion, the centrifugal energy, acting on the molten extrudate causes it to draw down into fibers. The fibers form circular orbits which are larger than the diameter of the die. A stationary circular air quench ring, located above the die, as shown in FIG. 2, including orifices designed so as to direct the air downwardly and outwardly relative to the perimeter of the die, deflects the fibers at an angle of substantially 45 degrees below the plane of the die. In this example, process parameters are varied and the resultant fibers collected for testing.
______________________________________1. Equipmenta. Extrusion set-up: as shown in FIG. 1b. Extruder: Diameter, inches: 1.0 Temperature Zones: 3.0 Length/diameter, inches: 24/1 Drive, Hp: 1.0c. Extrusion head: see FIG. 2d. Die: Diameter, inches: 6.0 Number of spinnerets: 16.0 Spinneret hole diameter, 0.020 inchese. Quench and Fiber Removal: circular ring Ring diameter, inches: 8.0 Orifice spacing, inches 1.0 angled 45° down- wardly and outwardly of the perimeter of the die2. Process Conditionsa. Extrusion conditions Extruder temperature, °F.: Zone-1 350 Zone-2 400 Zone-3 450 Adap- 450 ter Rot. 450 Union Die 550-600 Screw rotation, r.p.m.: set for a given extrusion rate Extrusion pressure, p.s.i.: 200-400b. Die rotation, r.p.m.: 500-3000 (See table below)c. Air quench pressure, p.s.i.: 10-30 (See table below)______________________________________3. Data and Results FiberExtrusion Die Fiber Orbit Spinning FiberRate Rotations Diameter Speed Denier(g/min/hole) (r.p.m.) (inches) (meter/min) (g/9000 m)______________________________________1.9 500 16 640 272.0 1,000 14 1,120 162.0 1,500 15 1,800 102.1 2,000 14.5 2,300 82.1 3,000 15 3,600 53.0 1,000 16 1,300 213.0 1,500 19.5 2,300 123.0 2,000 20.5 3,300 83.0 2,500 21.5 4,300 63.8 1,000 19 1,500 233.8 3,000 24.5 5,900 6______________________________________4. Extrusion ConditionsNote:(a) Fiber orbit diamter was measured visually with an inch-ruler.(b) Fiber spinning speed was calculated (speed = orbit circum-ference × rotation).(c) Denier was calculated, based on extrusion rate and fiberspinning speed in the well known manner.
According to the results of this experiment, the fibers become smaller with increasing die rotation, Furthermore, increasing extrusion rate, at a given die rotation, increases filament orbit and, therefore, decreases the rate of increase of filament denier.
EXAMPLE II
In the apparatus described in Example I, a polyethylene methacrylic copolymer (DuPont Ionomer resin type Surlyn--1601) was extruded. Fibers of various deniers were produced at different die rotations.
______________________________________Process Conditions______________________________________a. Extrusion conditionsTemperature Zone-1 300 Zone-2 350 Zone-3 400 Adapt. 400 Rot. Union 400 Die 500-550Screw rotation, r.p.m.: 10Screw pressure, p.s.i.: 100-200b. Die rotation, r.p.m.: 1000, 2000, 3000c. Air quench pressure, p.s.i.: 10-30______________________________________
In another variation of this example, fibers were collected on the surface of a moving screen. The screen was moved horizontally, four inches below the plane of the die. Upon contact of the fibers with each other, the fibers were bonded to each other at the point of contact. The resultant product is a nonwoven fabric. The fabric was then placed between a sheet of polyurethane foam and a polyester fabric. Heat and pressure was then applied through the polyester fabric. The lower melting ionomer fabric was caused to melt and bond the two substrates into a composite fabric.
EXAMPLE III
In the apparatus of Example I, the following polymers which are listed in the table below, have been converted into fibers and fabrics.
______________________________________Polymers Converted into Fibers and Fabrics Extrusion DiePolymer Temp. °F. Temp. °F.______________________________________Polypropylene Amoco CR-34 400-500 550-625Polyioner Surlyn 1601 350-400 450-550Nylon terpolymer Henkel 6309 280-300 350-400Polyurethane Estane 58122 350-400 450-400Polypropylene- 400-500 550-600ethylene copolymer______________________________________
Spunbonded fabrics are produced by allowing the freshly formed fibers to contact each other while depositing on a hard surface. The fibers adhere to each other at their contact points thus forming a continuous fabric. The fabric will conform to the shape of the collection surface. In this example, fibers were deposited on the surface of a solid mandrel comprising an inverted bucket. The dimensions of this mandrel are as follows.
______________________________________Top diameter, inches: 8.25Height of mandrel, inches: 7.0______________________________________
EXAMPLE IV
Nylon-6 polymer, 2.6-relative viscosity (measured in sulfuric acid), was converted into low-denier textile fibers and spun-bonded continuously into a nonwoven fabric. The fabric was formed according to the apparatus of FIG. 8. The extrusion head employed is illustrated in the cross section of FIG. 7. The fabric produced in this system is very uniform and even, with good balance in physical properties.
______________________________________Equipment and Set-upSet-Up FIG. 8______________________________________a. Extruder One-inch diameter, One Hp driveb. Extrusion head FIG. 7 Stationary shaft, rotating die grooves are in the ouside member of the rotary unionc. Die, diameter, inches 12.0 numbers of spinnerets 16 spinning holes per 1 (0.020 in. diameter) spinneretd. Quench ring, diameter, 14.0 inches orifices: 0.06 inches diameter at 1" spacing, angled 45 degrees downwardly and outwardlyProcess ConditionsExtrusion Temperature, °F. Z-1: 480° F. Z-2: 670° F. Z-3: 620° F. Adapter: 550° F. Melt Tube: 600 Die heaters 13 ampExtruder screw rotation, r.p.m. 33.0Die rotation, r.p.m. 2530.Air-quench pressure, psi 30.Winder speed, ft/min 10.Product 2-ply, lay-flat fabricWidth, inches 35.Basis Weight oz/yd.sup.2 0.75______________________________________
The hole diameter of the spinneret is preferably between 0.008" and 0.030 inches with the length-to-diameter ratio being between 1:1 and 7:1. This ratio relates to desired pressure drop in the spinneret.
Shaped, tubular articles were formed by collecting fibers on the outside surface of a mandrel. The mandrel used in this experiment was a cone-shaped, inverted bucket. The mandrel was placed concentric with, and below a revolving, 6-inch diameter die. The centrifugal action of the die and the conveying action of the air quench system caused fibers to be deposited on the surface of the mandrel (bucket), thus forming a shaped textile article. The resultant product resembles a tubular filter element and a textile cap.
In another experiment, a flat plate was placed below the rotating die. The flat plate was slowly withdrawn in a continuous motion thereby producing a continuous, flat fabric.
The air quench with its individual air streams causes fiber deflection and fiber entanglement, thereby producing an interwoven fabric with increased integrity.
Copolymer and Polymer Blends
Virtually every polymer, copolymer and polymer blend which can be converted into fibers by conventional processing can also be converted into fibers by centrifugal spinning. Examples of polymer systems are given below:
______________________________________Polyolefin polymers and copolymers;Thermoplastic polyurethane polymers and copolymers;Polyesters, such as polyethylene and polybutyleneterephthalate;Nylons;Polyionomers;Polyacrylates;Polybutadienes and copolymers;Hot melt adhesive polymer systems;Reactive polymers.______________________________________
EXAMPLE V
In the apparatus of Example IV, thermoplastic polyurethane polymer, Estane 58409 was extruded into fibers, collected on an annular plate and withdrawn continuously as a bonded non-woven fabric. Very fine textile fibers were produced at high die rotation without evidence of polymer degradation.
______________________________________Process conditionsExtrusion Temperatures, °F.______________________________________Z-1: 260Z-2: 330Z-3: 350Adapter 350Melt tube 250Die (7 amps) 450-500Quench air pressure 20 psiDie rotation, r.p.m. 2,000.00Extruder-Screw rotation, r.p.m. 12.0______________________________________
Process Parameters Controlling Fiber Production
As will be evident from the above illustrations, three major criteria govern the control of fiber formation from thermoplastic polymers with the present system:
1. Spinneret hole design and dimension will affect the process and fiber properties as follows:
a. control drawdown for a given denier
b. govern extrudate quality (melt fracture)
c. affect the pressure drop across the spinnerets
d. fiber quality and strength and fiber processability (in-line stretching and post-stretching propensity)
e. process stability (line speed potential, productivity, stretch, etc.).
2. Extrustion rate, which is governed by pumping rate of the extruder and/or additional pumping means, will affect
a. fiber denier
b. productivity
c. process stability
3. Die rotation, which controls filament spinning speed influences and controls
a. drawdown
b. spinline stability
c. denier
d. productivity for a given denier
It should be noted that temperature controls process stability for the particular polymer used. The temperature must be sufficiently high so as to enable drawdown, but not so high as to allow excessive thermal degradation of the polymer.
In the conventional non-centrifugal fiber extrusion process and in the centrifugal process of this invention, all three variables are independently controllable. However, in the known centrifugal process discussed above these variables are interdependent. Some of this interdependency is illustrated below.
1. Spinneret hole design will affect extrusion rate since it determines part of the backpressure of the system.
2. Extrusion rate is affected by die rotation, the pressure drop across the manifold system, the spinneret size, polymer molecular weight, extrusion temperature, etc.
3. Filament speed will depend on the denier desired and all of the beforementioned conditions, especially die rotation and speed.
Thus, it can be seen that the system of the present invention provides controls whereby various deniers can be attained simply by varying die rotation and/or changing the pumping rate.
It will be apparent from the above disclosure that since the extrudate is being pumped into the system at a controlled rate, the total weight of the extruded fibers can be increased by increasing the amount of extrudate being pumped into the system. Additionally, the consistency and control of fiber production is much greater than that for fibers which are extruded depending solely upon centrifugal force to drive the extrudate through the holes in the wall of a cup as described in the patents cited hereinabove.
The fibers may be used by themselves or they may be collected for various purposes as will be discussed hereinafter.
FIG. 7 discloses a modified system similar to FIG. 1 wherein the central shaft remains stationary and the die is driven by external means so that it rotates about the shaft. The actual driving motor is not shown although the driving mechanism is clearly illustrated.
Non-rotatable shaft 101 includes extrudate melt flow channel 105 therethrough which interconnects with feed pipe 13 of FIG. 1. There is also provided a utility channels 102 and 104 which may be used for maintaining electrical heating elements (not shown). Shaft 101 is supported and aligned at its upper end by support plate 107 and is secured thereto by bolt 106 and extends downwardly therefrom.
Cylindrical inner member 111 is secured and aligned to plate 107 by means such as bolt 112. At its lower end, inner member 111 has secured thereto a flat annular retainer plate 114 by means of a further bolt. Plate 114 supports outer member 115 of the spindle assembly and has bearings 121 and 123 associated therewith. Onto the lower end of outer member 115 is bolted an annular plate 150 by means of bolts such as 151. A thin-walled tube 152 is welded on the inside wall of member 150. The three interconnected members 152, 150, and 115 form an annular vessel containing bearings 121 and 123 and oil for lubrication. The entire vessel is rotated by drive pulley 116 which is driven by belt 116 and is secured to outer member 115 by means such as bolt 118. The rotating assembly is connected to die 141 by means of adapter 120 and rotates therewith.
Bushing 125 surrounds shaft 101 and supports graphite seals 129a and 129b and springs 130 and 131 on either side thereof. Sleeves 126 and 128 are secured to the die by screws 153 and 154 and rotate with die 141. The inside surfaces of the sleeves include integral grooves 137 and 139 which extend above and below melt flow channel 143 so as to drive any liquid extrudate leaking along the sleeves towards channel 143 in the same manner as is described in connection with the grooves on the rotating shaft of FIG. 2.
The die 141 is bolted onto the adapter 120 via bolts such as bolt 155. Each melt flow channel, such as 143, contains replaceable spinneret 145 with melt spinning hole 156. Melt flow channel 143 terminate at their inner ends with melt flow channel 105. The die is heated with two ring heaters 157 and 158 which are electrically connected to a pair of slip rings 159 and 160 by means not shown. Power is introduced through brushes 161 and 162 and regulated by a variable voltage controller (not shown).
FIG. 8 is a schematic illustration of an assembly using the present invention to form fabrics.
Unistrut legs 201, support base frame 203 which in turn supports extruder 205. Extruder 205 feeds into adapter 207 and passes downwardly to die 215. Motor 209 drives belt 211 which in turn rotates the assembly as described in FIG. 7. Stationary quench ring 213 of the type shown in FIG. 2 surrounds the die as previously discussed so as to provide an air quench for the fibers as they are extruded. A web forming plate 219 is supported beneath the base support frame and includes a central aperture 221 which is of a larger diameter than the outside diameter of the rotating die.
As the die is rotated and the fibers are extruded, they pass beyond aperture 221 and strike plate 219. Fibers are bonded during contact with each other and plate 219, thus producing non-woven fabric 225 which is then drawn back through aperture 221 as tubular fabric 225. Stationary spreader 220 supported below the die, spreads the fabric into a flat two-ply composite which is collected by pull roll and winder 227. Thus, the fabric which is formed as a result of the illustrated operation may be collected in a continuous manner.
FIGS. 9 and 10 are schematic representations of a plan and side view of a web forming system using the present invention.
The frame structure and extruder and motor drive are the same as described in connection with FIG. 8. The die is substantially the same as in FIG. 8 and includes therewith the quench ring 213.
In the web forming system, mandrel 235 is added below and substantially adjacent die 215. As can be seen, mandrel 235 is substantially domed shaped with a cut out portion to accommodate continuous belts 237 and 239 which constitute a spreader. As the fibers leave die 215 in an orbit fashion, they drop downwardly onto the mandrel and are picked up and spread by continuous belts 237 and 239.
Nip roll 243 is located below belts 237 and 239 and draws web 241 downwardly as it passes over the spreader, thus creating a layered web.
Layered web 249 then passes over pull roll 245 and 247 and may be stored on a roll (not shown) in a standard fashion.
FIG. 11 is a schematic of a yarn and tow forming system using the present invention.
Frame 300 supports extruder 301, drive motor 302 and extrusion head 303 in a manner similar to that discussed in connection with FIG. 8. Radial air aspirator 304 is located around die 305 and is connected to air blower 306. Both are attached to frame 300. In operation, fibers are thrown from the die by centrifugal action into the channel provided by aspirator 304. The air drag created by the high velocity air causes the fibers to be drawn-down from the rotating die and also to be stretched. The fibers are then discharged into perforated funnel 308 by being blown out of aspirator 304. The fibers are then caused to converge into a tow 309 while being pulled through the funnel by nip rolls 310. Tow 309 may then be stuffed by nip rolls 311 into crimper 312 and crimped inside of stuffing box 313, producing crimped tow 314. The crimped tow is then conveyed over rolls 315 and continuously packaged on winder 316.
The above description, examples and drawings are illustrative only since modifications could be made without departing from the invention, the scope of which is to be limited only by the following claims.
|
A method wherein there is provided a source of fiber forming material, with said fiber forming material being pumped into a die having a plurality of spinnerets about its periphery. The die is rotated at a predetermined adjustable speed, whereby the liquid is expelled from the die so as to form fibers. It is preferred that the fiber forming material be cooled as it is leaving the holes in the spinnerets during drawdown. The fibers may be used to produce fabrics, fibrous tow and yarn through appropriate take-up systems. The pumping system provides a pumping action whereby a volumetric quantity of liquid is forced into the rotational system independent of viscosity or the back pressure generated by the spinnerets and the manifold system of the spinning head, thus creating positive displacement feeding. Positive displacement feeding may be accomplished by the extruder alone or with an additional pump of the type generally employed for this purpose. A rotary union is provided for positive sealing purposes during the pressure feeding of the fiber forming material into the rotating die.
| 3
|
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a cooling system for automotive vehicles, and more particularly relates to an improved cooling system in which liquid coolant is subjected to a comparatively low system pressure, resulting in a reduced boiling point for the liquid coolant, thus enabling the engine being cooled to operate at a controlled temperature under the influence of a thermostat in the cooling system.
2. The Prior Art
Liquid cooling systems for present-day automotive vehicles are pressurized to approximately 15 psi by use of a spring-loaded pressure radiator cap. When the liquid coolant is a 50--50 mixture of water and commercial anti-freeze coolant, the boiling point of the coolant is elevated to approximately 262° F. The prevailing theory is that this pressurization and elevated boiling point is necessary to allow the radiator to retain as much coolant as possible to cool the engine.
In fact, this prevailing cooling method for today's automobiles is contrary to conventional practice, as a result of which the problems of engine overheating, and the deterioration of engine cooling systems have been magnified rather than decreased or eliminated. In high pressure liquid cooling systems which operate at high temperatures, the entire system including the radiator and water pump can be destroyed rather rapidly.
In view of the above, the primary object of the present invention is to provide an engine cooling system which allows the engine to be operated in a strictly controlled temperature range under influence of a thermostat, typically a 195° F. thermostat. The controlled cooling system according to the present invention forces the engine to operate at its thermostat temperature, without substantially overheating or underheating.
When the liquid coolant of a cooling system becomes heated, it must expand, causing an increase in pressure. The present invention allows the coolant to expand without a significant increase in system pressure as normally caused by the pressure cap on the radiator, which cap the invention does not employ. Consequently, with cooling system pressure markedly reduced, the boiling point of the coolant is correspondingly reduced and this allows the system to conform to a well-known principle of physics, i.e. the lower the pressure the lower the boiling point of a liquid. For a liquid to perform as a good coolant, it must have a low boiling point. This phenomenon is made use of in mechanical refrigeration systems where the boiling point of the most commonly used refrigerant R-12 boils at -21.7° F. Once a liquid reaches its boiling point, it can become no hotter as a liquid. The temperature of a liquid coolant at the boiling point is a major concern. The lower the boiling point temperature of the coolant, the greater the amount of heat which it can extract by conduction from the engine. High pressure, high boiling point liquids can naturally extract less heat from an engine, and it is this situation in the prior art which the present invention seeks to eliminate.
The Environmental Protection Agency requires that new automobiles be equipped with 195° F. thermostats. The Agency knows that this is the proper operating temperature to achieve best engine performance and best fuel efficiency with the least pollution. The difficulty is that the 195° F. thermostat in the modern automobile remains closed only until the cold engine, after starting, reaches the optimum thermostat temperature. At all other times, the 195° F. thermostat will remain open because the pressurized cooling system has been designed to operate in the range of 220° F. to 240° F. Thus, with the modern-day engine cooling system, the thermostat does not and cannot control the operating temperature of the engine as it was intended to do. The operating temperature of the engine is actually 25° F. to 45° F. above the temperature which the thermostat was designed to maintain. This elevated engine operating temperature results in excessive fuel consumption, greater atmospheric pollution and more rapid deterioration of the cooling system.
Similarly, most automotive pollution control systems have a thermostat controlled bypass. Since most engines operate at temperatures far above this thermostat setting, to save overheating, the pollution control system is bypassed, rendering the system ineffective most of the time.
Clutch fans are provided in automobiles to blow air over the engine to assist in cooling. These fans are thermostatically controlled as an economy measure to lessen strain on the engine. The fans engage at approximately 225° F. When the automotive engine is equipped with a cooling system thermostat, such as a 195° F. thermostat, and this thermostat is allowed to actually control engine temperature, as indeed occurs with the present invention, the cooling fan would never require activation. However, with the prevailing high pressure-high temperature cooling systems, the cooling fans operate most of the time.
Under actual testing of the present invention, during afternoon temperatures slightly in excess of 100° F., with a 195° F. thermostat in the system, the engine operated at this temperature. With a 180° F. thermostat, it operated at 180° F. With the thermostat removed entirely, allowing free flow of the coolant, the engine operated at 145° F. Thus, according to the present invention, the operating temperature of the engine is truly controlled as it should be by means of the cooling system thermostat. With the low pressure, low temperature cooling system of the present invention it is virtually impossible to overheat the system, and this feature is in accordance with another main objective of the invention.
Other features and advantages of the invention will become apparent to those skilled in the art during the course of the following detailed description.
SUMMARY OF THE INVENTION
The present invention is best summarized as a sealed low pressure, low temperature cooling system for engines in which the engine radiator is equipped with a clear sealed closure cap allowing visual inspection of the radiator coolant level at all times. An expansion reservoir or tank also formed of clear material is supported exteriorly of the radiator at the same level or slightly above the level of the customary radiatorexpansion fitting. This fitting and a similar fitting provided on the expansion reservoir are connected by a hose of any required length The expansion reservoir is equipped with a sealed closure cap which can be similar to a jar lid or a standard type radiator cap. If the latter type cap is employed, it should not be equipped with a vacuum release valve, and only a pressure release valve radiator cap should be used.
Ambient air is totally excluded from the sealed system. When normal operating engine temperature is achieved under control of a thermostat, such as a 195° F. thermostat, the sealed cooling system will be pressurized within a range of 41/2 to 5 psi. The liquid coolant will expand freely into the expansion reservoir which has a capacity of approximately 20 ounces. The liquid entering the expansion reservoir compresses the air trapped therein, the coolant remaining in the part of the expansion reservoir nearest the radiator. As pressure increases on the coolant in the expansion reservoir, the coolant is returned by the pressurized air into the radiator, thus assuring that the cooling system remains full of coolant at all times for optimum engine cooling efficiency under thermostatic control. Since the system is hermetically sealed, oxygen is excluded and the system remains substantially free of oxidation or corrosion for the life of the automobile or other vehicle.
A second embodiment of the invention unites the expansion reservoir with the radiator and places the reservoir at the top of the radiator, separated therefrom by plates with a tube connecting the interiors of the radiator and expansion reservoir. The customary hoses and hose clamps of the vehicle cooling system are eliminated. The two embodiments of the invention involve the same principle of operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an engine cooling system according to the present invention.
FIG. 2 is a fragmentary side elevation of the cooling system, partly in cross section.
FIG. 3 is a partly schematic side elevation of a united radiator and expanded coolant reservoir according to a second embodiment of the invention.
FIG. 4 is a schematic view of the cooling system according to the second embodiment of the invention.
DETAILED DESCRIPTION
Referring to the drawings in detail wherein like numerals designate like parts, the numeral 10 designates a cooling radiator for an automobile engine or the like, not shown. The radiator 10 has a top filling neck 11 normally equipped with spaced upper and lower flanges which are engaged by the customary spring-loaded high pressure cap which the present invention omits entirely. Instead of this cap, a durable clear radiator closure cap 12 having a neoprene seal 13 is applied to the filling neck 11, with the seal 13 engaging the top lip or flange 14 of the neck 11 to hermetically seal the same. The customary lower lip or flange normally engaged by the high pressure radiator cap can be omitted from the radiator structure, and if present on existing radiators is not utilized, that is to say, is not engaged in any way by the clear closure cap 12. Therefore, the lower sealing flange of existing radiators does not impede the outflow of coolant from the radiator into an expansion reservoir in accordance with the present invention, as will be further described.
A preferably clear plastic expansion reservoir or tank 15 forming an important element of the invention is connected by a flexible hose 16 of any required length with the radiator 10. More particularly, the hose 16 is connected by a first clamp 17 with the usual horizontal overflow nipple 18 of the neck 11. The elevation of the nipple 18 establishes the level of liquid in the radiator 10 when the cooling system is full. A second clamp 19 connects the other end of the hose 16 with a horizontal nipple 20 carried by one end of the expansion reservoir 15. The nipple 20 is arranged at the same elevation as the nipple 18, or slightly above this elevation, so that liquid coolant in the expansion reservoir 15 is able to flow by gravity back into the radiator 10 at proper times.
The reservoir 15 is stably supported at any convenient location on existing vehicle structure by an adjustable height strap or bracket means 21 of any preferred type.
For emergency purposes primarily, the expansion reservoir 15 is equipped with a sealed simple twist-off cap 22 or, if preferred, a standard type radiator cap having a pressure release valve 23.
Assuming that the cooling system is free of leaks and full of coolant, it will be necessary to add coolant to the system at very infrequent intervals only since there will be no escape of coolant from the low pressure, low temperature system. However, should the addition of coolant be necessary because of a leak or after cleaning and flushing of the system, the cap 12 is removed to facilitate this filling or refilling.
The expansion reservoir 15 can be of any convenient shape. It remains empty normally, and its purpose is for receiving expanded coolant only, as will be further explained. It is preferable and more practical for the expansion reservoir 15 to be comparatively shallow in its vertical dimension so that horizontal flow of coolant to and from the radiator at proper times is not inhibited.
OPERATION
When the engine is started, the conventional thermostat, not shown, remains closed until the engine reaches its normal operating temperature, namely, 195° F. for newer automobiles. The proper thermostat is chosen, in all cases, to establish and maintain the desired engine operating temperature.
When the heated coolant normally a 50--50 mixture of water and commercial anti-freeze expands, such expanded coolant can freely enter the reservoir 15 through the nipple 18, hose 16 and nipple 20 since there is no restrictive effect on such flowing caused by the sealed cap 12. In so flowing into the reservoir 15, the expanding coolant will create its own relatively low pressure, pushing ahead of it the air trapped within the sealed reservoir 15 toward the back of the reservoir remote from the radiator 10, the coolant remaining in the end of the reservoir nearest the nipple 20 and radiator.
As the pressure increases in the reservoir 15, the trapped air therein pushes the coolant back into the radiator 10. This pressure will increase only to about 41/2 to 5 psi and approximately five ounces of coolant will expand into the twenty ounce capacity reservoir 15, the rest of whose capacity is taken up by trapped air. This trapped air in the reservoir continues to push against the coolant, insuring that the radiator 10 and the entire cooling system remains 100% full at all times.
Maintaining pressure of only 41/2 to 5 psi in the coolant system greatly lowers the boiling point of the coolant, from which it follows that the functional temperature of the coolant remains low. This low temperature coolant is forced into and through the engine cooling jackets by the water pump. The low temperature coolant can extract a much greater amount of heat from the engine than the customary high pressure, high temperature coolants employed in today's automobile.
When the initially cold engine is started and reaches normal operating temperature, 195° F., the thermostat opens, releasing coolant into the radiator 10 to be cooled. The thermostat continues to open and close automatically for maintaining and controlling the temperature of the engine.
Since the cooling system is hermetically sealed, no fresh air or oxygen can enter the system and any oxygen initially in the system is quickly dissipated or absorbed. Therefore the entire cooling system is protected from oxidation and will remain in its original uncorroded state throughout the life of the vehicle.
FIGS. 3 and 4 of the drawings depict a second embodiment of the invention particularly suitable for newly manufactured vehicle cooling systems of the water and anti-freeze types. The invention according to the second embodiment can also be installed on existing vehicles in the field, if desired.
In FIGS. 3 and 4, the radiator 24 is united with a small capacity top expanded coolant reservoir 25 having a capacity of approximately 25 fluid ounces. The reservoir 25 is separated from the radiator 24 by plates 26. A small diameter tube 27 extends vertically inside of the radiator 24 and has its open lower end terminating approximately at the mid-point of the height of the radiator. This tube includes an upper horizontal branch 28 near and below the top of the radiator and the plates 26 and being in communication with the interior of the reservoir 25 through an aperture 29 within or defined by the plates 26. Otherwise, the expanded coolant reservoir 25 is entirely separated from the interior of the radiator 24.
At its top, the radiator 24 has an unrestricted filling neck 30 sealed by a removable transparent cap 31, which may be identical to the previously-described cap 12. When the radiator is filled with coolant through the neck 30, there is no danger of overfilling into the expansion reservoir 25 because the neck 30 is at or near the level of the plates 26 and the radiator will overflow through the neck 30 before any coolant could rise into the reservoir 25.
The arrangement provides a completely hermetically sealed cooling system having basically the same mode of operation and advantages described for the prior embodiment having the separate expanded coolant reservoir 15. In addition to its simplicity and unitary construction, the cooling system in FIGS. 3-4 entirely eliminates the traditional rubber hoses and hose clamps of automotive cooling systems which are known to be the focal points of most problems arising in cooling systems. The rubber hoses rapidly deteriorate and sometimes burst under the high pressure of conventional cooling systems and the hose clamps frequently become loose due to engine vibration.
As shown in FIG. 4, the radiator cooling fan is indicated by the numeral 32. A water pump 33 is connected to a metal tube 34 by opposing apertured plates or flanges 35 which are bolted together with a sealing gasket 36 placed between them to effect an air and liquid tight seal. The tube 34 is similarly connected to a radiator coolant inlet metal tube 37 by an additional pair of apertured plates 38 which are also bolted together with one of the sealing gaskets 36 interposed therebetween.
At a higher elevation on the radiator 24, a metal coolant outlet tube 39 is connected into the radiator by another pair of opposed apertured plates 40 having one of the sealing gaskets 36 disposed therebetween. Exteriorly of the radiator 24, the tube 39 is connected by still another pair of apertures plates 41 having a gasket 36 therebetween with a thermostat housing 42.
By these described means, the unified cooling system is completely hermetically sealed and external air is excluded from the system, thereby minimizing oxidation and corrosion, as previously explained.
The mode of operation of the system is essentially the same as described for the prior embodiment in FIGS. 1 and 2. When the engine and cooling system reach normal operating temperature under full thermostat control at all times, a small volume of expanded coolant will pass through the tube 27 into the expansion reservoir 25 and the coolant will interface with and compress the air trapped in the reservoir 25. This enables the system to create its own internal pressure which will be at least 10 psi less than the pressure of today's conventional cooling systems for vehicles. As the thermostat continues to regulate the system temperature, compressed air and gravity will return the expanded coolant from the reservoir 25 to the radiator 24 to maintain the latter full at all times.
The expanded coolant reservoir 25 is preferably made of the same material as the radiator 24 to promote efficiency of manufacturing the system.
It is to be understood that the forms of the invention herewith shown and described are to be taken as preferred examples of the same, and that various changes in the shape, size and arrangement of parts may be resorted to, without departing from the spirit of the invention or scope of the subjoined claims.
|
A hermetically sealed low pressure, low temperature cooling system for internal combustion engines which include a thermostat that operates at a predetermined temperature, typically 195° F. Thermostatic control of engine operation temperature is maintained at or in relatively close proximity to this predetermined temperature thereby eliminating overheating and corrosive deterioration of the cooling system. Free coolant flow between the radiator and a small expansion reservoir is maintained at all times with the expansion reservoir positioned at the elevation of an outlet near the top of the radiator or slightly above this elevation. The system is provided with a transparent viewing cap for the radiator so that the level of liquid coolant can be observed at all times.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of co-pending U.S. patent application Ser. No. 13/700,090, filed Jan. 31, 2013, now U.S. Pat. No. ______, which is a national phase entry under 35 U.S.C. §371 of International Patent Application PCT/NL2011/050366 filed on May 26, 2011, published in English as International Patent Publication No. WO 2011/149349 A1, which claims the benefit under Article 8 of the Patent Cooperation Treaty to European Patent Application Serial No. 10163925.0, filed May 26, 2010, the disclosure of each of which is hereby incorporated herein in its entirety by this reference.
TECHNICAL FIELD
[0002] The application relates to pharmaceutics and improving the aqueous solubility of 2-iminobiotin. In a particular aspect, the application pertains to formulations suitable for administration of 2-iminobiotin to mammals suffering from disorders or conditions that benefit from that administration.
BACKGROUND
[0003] It has been reported that 2-iminobiotin can be used to prevent and/or treat the effects of perinatal asphyxia (hypoxia-ischemia) in neonates (U.S. Pat. No. 6,894,069, which is hereby incorporated by reference in its entirety). In particular, in-vivo studies involving piglets demonstrated that 2-iminobiotin is more effective in preventing and/or treating these effects than either allopurinol or deferoxamine.
[0004] The low solubility of 2-iminobiotin at physiological pH, however, limits its usefulness as a therapeutic agent. There exists a need in the art for improved 2-iminobiotin formulations and methods of increasing its solubility. The disclosure provides such improvements.
BRIEF SUMMARY
[0005] Provided is an aqueous, soluble formulation of 2-iminobiotin (2-IB), or a derivative thereof, having a pH between around 3 and around 7, and comprising around 1 mg/ml or more of 2-iminobiotin, or a derivative thereof, and between around 2.5 to around 40% of a substituted beta-cyclodextrin.
[0006] In some embodiments, the formulation has a pH between around 4 and around 7, and comprising around 2 mg/ml or more of 2-iminobiotin, or a derivative thereof, and around 2.5 to around 20% of a substituted beta-cyclodextrin, preferably selected from sulfobutyl-ether-beta-cyclodextrin (SBE-CD) and hydroxypropyl-beta-cyclodextrin (HP-CD).
[0007] In some embodiments, the formulation has a pH between around 4 and around 5, and comprising around 3.5 mg/ml or more of 2-iminobiotin and between around 2.5 to around 40, preferably between around 5 to around 10% of a substituted beta-cyclodextrin, preferably selected from sulfobutyl-ether-beta-cyclodextrin (SBE-CD) and hydroxypropyl-beta-cyclodextrin (HP-CD).
[0008] In some embodiments, the formulation has a pH between around 4 and around 5 and comprising between around 3 to around 5 mg/ml, preferably between around 4 to around 5 mg/ml of 2-iminobiotin, and around 2.5 to around 5% of a substituted beta-cyclodextrin, preferably selected from sulfobutyl-ether-beta-cyclodextrin (SBE-CD) and hydroxypropyl-beta-cyclodextrin (HP-CD).
[0009] Preferably, the formulation further comprises citric acid or a deprotonated version thereof (citrate) as a solubility enhancer.
[0010] In some embodiments, a soluble formulation of 2-iminobiotin, or a derivative thereof, is provided having a pH around 5 and comprising around 3 mg/ml or more of 2-iminobiotin and around 3 to around 40%, preferably around 5% of SBE-CD.
[0011] In some embodiments, a soluble formulation of 2-iminobiotin, or a derivative thereof, is provided having a pH around 4, and comprising around 3 mg/ml or more of 2-iminobiotin and around 5 to around 40% of HP-CD. Preferably the formulation comprises from around 5 to around 20% HP-CD.
[0012] In some embodiments, the formulations further comprise NaCl, preferably between 0.1 and 2%, more preferably between 0.5 and 0.8% as an isotonicity agent.
[0013] Also provided is an aqueous, soluble formulation of 2-iminobiotin (2-IB), or a derivative thereof, having a pH between around 3 and around 7, and comprising around 0.75 mg/ml or more of 2-iminobiotin and citric acid, a deprotonated version thereof, or a mixture thereof. Surprisingly, 2-IB was found to have a higher solubility in citric acid buffer. As used herein, citric acid buffer refers to citric acid, a deprotonated version thereof, or a mixture thereof and includes aqueous solutions of, e.g., sodium citrate dehydrate.
[0014] Preferably, the formulation has a pH between around 3 and around 7, preferably between around 3 and around 6, more preferably between around 3.5 and around 4.5, even more preferably around pH 4, and comprises between around 0.5 mg/ml and around 10 mg/ml, preferably between around 0.5 mg/ml and around 5 mg/ml of 2-iminobiotin, more preferably between around 0.5 mg/ml and around 2 mg/ml, even more preferably between around 0.5 mg/ml and around 1 mg/ml of 2-iminobiotin and citric acid, a deprotonated version thereof, or a mixture thereof. Preferably, the formulations comprise between about 1 to about 40, about 5 to about 30, preferably about 10 to about 20, more preferably about 12.5 to about 17.5 mM, even more preferably around 15 mM citric acid, a deprotonated version thereof, or a mixture thereof. It is clear to a skilled person that the amount of buffer can be adjusted to obtain the desired pH level. Preferably, the formulation comprises between 0.1 and 2% of NaCl as an isotonicity agent, more preferably between 0.5 and 1.5%. An exemplary formulation has a concentration of about 0.9% NaCl.
[0015] Preferably, the formulation is suitable for administration to a human neonate. Preferably, the 2-iminobiotin, or a derivative thereof, remains soluble for at least 3 days at 5° C. In some embodiments, the 2-iminobiotin, or a derivative thereof, remains soluble for at least 0.5, 1, 1.5, 2, or 3 years at 5° C.
[0016] Also provided are 2-iminobiotin formulations, or a derivative thereof, as described herein for use in treating the effects of complications during childbirth, preferably for treating perinatal asphyxia or the risk thereof, in a neonate. In some embodiments, the formulation is administered to the neonate. In some embodiments, the formulation is administered to the mother of the neonate prior to and/or during labor.
[0017] Further provided is the use of 2-iminobiotin, or a derivative thereof, for use in treating the effects of complications during childbirth, preferably for treating perinatal asphyxia or the risk thereof, wherein the treatment is combined with subjecting the neonate to hypothermia.
[0018] Also provided are methods for treating the effects of complications during childbirth in a neonate, comprising administering a therapeutically effective amount of the formulation described herein to the neonate in need thereof. In some embodiments, the formulation is also administered, or administered instead, to the mother of the neonate in need thereof prior to and/or during labor. Preferably, the complication is perinatal asphyxia or the risk thereof.
[0019] Further provided are methods for treating the effects of complications during childbirth in a neonate, comprising administering a therapeutically effective amount of 2-iminobiotin, or a derivative thereof, to the neonate in need thereof and subjecting the neonate to hypothermia. In some embodiments, the 2-iminobiotin, or a derivative thereof, is also administered, or administered instead, to the mother of the neonate in need thereof prior to and/or during labor. Preferably, the complication is perinatal asphyxia or the risk thereof. Preferably, the 2-iminobiotin, or a derivative thereof, is in a formulation as described herein.
[0020] Still further provided is the use of 2-iminobiotin, or a derivative thereof, for the manufacture of a medicament with a formulation as described herein for treating the effects of complications during childbirth. In some embodiments, the treatment is combined with subjecting the neonate to hypothermia. Preferably, the complication is perinatal asphyxia. The formulations are also provided for use in treating a disease or disorder responsive to 2-iminobiotin treatment.
[0021] Further provided are methods for preparing the formulations described herein comprising the steps of dissolving 2-iminobiotin, or a derivative thereof, in an aqueous solution comprising a beta-cyclodextrin followed by adjusting the pH of the solution resulting in a 2-iminobiotin solution, or a derivative thereof Preferably, the p14 of the 2-iminobiotin solution is adjusted using citric acid. Preferably, the pH is adjusted to between around 3 to around 7. Preferably, the aqueous solution is between pH 4 and 6.6. Preferably, the beta-cyclodextrin is SBE-CD. Preferably, the aqueous solution comprises NaCl. Preferably, the aqueous solution comprises citric acid or a deprotonated version thereof.
[0022] Preferably, 2-IB derivatives are 2-iminobiotin carboxy derivatives. Preferably, 2-iminobiotin carboxy derivatives are 2-iminobiotin hydrazide and/or 2-iminobiotin N-hydroxysuccinimide ester. Preferably, the formulations described herein comprise 2-IB.
[0023] 2-iminobiotin (2-IB) has poor water solubility and, thus, is difficult to formulate as an aqueous solution for administration (see Comparative Examples). In accordance with the disclosure, it has been found that the water-solubility of 2-IB may be sufficiently increased to allow it to be formulated as an aqueous solution by adding 2-IB to a citric acid/citrate buffer and/or a substituted beta-cyclodextrin. The terms “insoluble” and “poorly soluble” are used herein to characterize a drug in respect of its water solubility. As used herein, “insoluble” refers to solubility of less than 0.1 mg/ml and “poorly soluble” refers to solubility in the range of 0.1 to 1 mg/ml.
[0024] The solubility of 2-IB is pH dependent. The solubility of 2-IB in water is around 0.34 mg/ml at pH 7.4, around 0.59 mg/ml at pH 5, and around 4.5 mg/ml at pH 3.5. As administration of low pH solutions intramuscularly can illicit pain in a subject (R. Rukwied, J. Pain. 2007 May; 8(5):443-51) and can lead to metabolic acidosis when administered as a continuous intravenous infusion (M. C. Federman, Clinical Neuropharmacology 2009 November-December; 32(6):340-1), one object of the disclosure is to provide 2-IB formulations with a pH and 2-IB concentration suitable for administration in a therapeutic setting.
[0025] In the treatment of conditions associated with, e.g., asphyxia or hypoxia, a therapeutically effective amount of drug needs to be administered within a specific period of time in order to be effective. With the formulations present in the prior art, a significant volume of 2-IB solution needs to be administered due to the low solubility of 2-IB. The larger the volume of solution needed to be administered, the longer the time before a therapeutically effective concentration in the body is reached. For some applications, such as the treatment of neonates, the volume of solution needed to be administered within the therapeutic window is a limiting factor. Typically, the maximum amount of fluid to be considered, save to administer intravenously to an asphyxiated term neonate, is 50 ml/kg/day. By increasing the solubility of 2-IB, the drug can be more quickly administered and in a lower volume.
[0026] 2-IB formulations should, optimally, be stable for long periods of time, preferably for several years. In addition, the formulations should not precipitate when stored in a cool environment, such as 5 degrees C.
[0027] Various drug formulations were produced using a variety of solvents, co-solvents, surfactants, cyclodextrins, and other excipients. The solubility of 2-IB was either low or the formulation was toxic (see Comparable Examples). Surprisingly, formulating 2-IB with more than 1% substituted beta-cyclodextrins, in particular with 2.5% or more, and/or with citric acid buffers, provided solutions with increased solubility at suitable pH levels.
[0028] The formulations described herein are suitable for preparing pharmaceutical solutions of 2-IB (C 10 H 17 N 3 O 2 S) as well as 2-IB derivatives. 2-IB derivatives include 2-iminobiotin carboxy derivatives. 2-iminobiotin carboxy derivatives have been shown to be inhibitors of iNOS, indicating that the free carboxyl group of 2-IB is not required for iNOS inhibition (S. J. Sup et al., Biochem. and Biophys. Res. Comm. 1994 204:962-968). Preferably, 2-iminobiotin carboxy derivatives are 2-iminobiotin hydrazide and/or 2-iminobiotin N-hydroxysuccinimide ester. Preferably, the formulations described herein comprise 2-IB.
[0029] Cyclodextrins vary in structure and properties. For example, the size (e.g., diameter, and depth) and functionality (e.g., hydrophobicity, charge, reactivity and ability to hydrogen bond) of the hydrophobic cavity varies among substituted and unsubstituted alpha-, beta- and gamma-cyclodextrins. The term “cyclodextrin” refers to a compound including cyclic alpha-linked D-glucopyranose units. Alpha-cyclodextrin refers to a cyclodextrin with six cyclic, linked D-glucopyranose units, beta-cyclodextrin has seven cyclic, linked D-glucopyranose units, and gamma-cyclodextrin has eight cyclic, linked D-glucopyranose units. These cyclic, linked D-glucopyranose units define a hydrophobic cavity, and cyclodextrins are known to form inclusion compounds with other organic molecules, with salts, and with halogens, either in the solid state or in aqueous solutions. Typically, a cyclodextrin selected for a formulation has a size and functionality that is suitable for the target component and the other components of the formulation. Unfortunately, there are many drugs for which cyclodextrin complexation either is not possible or produces no apparent advantages (J. Szejtli, Cyclodextrins in Drug Formulations: Part II, Pharmaceutical Technology, 24-38, August, 1991).
[0030] Substituted cyclodextrins can include as side chains any organic moiety or a hetero-organic moiety. Preferred cyclodextrins include substituted beta-cyclodextrins that have been alkylated, hydroxyalkylated, or reacted to form a sulfoalkyl ether. Preferred beta-cyclodextrins include hydroxypropyl-beta-cyclodextrin, e.g., (S)-2-hydroxypropyl-beta-cyclodextrin, 2-O-[(S)-2′-hydroxylpropyl]-beta-cyclodextrin, 2-O-[(R)-2′-hydroxylpropyl]-beta-cyclodextrin, 6-O-[(S)-2′-hydroxylpropyl]-beta-cyclodextrin, 2-O-[(R)-2′,3′-hydroxylpropyl]-beta-cyclodextrin; hydroxyethyl-beta-cyclodextrin; carboxymethyl-beta-cyclodextrin; carboxymethyl-ethyl-beta-cyclodextrin; diethyl-beta-cyclodextrin; dimethyl-beta-cyclodextrin; glucosyl-beta-cyclodextrin; hydroxybutenyl-beta-cyclodextrin; maltosyl-beta-cyclodextrin; and sulfobutylether-beta-cyclodextrin. For the present formulations and methods, it is believed that substituted beta-cyclodextrins, such as, e.g., hydroxypropyl-beta-cyclodextrin and sulfobutylether-beta-cyclodextrin, have a size and functionality that complement the other components of the formulation. More preferably, the cyclodextrin is sulfobutylether-beta-cyclodextrin (“SBE-CD”).
[0031] Two types of substituted beta-cyclodextrins were tested in the 2-IB formulations. Both markedly increased the solubility of 2-IB. (See Examples.) Sulfobutylether-beta-cyclodextrin (SBE-CD) is a commercially available polyanionic beta-cyclodextrin derivative with a sodium sulfonate salt separated from the hydrophobic cavity by a butylether spacer group, or sulfobutylether (CAPTISOL® is the trade name for hepta-substituted sulfobutylether-beta-cyclodextrin available from CyDex Inc.). Hydroxypropyl-beta-cyclodextrin (HP-CD) is a commercially available beta-cyclodextrin derivative available from Roquette Pharma S.A. as KLEPTOSE®. Cyclodextrins are further described in U.S. Pat. Nos. 5,134,127 and 5,376,645, the entire contents of which are hereby incorporated by reference.
[0032] The 2-IB formulations disclosed herein may be formed of dry physical mixtures of 2-IB and the substituted beta-cyclodextrin or dry inclusion complexes thereof, which, upon addition of water, are reconstituted to form an aqueous formulation. Alternatively, the aqueous formulation may be freeze-dried and later reconstituted with water.
[0033] In some embodiments, the 2-IB formulations disclosed herein are in the form of an aqueous solution and include an acid buffer to adjust the pH within the range from about 4 to about 7. Examples of acid buffers suitable for use herein include acids such as hydrochloric acid, sulfuric acid, phosphoric acid, hydrobromic acid and the like, and organic acids such as oxalic acid, maleic acid, fumaric acid, lactic acid, malic acid, tartaric acid, citric acid, benzoic acid, acetic acid, methanesulfonic acid, toluenesulfonic acid, benzene sulfonic acid, ethane sulfonic acid, and the like. Acid salts of the above acids may be employed as well. Preferably, the formulation comprises sufficient citric acid and/or sodium citrate or other citrate salt to reach the desired pH. In some embodiments, the formulations comprise between 1 and 25 mM citric acid. In some embodiments, the formulations comprise between 0.1 and 5 mM sodium citrate. In some embodiments, the formulations comprise at least 20 mM citric acid/citrate. Preferably, the formulations comprise between about 1 to about 40, about 5 to about 30, preferably about 10 to about 20, more preferably about 12.5 to about 17.5 mM citric acid, a deprotonated version thereof, or a mixture thereof. Preferably the formulations comprise around 15 mM citric acid, a deprotonated version thereof, or a mixture thereof.
[0034] The 2-IB formulations disclosed herein may be prepared as follows: citric acid or other acid buffer is dissolved in water for injection. The substituted beta-cyclodextrin (preferably SBE-CD), if used, is dissolved in the acid buffer-water solution. 2-IB is then dissolved in the solution. Alternatively, the substituted beta-cyclodextrin (preferably SBE-CD), if used, is dissolved in a water solution, and 2-IB is then dissolved in the solution. The pH is adjusted to within the range from about 3 to about 6.
[0035] The formulations are preferably prepared and packaged for use as sterile and pyrogen-free. For example, the resulting solution may be aseptically filtered, e.g., through a 0.22-micron membrane filter and filled into sterile vials. The vials are stopped and sealed and may be terminally sterilized. The solutions may also be provided in ampoules, syringes, IV bags, or other dispensers. Preferably, the formulation is provided in a single dose unit. The solutions can be autoclaved without affecting 2-IB stability (Table 24).
[0036] It may also be desirable to include isotonic agents, for example, sugars, sodium chloride and the like. Prolonged absorption of the injectable pharmaceutical form can be brought about by the use of agents delaying absorption, for example, aluminum monostearate and gelatin.
[0037] 2-IB formulations intended for pediatric administration preferably do not comprise contraindicated excipients (e.g., lactic acid, docusate sodium, propylene glycol, etc.). Preferably, formulations for pediatric administration also do not contain benzyl alcohol, propyl gallate, polysorbate 20, 40 or 60, sodium benzoate, thimerosal, peanut oil, or boric acid. It is within the purview of one skilled in the art to select suitable additional agents.
[0038] Preferably, the 2-IB formulations are isotonic. In some embodiments, the 2-1B formulations further comprise NaCl, preferably between 0.1 and 0.9%, more preferably between 0.2 and 0.9%. In some embodiments, the 2-IB formulations further comprise sugars, such as glucose, lactose, or mannitol, preferably between 1 and 5%, more preferably between 2 and 5%. Preferably, in particular with a pediatric formulation, the sugar is glucose. The formulation may comprise a combination of NaCl and sugar in such an amount that the formulation is isotonic.
[0039] The disclosure provides solutions and dosage forms of 2-IB for, preferably, parenteral administration. “Parental administration” as used herein refers to modes of administration including, without limitation, intravenous, intramuscular, intra-arterial, intrathecal, intracapsular, intraorbital, intracardiac, intradermal, intraperitoneal, transtracheal, subcutaneous, subcuticular, intraarticular, subcapsular, subarachnoid, intraspinal and intrasternal injection and infusion. Preferably, the formulations are administered intravenously.
[0040] The formulations may be provided in vials, ampoules, syringes, IV bags, or other dispensers. They may be administered directly to a subject or further diluted. A dose-concentrate of a provided formulation can be in a sealed container holding an amount of the formulation to be employed over a standard treatment interval such as immediately upon dilution, or up to 24 hours after dilution, as necessary. A solution for intravenous administration can be prepared, for example, by adding a dose-concentrate formulation to a container (e.g., glass or plastic bottles, vials, ampoules) in combination with diluent so as to achieve desired concentration for administration.
[0041] Addition of aqueous solvent to a liquid dose concentrate may be conveniently used to form unit dosages of liquid pharmaceutical formulations by removing aliquot portions or entire contents of a dose concentrate for dilution. Dose concentrate may be added to an intravenous (IV) container containing a suitable aqueous solvent. Useful solvents are standard solutions for injection (e.g., 5% dextrose, saline, lactated ringer's, or sterile water for injection, etc.). Typical unit dosage IV bags are conventional glass or plastic containers having inlet and outlet means and having standard (e.g., 25 mL, 50 mL, 100 mL and 150 mL) capacities.
[0042] In other embodiments, it may be desirable to package a provided dosage form in a container to protect the formulation from light until usage. In some embodiments, use of such a light-protective container may inhibit one or more degradation pathways. For example, a vial may be a light container that protects contents from being exposed to light. Additionally and/or alternatively, a vial may be packaged in any type of container that protects a formulation from being exposed to light (e.g., secondary packaging of a vial). Similarly, any other type of container may be a light-protective container, or packaged within a light-protective container.
[0043] The formulations may be administered to a subject, which includes any vertebrate animal, preferably a mammal, and more preferably a human. Examples of subjects include humans, non-human primates, rodents, guinea pigs, rabbits, sheep, pigs, goats, cows, horses, dogs, cats, birds, and fish.
[0044] In some embodiments, the 2-IB formulations are suitable for administration to newborn babies and, in particular, to neonates who suffer from, are expected to suffer from, or are otherwise judged to be at risk from, complications during childbirth, in particular, from perinatal asphyxia, which can lead to hypoxia-ischemia. Perinatal asphyxia may also occur well before birth or after and are also suitable for treatment with the 2-IB formulations described herein. The terms “newborn baby” and “neonate” include babies born by natural childbirth as well as babies that have been delivered by, for instance, caesarean section, and also include babies that have been born prematurely and/or the birth of which has been artificially induced.
[0045] In some embodiments, the 2-IB formulations are suitable for administration to the mother of the fetus, when an asphyxiated newborn is expected. The term “mother” refers to the mother of the fetus or the newborn baby, including natural, inseminated, induced and carrier mothers.
[0046] Usually, treatment of a neonate with the 2-IB formulations will be carried out shortly after childbirth, e.g., during the “window” for therapeutic intervention. Usually, this window spans the first day following childbirth and, in particular, the first 0-24 hours following childbirth. However, if an asphyxiated baby can be expected, treatment may be carried out in the mother before the expected labor, in particular, about 0-24 hours before labor.
[0047] As part of such treatment, the 2-IB formulations will generally be administered to the neonates in one or more pharmaceutically effective amounts and, in particular, in one or more amounts that are effective in preventing and/or treating the above-mentioned effects. Such treatment may involve only single administration, but usually--and preferably--involves multiple administrations over several hours or days, e.g., as part of, or according to, an administration regimen or treatment regimen. Such a treatment regimen may, for instance, be as follows: every 4 hours by intravenous injection of the substance during the first 24 hours.
[0048] Usually, the amount of 2-IB administered to the neonate will correspond to between 0.01 and 30 mg per kg body weight per day, preferably between 0.1 and 25 mg/kg per day, more preferably between 1.8 and 12 mg/kg/day. These amounts refer to the active component and do not include carrier or adjuvant materials such as carbohydrates, lipids or proteins, or the like. These amounts may be administered as a single dose or as multiple doses per day, or essentially continuously over a certain period of time, e.g., by continuous infusion. Preferably, the 2-IB is administered in 3-6 dosages/day. Preferably, 2-IB is administered to a human neonate in a dose of between 0.01 to 1 mg/kg, preferably between 0.05 to 0.75 mg/kg, more preferably between 0.05 to 0.5 mg/kg. Exemplary doses are 0.075, 0.45, and preferably 0.15 mg/kg.
[0049] Treatment may be continued up to 24, 48 or 72 hours after asphyxia, or otherwise until the neonate is judged no longer to be at risk of the effects mentioned above. However, the treatment, especially the preventive treatment, may also involve administration of the 2-IB formulation to the mother before or during parturition. The formulation may be administered to the mother, e.g., orally, subcutaneously, or by intravenous injection. The amounts to be administered can then be the same or higher, depending on the placental transfer and the metabolism, the first pass effect in the liver and the distribution volume of the compound. Thus, the amounts administered to the mother may vary between, e.g., 0.01-25 mg of active component per kg of the body weight of the mother per day.
[0050] One aspect of the disclosure provides for treating complications in childbirth comprising the administration of 2-IB in combination with hypothermia. Hypothermia has been demonstrated to have a therapeutic effect in several models of brain injury. For example, numerous publications exist showing the beneficial effect of hypothermia in both in-vitro (M. Onitsuka et al. 1998, mild hypothermia protects rat hippocampal CAl neurons from irreversible membrane dysfunction induced by experimental ischemia, Neuroscience Research 30:1-6) and in-vivo models of neonatal asphyxia (T. Debillon et al. 2003, whole-body cooling after perinatal asphyxia: a pilot study in term neonates, Developmental Medicine and Child Neurology 45:17-23).
[0051] As used herein, the term “hypothermia” refers to subjecting a particular subject (in this case, a neonatal subject) to hypothermic conditions, for example, by lowering the body temperature through passive or active techniques. Typically, subjecting to hypothermic conditions leads to a decrease in metabolism of body tissues of the subject, thereby decreasing the need for oxygen.
[0052] In some embodiments, the core body temperature in a mammal is lowered by at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10° below the normal core body temperature for the mammal. In some embodiments, the core body temperature in a mammal is lowered by between 1-10, 2-6, or preferably 2-4° below the normal core body temperature for the mammal.
[0053] In one preferred embodiment, the temperature of the mammal is maintained at a temperature of from about 31° to about 37 degrees Celsius. More preferably, the temperature of the mammal is maintained at a temperature of from about 32 degrees Celsius to about 36 degrees Celsius; more preferably from about 32 degrees Celsius to about 35 degrees Celsius; more preferably still from about 33 degrees Celsius to about 35 degrees Celsius.
[0054] Induction of hypothermia by lowering of the core temperature of the body may be performed by any method known in the art. Typical hypothermia induction means use either whole body or head cooling. Hypothermia may be induced using ice/cold water or mechanical cooling devices such as surface cooling, the Olympic CoolCap™ system, and cooling using catheters placed in a large vessel. Alternatively, hypothermia may be induced using pharmaceutical agents such as, e.g., vanilloid receptor agonists, capsaicinoids or capsaicinoid-like agonists (described in U.S. Patent Publication 20090197966, the content of which is hereby incorporated by reference) and neurotensin analogs capable of crossing the blood-brain barrier, such as NT69L and NT77 (described in U.S. Pat. No. 7,319,090, the content of which is hereby incorporated by reference).
[0055] Hypothermia and 2-IB may be administered simultaneously, sequentially, or separately. As used herein, “simultaneously” is used to mean that the 2-IB is administered concurrently with hypothermia, whereas the term “in combination” is used to mean the 2-IB is administered, if not simultaneously, then “sequentially” within a timeframe in which the 2-IB and the hypothermia both exhibit a therapeutic effect, i.e., they are both available to act therapeutically within the same time-frame. Thus, administration “sequentially” may permit the 2-IB to be administered within 5 minutes, 10 minutes or a matter of hours before or after the hypothermia, provided the circulatory half-life of the 2-IB is such that it is present in a therapeutically effective amount when the neonatal subject is exposed to hypothermic conditions.
[0056] In contrast to “in combination” or “sequentially,” “separately” is used herein to mean that the gap between administering the 2-IB and exposing the neonatal subject to hypothermia is significant, i.e., the 2-IB may no longer be present in the bloodstream in a therapeutically effective amount when the neonatal subject is exposed to hypothermic conditions.
[0057] In one preferred embodiment, the 2-IB is administered in a therapeutically effective amount.
[0058] In another preferred embodiment, the 2-IB is administered in a sub-therapeutically effective amount. In other words, the 2-IB is administered in an amount that would be insufficient to produce the desired therapeutic effect if administered in the absence of hypothermic conditions. Even more preferably, the combination of 2-IB and hypothermia has a synergistic effect, i.e., the combination is synergistic.
[0059] In some embodiments, the hypothermia is maintained for a period of at least about 6, 12, 18, 24, 36, 48, 72, or 96 hours after the hypoxic-ischemic (HI) insult or after birth. In one preferred embodiment, the hypothermia is maintained for a period of from about 6 to about 24 hours after the hypoxic-ischemic (HI) insult or after birth, preferably at least 72 hours.
[0060] Preferably, treatment in accordance with a method hereof is initiated within about 6 hours of the hypoxic-ischemic (HI) insult, and more preferably within about 2 hours, more preferably within 1 hour, of the hypoxic-ischemic insult.
[0061] In another aspect, the 2-IB is administered prior to the hypoxic insult. Thus, in one preferred embodiment, the 2-IB is administered to the neonate via the mother prior to birth, for example, by administering to the mother prior to or during labor. Methods are provided for treating neonatal asphyxia in a mammal in need thereof, the method comprising: (a) administering a therapeutically effective amount of 2-IB to the mother of the mammal prior to and/or during labor; and (b) subjecting the mammal to hypothermia after birth.
[0062] Preferably, the 2-IB is administered to the mother for up to about 48 or 24 hours prior to birth. After birth, the neonate is then subjected to hypothermic conditions. In some embodiments, 2-IB is administered to the mother as soon as the mother is found at risk or the fetus is found to be asphyctic or has delayed growth.
[0063] “About” and “approximately” shall generally mean an acceptable degree of error for the quantity measured given the nature or precision of the measurements. Typically, exemplary degrees of error are within 20 percent (%), preferably within 10%, and more preferably within 5% of a given value or range of values.
[0064] As used herein, a therapeutic that “prevents” a disorder or condition refers to a compound that, in a statistical sample, reduces the occurrence of the disorder or condition in the treated sample relative to an untreated control sample, or delays the onset or reduces the severity of one or more symptoms of the disorder or condition relative to the untreated control sample.
[0065] The term “treating” includes prophylactic and/or therapeutic treatments. The term “prophylactic or therapeutic” treatment is art-recognized and includes administration to the host of one or more of the subject compositions. If it is administered prior to clinical manifestation of the unwanted condition (e.g., disease or other unwanted state of the host animal), then the treatment is prophylactic (i.e., it protects the host against developing the unwanted condition), whereas if it is administered after manifestation of the unwanted condition, the treatment is therapeutic (i.e., it is intended to diminish, ameliorate, or stabilize the existing unwanted condition or side effects thereof).
BRIEF DESCRIPTION OF THE DRAWINGS
[0066] FIG. 1 : Solubility of 2-IB with and without 10% SBE-CD at a different pH.
DETAILED DESCRIPTION
EXEMPLIFICATION
[0067] 2-IB has both an acidic, carboxylic acid, group as well as a basic amino group. The calculated pKa for these groups are 4.78 for the carboxylic acid group and 11.48 for the amino group, respectively, using the PrologP calculation software. Due to the acidic and basic groups present in 2-IB, 2-IB exhibits zwitterionic behavior in the neutral pH range. As a result, the water solubility of 2-IB is strongly pH dependent and much lower than the calculated value of 35 g/l at neutral pH conditions (see Table 1). Based on the zwitterionic nature of 2-IB, it is difficult to develop a suitable formulation. The following comparative examples demonstrate a number of attempts to develop a formulation of 2-IB suitable for IV administration.
Comparative Example 1
Solvent selection
[0068] Solubility of 2-IB was determined in the following solvents:
0.9% Sodium chloride in water 5% Dextrose in water N,N-dimethyl acetamide N,N-dimethylformamide Dimethyl sulfoxide Ethanol Propylene glycol Polyethylene glycol 400 Corn oil
[0078] Approximately 10 mg of 2-IB was weighed into a 10 ml tube. Subsequently, small aliquots (100 μl-200 μl-400 μl-800 μl-1600 μl -3200 μl) of the respective solvents were added stepwise. After each addition, the solution was mixed intensively and visually judged for solubility. The end volume for all solvents was 6400 μl (1.6 mg/ml).
[0079] In all of the experiments, a large amount of undissolved 2-IB remained after addition of 6400 μl of solvent, indicating that 2-IB is not sufficiently soluble in any of these solvents. After addition of 100 μl of 1 N hydrochloric acid, 2-IB fully dissolved in all solvents. This further illustrates the zwitterionic behavior of 2-IB and the strong influence of pH on solubility.
[0080] Visually, the highest fraction of 2-IB was dissolved in propylene glycol. Therefore, the experiment was repeated for propylene glycol but with addition of 100 μl N hydrochloric acid after 200 μl propylene glycol (i.e., 10 mg 2-IB+200 μl propylene glycol+100 μl 1 N hydrochloric acid). This resulted in a 33 mg/ml solution of 2-IB that was fully dissolved and stable. Addition of water to this formulation immediately resulted in precipitation of 2-IB illustrating that this is not a viable route toward an IV formulation.
[0081] Since all solvents tested required the addition of acid for full solubilization of 2-IB, it was decided to continue with 5% dextrose in water since the other solvents were obviously much less biocompatible during IV introduction or possessed a higher risk of salting out effects (0.9% sodium chloride in water).
[0082] When an acidified 2-IB formulation in 5% dextrose is prepared, the pH after acidification is approximately 2 for nominal 2-IB concentrations in the range 1-5 mg/ml. Partial neutralization with 0.1% sodium hydroxide is possible up to a pH of 3-3.5 (depending on nominal concentration) but eventually precipitation of 2-IB occurs, first in the form of very fine “hair”-like needles that grow out to larger agglomerates. At a pH of 7, nearly all 2-IB has precipitated out of solution based on visual observation.
Comparative Example 2
Surfactants
[0083] The following surfactants were studied for their solubility-enhancing behavior:
Hexadecyl trimethyl ammonium bromide (cationic surfactant, 1%) Polyoxyethylene(40) stearate (non-ionic surfactant, 1%, 0.1% and 0.01%) Polysorbate 80 (non-ionic surfactant, 1%) Sodium dodecylsulfate (anionic surfactant, 1%, 0.1%, 0.01%)
[0088] Stock solutions of the surfactant were prepared in 5% dextrose. The test procedure used was the stepwise addition of the respective surfactant solution to a small amount of 2-IB (10 mg), as described in Comparative Example 1. 2-IB did not dissolve in any of the surfactant solutions at the nominal concentration of 1.6 mg/ml without the addition of acid. After addition of acid, it fully dissolved, but following subsequent (partial) neutralization with 0.1 N sodium hydroxide, 2-IB precipitated again exactly as was observed in the experiments without surfactants. This leads to the conclusion that the surfactants do not enhance the solubility of 2-IB (also not at low pH) and are, therefore, not a useful addition for formulations.
[0089] Table 1 depicts several examples of 2-IB solubility in various formulations. An excess of 2-IB was added to the solvent/surfactant solutions, mixed at room temperature and then filtered to removed non-solubilized 2-IB. These solutions were then analyzed by RP-HPLC to determine the solubilized content of 2-IB.
[0000]
TABLE 1
Overview of 2-IB
Visual inspection
Conc.
after 12 hours
2IB
Description
at 5° C.
(mg/mL)
2-IB in 10% Propylene glycol/90% water
Precipitation
0.40
2-IB in 30% Propylene glycol/70% water
Small amount
0.51
of precipitation
2-IB in 10% PEG 300/90% water
Small amount
0.35
of precipitation
2-IB in 30% PEG 300/70 % water
No precipitation
0.38
2-IB in 2% TWEEN ® BO/98% water
No precipitation
0.37
2-IB in 10% CREMOPHOR ® ELP/90%
No precipitation
0.34
water
2-IB in 10% Propylene glycol, 10% PEG
Small amount
0.24
300/80% Water
of precipitation
2-IB in 10% Propylene glycol, 10% PEG
Small amount
0.37
300, 2% TWEEN ® 80/78% Water
of precipitation
2-IB in 10% Propylene glycol, 10% PEG
Small amount
0.35
300, 10% CREMOPHOR ® ELP/70% Waier
of precipitation
2-IB in 10% Propylene glycol, 10% PEG
Small amount
0.33
300, 2% TWEEN ® 80, 10%
of precipitation
CREMOPHOR ® ELP/68% Water
Comparative Example 3
Cyclodextrins
[0090] The following cyclodextrins were tested, all at a 1% concentration in a 5% dextrose solution:
α-cyclodextrin β-cyclodextrin hydroxypropyl-α-cyclodextrin (2-hydroxypropyl)-β-cyclodextrin (2-hydroxypropyl)-γ-cyclodextrin
[0096] Similar to the surfactants, no increase in solubility was observed during any of the experiments, also not at low pH.
Comparative Example 4
Novel Excipients
[0097] Finally, two novel excipients were tested, CREMOPHOR® EL and SOLUTOL® HS 15. Stock solutions of these excipients were prepared at a concentration of 10% in 5% dextrose and then the stepwise solubility approach was performed. Using SOLUTOL® HS 15, the best results were obtained (after addition of hydrochloric acid) and, therefore, the next step was to optimize the SOLUTOL® HS 15 concentration.
[0098] Five concentrations, 5-10-15-20-25%, of SOLUTOL® HS 15 were tested at a formulation concentration of approximately 5 mg/ml (Table 2). Optimal solubility of 2-IB was observed in 20% SOLUTOL® HS 15, but still a very acidic (pH <2) initial solution was required to solubilize 2-IB complete. However, upon subsequent partial neutralization with sodium hydroxide precipitation of 2-IB occurred at higher pH and at much lower amounts than that observed in formulations of 2-IB in dextrose. A range of 2-IB formulations were prepared that were stored for 48 hours and measured for 2-IB content:
[0000]
TABLE 2
Concentration
Nominal
Concentration
t = 48 hours
concentration
Concentration
t = 48 hours
relative to t = 0
(mg/ml)
pH 1
t = 0 (mg/ml) 2
(mg/ml) 2
(%) 2
5.0
2.4
5.65
4.78
85
2.8
5.43
5.45
100
3.0
4.64
4.87
105
3.5
5.21
4.94
95
3.6
4.52
3.93
87
3.8
5.10
2.62
51
10.2
5.71
0
0
10
3.0
9.06
8.64
95
3.5
8.30
8.04
97
20
3.0
16.6
16.7
101
3.5
14.7
13.2
90
1 pH adjusted using 1N hydrochloric acid and 0.1N Sodium hydroxide
2 Concentration was analyzed after filtration
[0099] Based on the research performed during this project, a vehicle consisting of 20% SOLUTOL® HS 15 and 5% Dextrose in water was selected as the optimal vehicle for preparation of 2-IB formulations. Due to the zwitterionic nature of 2-IB, the formulation could only be prepared at a relatively low pH (i.e., <3.5-3.6).
Comparative Example 5
SOLUTOL® HS 15 Toxicity Study
[0100] Preliminary toxicity study via continuous intravenous infusion in Wistar rats.
[0101] Group I: vehicle 20% SOLUTOL® (continuous intravenous infusion)
[0102] Animals received a continuous infusion of vehicle only (20% SOLUTOL® in 5% dextrose) at a dose volume of 4 mL/kg/hour for 24 hours.
[0103] No mortality occurred and body weights were normal. A hunched posture and piloerection was noted for all animals from approximately 12 hours after start of infusion onward. Necropsy was performed to investigate any macroscopic effects of SOLUTOL® treatment. Macroscopic findings at necropsy comprised of yellow discoloration of the whole body and body cavities (2/4), minimal fibrin-like coating in the vena cava (4/4), accentuated lobular pattern of the liver (1/4), a small liver (1/4), and pelvic dilation of the kidneys (1/4).
[0104] Group II: vehicle 5% SOLUTOL® (Continuous Intravenous Infusion)
[0105] Animals received a continuous infusion of vehicle only (5% SOLUTOL® in 5% dextrose) at a dose volume of 4 mL/kg/hour for approximately 96 hours.
[0106] No mortality occurred, no consistent clinical signs were observed, and body weights were normal. A moderate to marked increase in alanine aminotransferase (2/3), aspartate aminotransferase (2/3) and bilirubin (2/3), and a slight increase in alkaline phosphatase (3/3) and glucose (3/3) was found at the end of treatment. Yellow discoloration of plasma was observed for two animals.
[0107] Group III: 960 mg/kg/24 hours of 2-IB in 5% SOLUTOL® (continuous intravenous infusion).
[0108] Animals received a continuous infusion (dose concentration of 10 mg/mL at a dose volume of 4 mL/kg/hour) using 5% SOLUTOL®/5% dextrose (the end concentration of dextrose and saline was hypotonic; approximately 2.5% and 0.45%, respectively). The infusion was terminated after 46 hours, due to adverse clinical effects and difficulties with the formulation in the infusion system (pump alarms indicative of blockage of the infusion systems, probably at the swivels).
[0109] One animal died after 46 hours of infusion. Body weights were increased for two animals. A hunched posture, piloerection and pallor were observed for all animals on Days 2-3 of treatment. A slight to moderate increase in aspartate aminotransferase (1/2), alkaline phosphatase (1/2), and glucose (2/2) was found at the end of treatment, as well as high values for creatinine and urine (1/2). Bilirubin levels were within the normal range.
[0110] Macroscopic findings at necropsy comprised of edema (2/3), pelvic dilation of the kidneys (2/3), enlarged liver (1/3), enlarged iliac lymph node (1/3), dark spots on the lungs (1/3), and fibrin-like coating in or around the femoral vein. Yellow discoloration of tissues was not in evidence.
[0111] Based on these results, it was concluded that, although better dissolution characteristics in 5-20% SOLUTOL® were found for 2-IB, this vehicle was not suitable for continuous intravenous infusion in rats with the applied dose volumes and rates.
Comparative Example 6
pH
[0112] The solubility of 2-IB (5 mg/ml) was tested using different acids. The solubility was achieved at a relatively higher pH (pH 3.3) using weak acids (acetic acid and citric acid) in comparison to pH 3.0 using HCl. This difference is probably due to the synergistic effect of pH-adjustment and the hydrogen-bonding formation between 2-IB and the carboxylic groups of weak acids.
Comparative Example 7
Citrate Buffer
[0113] An excess of 2-IB was added to citrate buffers, mixed at room temperature, and then filtered to remove non-solubilized 2-IB. These solutions were then analyzed by RP-HPLC to determine the solubilized content of 2-IB (Table 3). The solubility of 2-IB in 50 mM citrate buffer at a range of pH was determined to be 11 mg/ml at pH 3.0 (room temperature). At pH 3.5, there is approximately half the amount of 2-IB solubilized.
[0000]
TABLE 3
pH of
Final
Final Citrate
Appearance after
Conc. 2-IB
50 mM Citrate
pH
(mM)
12 hours at 5° C.
(mg/mL)
3.0
3.07
106
Precipitated
11.27
3.5
3.52
65
Precipitated
4.45
4.0
4.03
52
Precipitated
1.72
4.5
4.54
49
Precipitated
0.86
5.0
5.02
49
Precipitated
0.59
Example 1
[0114] Although the earlier experiments demonstrated that cyclodextrin did not significantly increase 2-IB solubility, the experiments were repeated using higher concentrations of cyclodextrin. Surprisingly, in contrast to the results from using 1% cyclodextrin, it was found that a higher concentration of cyclodextrin did increase 2-IB solubility. An excess of 2-IB was added to the cyclodextrin solutions, mixed at room temperature for three days and then filtered to remove non-encapsulated/non-solubilized 2-IB. These solutions were then analyzed by RP-HPLC to determine the solubilized content of 2-IB (see Table 13). Approximately 14 mg/ml of 2-IB was dissolved/encapsulated in 40% SBE-CD in 50 mM Citrate pH 4.0 with a final formulation pH of 5.1. At 40% SBE-CD but using Citrate buffer pH 5 with a final pH of 5.5, approximately 10 mg/ml was encapsulated. At 40% SBE-CD, but using water with a final pH of 6.8, approximately 4.2 mg/ml was dissolved/encapsulated. The results of this experiment demonstrate that suitable levels of 2-IB can be encapsulated using a combination of relatively low pH, a low starting pH, and a 5-20% cyclodextrin concentration.
[0115] The results indicate a clear difference with the encapsulation efficiency of 2-IB for two types of cyclodextrin used. The solubility of 2-IB in SBE-CD (Sulfobutylether-(3-cyclodextrin) with water shows that at 40% SBE-CD, 4.2 mg/ml 2-IB is encapsulated. This is significantly higher than the 1.2 mg/ml 2-IB that was encapsulated using 40% HP-CD (Hydroxypropyl-β-cyclodextrin). The higher solubility of 2-IB in SBE-CD than in HP-CD could not be only attributed to the inclusion complexation by encapsulation because Mw of SBE-CD (2163) is higher than HP-CD (1400). Other physical interactions between 2-IB and SBE-CD molecules might contribute to the higher solubility, such as hydrogen bonding or charge interaction.
[0116] Visual inspection of the cyclodextrin formulations after 12 hours' storage at 5° C. showed that both formulation pH and the concentration of cyclodextrin has an effect on the stability of the formulation in terms of precipitation/release from encapsulation (Table 13). For the SBE-CD formulations, all formulations remained encapsulated (clear solution) except the formulation with the lowest cyclodextrin concentration or 2.5% at pH 4.4. At a higher concentration of cyclodextrin (5%) with a comparable pH (4.5), the 2-IB remained solubilized. Similarly, at a comparable cyclodextrin concentration (2.5%) but a higher pH (5.0), the 2-IB remained solubilized, indicating that both pH and cyclodextrin concentration contribute to the stability of the SBE-CD formulations during storage at pH 5. Tables 4A and 4B summarize the effects of pH and cyclodextrin type and concentration on 2-IB.
[0000]
TABLE 4A
Effect of SBE-CD and pH on the concentration of 2-IB (mg/ml)
SBE-CD
WFI
Citrate pH 5.0
Citrate pH 4.0
% Cyclodextrin
Final pH
2-IB mg/ml
Final pH
2-IB mg/ml
Final pH
2-IB mg/ml
0
6.5
0.4
5.0
0.6
4.0
1.7
2.5
6.3
0.7
5.0
1.9
4.3
3.7
5
6.5
1.0
5.1
2.9
4.4
5.5
10
6.5
1.5
5.1
4.6
4.6
8.0
20
6.7
2.4
5.3
7.0
4.9
11.4
40
6.8
4.2
5.5
9.9
5.1
14.5
[0000]
TABLE 4B
Effect of HP-CD and pH on the concentration of 2-IB (mg/ml)
HP-CD
WFI
Citrate pH 5.0
Citrate pH 4.0
% Cyclodextrin
Final pH
2-IB mg/ml
Final pH
2-IB mg/ml
Final pH
2-IB mg/ml
0
6.5
0.4
5.0
0.6
4.0
1.7
2.5
6.5
0.5
5.1
0.9
4.2
2.5
5
6.5
0.5
5.1
1.2
4.3
3.0
10
6.5
0.6
5.2
1.6
4.5
4.1
20
6.6
0.9
5.3
2.1
4.7
5.1
40
6.7
1.2
5.6
2.6
5.0
5.6
Example 2
[0117] The solubility of 2-IB was screened in 10% SBE-CD solutions at different pH adjusted with 0.1 M citric acid solution. The experimental steps are shown below.
1. Weigh 0.5 g of SBE-CD into 10 ml glass vial 2. Add 3 ml WFI into each vial to dissolve SBE-CD 3. Weigh excess amount of 2-IB (25 mg-100 mg) into different vials 4. Magnetic stirring for 1 hour 5. Adjust pH to target pH with 0.1 M citric acid 6. Determine the weight of 0.1 M citric acid added 7. Add WFI to total weight of 5 g 8. Measure pH again after 1 hour stirring 9. Filtrate through the formulation through PVDF 0.22 μm filter 10. Determine the solubility of 2-IB by HPLC method
[0128] The solubility of 2-IB increased from 1.71 mg/g to 13.08 mg/g with pH decrease from 7.0 to 4.0 (Table 5). The saturated solutions were physically stable and no precipitates were observed at room temperature. However, 2-IB precipitates were observed after 5 days' storage at 5 degrees C. (Table 5). In the presence of 10% SBE-CD, the solubility of 2-IB was significantly increased when compared to pH-adjustment alone (pH 5.0: 5.2 vs. 0.59 mg/g; pH 4.0: 13.08 vs. 1.72 mg/g). The solubility increased 7.6-8.8 times in the presence of 10% SBE-CD ( FIG. 1 ).
[0000]
TABLE 5
Solubility of 2-IB in 10% SBE-CD at different pH
SBE-CD, %
pH
Solubility of 2-IB, mg/g
5 days at 5° C.
5 days at RT
10
7.0
1.71
−
+
10
6.2
1.94
−
+
10
5.5
3.29
−
+
10
5.0
5.21
−
+
10
5.1
5.30
−
+
10
4.5
9.00
−
+
10
4.0
13.08
−
+
−: Precipitation of 2-IB;
+: no precipitation
Example 3
[0129] Six formulations were prepared containing 8-10% of SBE-CD (Table 6A). The concentration of 2-IB in each formulation was approximately 75% of 2-IB solubility to prevent the precipitation of 2-IB at low temperature (Table 6A vs. Table 5). The final pH was adjusted with 0.1 M citric acid solution (or 0.1 M sodium citrate) to pH 4.0-6.0. The detailed procedure of formulation preparation is described as below using F429-02-001P004 as an example (see Table 14).
[0130] F429-02-001p004: 3.9 mg/g 2-IB, 10% SBE-CD, pH 5.0
1. Add 82.93 g water for injection in 200 ml glass bottle 2. Weigh 10 g of SBE-CD powder into the glass bottle and to be dissolved under magnetic stirring 3. Weigh 400 mg of 2-IB 4. Add 6.67 g of 0.1 mM citric acid solution 5. Magnetic stir 5 minutes to completely dissolve 2-IB 6. Adjust pH to 5.0 with 0.1 M sodium citrate 7. Filtrate the solution through 0.22 μm filter (Millex-GP (PES)) 8. Fill 1.5 ml in 6 ml glass vial and store at 5, 25, and 40° C.
[0000]
TABLE 6A
Formulations of 2-IB based on SBE-CD at different pH
SBE-CD, %
Citric add, mM
Sodium citrate, mM
2-IB, mg/g
pH
10
0.6
0.0
1.5
6.0
10
2.0
0.0
2.5
5.5
10
6.6
1.5
3.9
5.0
8
5.6
0.0
4.0
5.0
10
15.0
0.2
7.0
4.5
10
32.3
3.5
9.7
4.0
[0139] Although the solubility of 2-IB at pH 7.0 is 1.71 mg/g, a formulation at pH 7.0 with 1.5 mg/g of 2-IB in water was tested and was not feasible because 2-IB did not dissolve completely after overnight stirring. This might be due to the different approaches for the solubility testing and the formulation preparation. For the solubility testing, an excess amount of 2-IB powder was added in 10% SBE-CD solution and the small particles of 2-IB might dissolve quickly to reach the equilibrium. However, a precise amount of 2-IB powder was added for the formulation preparation, which contains 2-IB particles with different sizes. The large size of 2-IB particles might have a very slow dissolution rate in water at pH 7.0. For the six formulations in Table 6A, 2-IB was quickly dissolved within 30 minutes, indicating a fast dissolution rate. The six formulations were all transparent and colorless solutions.
[0140] It is not feasible to increase the solubility by preparing a formulation at a low pH first and then titrate to a high pH. Precipitation was observed when titrating the formulation F429-02-001P004 from pH 5.0 to pH 5.9 and the formulation F429-02-001P006 from pH 4.0 to pH 5.1 with 0.1 M tri-sodium citrate.
[0141] The six formulations in Table 6A were stored at 5, 25, and 40° C. for six weeks. At the time-point of T=0, 2 weeks, 4 weeks, and 6 weeks, the formulations were tested for appearance, pH, osmolality, and purity and content of 2-IB (HPLC) (Table 15). After 6 weeks storage, no precipitation was observed in the formulations at three storage conditions (Table 16). The appearance of the six formulations did not change at 5 and 25° C. by visual inspection. However, a slight brownish color was observed at 40° C. The color intensity appeared to increase with the increase of 2-IB concentration and the decrease of pH. The reason for this is not known. It appears that 2-iminobiotin is stable and the purity and content did not change. SBE-CD only degraded at extreme low pH and high temperature. pH and osmolality of the six formulations remain stable after 2, 4, and 6 weeks' storage at 5, 25, and 40° C. compared to T=0 values.
[0142] 2-IB remains stable in the six formulations after 6 weeks' storage at 5, 25 and 40° C. based on the purity, content, and recovery (Table 17). The purity of 2-IB in the six formulations was calculated based on the % peak area of 2-IB measured by the HPLC method. It was approximately 99% and did not decrease after 6 weeks' storage at 5, 25 and 40° C. The reason for the slightly higher content and the recovery compared to T=0 was likely due to the analytical variation of the HPLC method.
Example 4
[0143] Formulation conditions were further studied as shown in Tables 18 and 19. Each formulation was prepared to a final volume of 10 ml. 2-IB was weighed for the formulation preparation, taking into account water content as specified in the CoA of this batch (4.2% w/w). The preliminary stability of the formulations was evaluated by visual inspection for 3 days' storage at 5, 25 and 40° C. At T-0, samples were characterized additionally for pH and osmolality.
Example 5
[0144] Two of the formulations from Example 4 were studied in more detail. Formulations F30 and F34 were prepared as follows. 2-IB was weighed into a pre-weighted glass bottle, taking into account water content (4.2% w/w). Citric acid 100 mM (90% from total amount), NaCl/SBE-CD stock solution and WFI (water for injection) (80% from total amount) was added. The mixture was stirred using a magnetic stirrer plate. pH was above 4.0 and adjusted to 4.0±0.2 using Citric acid 100 mM solution. Final weight of the solution was corrected by addition of WFI to obtain 750 g. The obtained formulation was filtered using MILLIPAK® 20 DURAPORE® (PVDF membrane). Both formulations were divided to nine ethylene vinyl acetate infusion bags containing approximately 70 ml of solution. The composition of the formulation is shown in Table 6B.
[0000]
TABLE 6B
F30 (g)
F34 (g)
2-IB (95.8%)
0.418
0.522
NaCl
0.490
0.490
SBE-CD
5.00
5.00
Citric acid (100 mM)
11.7
14.3
WFI
Up to 100 g
Up to 100 g
[0145] A sample of both formulations was tested for appearance, pH, osmolality, 2-IB content and purity immediately after preparation. Samples for stability were stored at three temperatures: 5° C., 25° C. and 40° C. Time points for the stability were 1 day, 2 days and 3 days. At each stability time point, 2-IB samples at all storage conditions were tested for appearance, pH, 2-IB content and purity. Both tested formulations were found to be stable for 3 days at 5° C., 25° C. and 40° C. (see Tables 19A and 19B).
Example 6
[0146] The two formulations from Example 4 were tested to predict their potential for precipitation upon injection based on the In-Vitro Static Serial Dilution Model described in article of P. Li, R. Vshnuvajjala, S. E. Tabibi, and S. H. Yalkovsky, “Evaluation of in-vitro precipitation methods” published in J. Pharma. Sci. 1998 February; 87(2):196-9.
[0147] The procedure was performed as follows:
[0148] Three ml of formulation were diluted with 3 ml of ISPB or vehicle and agitated. (Isotonic Sorensen Phosphate buffer (ISPB) pH 7.4 was prepared using sodium phosphate dibasic heptahydrate—2.146%, sodium dihydrogen phosphate dehydrate—0.296% and sodium chloride—0.178%). Three ml of the resulting solution/suspension were then mixed with another 3 ml of ISPB/vehicle. This step was repeated until seven serial dilutions were obtained. In addition, a control tube for each dilution was prepared using vehicle as a diluent instead of ISPB.
[0149] Visual observations were used to determine the presence or absence of precipitate upon mixing. Following this initial observation, the formulation-buffer mixtures were placed in a water bath at 37° C. and 50 rpm for 1 hour and then centrifuged. The upper phase was analyzed by HPLC method.
[0150] For purposes of data analysis, the formulation-diluent ratio is defined as the ratio of the volume of formulation to the total volume (volume of formulation+volume of ISPB). The difference between the control concentration and the measured concentration in each dilution is the amount of drug absent per ml of original formulation.
[0151] In-vitro static serial dilution model for formulation F30
[0152] Formulation F30 was tested to predict its potential for precipitation upon injection using the in-vitro static serial dilution model. In this method, the formulation was sequentially diluted in a one-to-one ratio with ISPB. The appearance of the formulation at the different dilution steps is presented in Table 7. The equilibrium concentration of 2-IB obtained at each dilution step and the amount of drug absent per ml are presented in Table 8 (n=3 for each dilution). The equilibrium concentration in each diluted solution was determined by HPLC method. The difference between the control concentration and the measured concentration in each dilution is equal to the amount of drug that precipitated from 1 ml of original formulation. The formulation-diluent ratio is defined as the ratio of the volume of formulation to the total volume. At formulation-diluent ratio of 0.5, the formulation turned to translucent and slight precipitation was observed upon standing. The amount of drug lost at these dilution ratios was slight, and is probably a result of precipitation of the drug. Formulation-diluent ratios of 0.25-0.0625 resulted in a clear solution but the analytical results demonstrated that drug was lost. The missing drug amount may be a result of tiny precipitation, which was not observed visually or adsorption of the drug to the tube wall.
[0000]
TABLE 7
Visual observation of serial dilution steps
Formulation-
Appearance after
Appearance after
Dilution no.
diluent ratio
preparation
incubation
1
0.5
Clear solution
Translucent solution with
slight precipitation
2
0.25
Clear solution
Clear solution
3
0.125
Clear solution
Clear solution
4
0.0625
Clear solution
Clear solution
5
0.03125
Clear solution
Clear solution
6
0.015625
Clear solution
Clear solution
7
0.007875
Clear solution
Clear solution
[0000]
TABLE 8
Mean equilibrium 2-IB concentrations and amount of
2-IB absented per ml for the different
formulation-diluent ratios (average of n = 3)
Control 2-IB
Mean equilibrium
Formulation-
concentration
2-IB concentration
2-IB absent
diluent ratio
(mg/ml)
(mg/ml)
(mg/ml)
1
4.188
4.188
0.000
0.5
2.074
2.066
0.048
0.25
1.039
1.025
0.031
0.125
0.526
0.511
0.015
0.0625
0.265
0.256
0.009
0.03125
0.128
0.127
0.000
0.015625
0.063
0.064
0.000
10.007875
0.030
0.032
0.000
[0153] In-vitro static serial dilution model for formulation F34
[0154] Formulation F34 was tested to predict its potential for precipitation upon injection using the in-vitro static serial dilution model. The appearance of the formulation at the different dilution steps is presented in Table 9. The equilibrium concentration of 2-IB obtained at each dilution step and the amount of drug absent per ml are averaged in Table 10. At formulation-diluent ratios of 0.5-0.125, the formulation turned to turbid-to-translucent and precipitation was observed. The amount of drug lost at these dilution ratios was perceptible, and is probably a result of precipitation of the drug. As dilution continues and ratio reached 0.0625, a precipitate was observed but not detected by analytical test, probably due to a minor amount of a precipitate. Below the ratio 0.0625, the equilibrium concentration points overlap the control curve with the observation that the precipitate is redissolved.
[0000]
TABLE 9
Visual observation of serial dilution steps
Dilution
Formulation-
Appearance after
Appearance after
no.
diluent ratio
preparation
incubation
1
0.5
Turbid solution with
Turbid solution with
pronounced
pronounced
precipitation
precipitation
2
0.25
Turbid solution with
Turbid solution with
precipitation
precipitation
3
0.125
Translucent solution
Translucent solution
with slight precipitation
with slight precipitation
4
0.0625
Clear solution with
Clear solution with
slight precipitation
slight precipitation
5
0.03125
Clear solution
Clear solution
6
0.015625
Clear solution
Clear solution
7
0.007875
Clear solution
Clear solution
[0000]
TABLE 10
Mean equilibrium 2-IB concentrations and
amount of 2-IB absented per ml for the different
formulation-diluent ratios (n = 3 for each dilution)
Formulation-
Control 2-IB
Mean equilibrium
2-IB
diluent
concentration
2-IB concentration
absent
ratio
(mg/ml)
(mg/ml)
(mg/ml)
1
5.12
5.12
0.000
0.5
2.565
0.929
1.636
0.25
1.263
0.697
0.565
0.125
0.632
0.433
0.199
0.0625
0.317
0.358
0.000
0.03125
0.158
0.184
0.000
0.015625
0.078
0.091
0.000
0.007875
0.038
0.046
0.000
[0155] For the 4 mg/ml F30 formulation, the results showed no cloudiness or precipitation following serial dilution and the expected 2-IB concentrations were found, indicating that 2-iminobiotin (4 mg/ml) SBE-CD-based formulation is unlikely to precipitate in vivo due to physiological dilution by blood flow upon intravenous administration.
Example 7
[0156] The nature and purpose of this study was to assess the placental transfer of 2-iminobiotin (2-IB) and possible passage of 2-IB over the blood-brain-barrier, when administered by two subcutaneous injections to female Wistar rats on Day 20 post-coitum.
[0157] Four female Wistar rats were subcutaneously injected on Day 20 post-coitum with 55 mg/kg of 2-IB (each injection of 27.5 mg/kg). The 2-IB was prepared in a physiological saline solution, pH 3.6-3.8, with a concentration of 2.75 mg/ml. No mortality occurred amongst material animals during the study period and all fetuses were viable. Necropsy took place approximately one hour after the second injection. Blood and brain samples were collected from both the mother and fetuses.
[0158] 2-IB was quantifiable in the plasma samples of all maternal animals and fetuses. Plasma 2-IB concentrations were 3-7 times higher for the maternal animals (average concentration was 10,039 ng/mL) than for their fetuses (average concentration was 1,765 ng/mL for the males and 1,903 ng/mL for the females).
[0000]
TABLE 11A
2-IB plasma concentration
Concentration
Concentration
Concentration
maternal
pooled fetuses
pooled fetuses
animals (ng/mL)
male (ng/mL)
female (ng/mL)
female 1
7,104
1,868 (n = 8)
2,442* (n = 3)
female 2
14,185
2,080 (n = 4)
2,063 (n = 8)
female 3
7,490
1,598 (n = 5)
1,474 (n = 4)
female 4
11,378
1,512 (n = 8)
1,634 (n = 7)
average (±SD)
10,039 (±3371)
1,765 (±259)
1,903 (±437)
Lower Limit of Quantification (LLOQ) was 5.0 ng/mL and Upper Limit of Quantification (ULOQ) was 5000 ng/mL.
*Indicative value (initial analytical batch was rejected, but due to the low volume, this sample could not be re-analyzed).
2-IB was quantifiable in the brain samples of all maternal animals and fetuses. Brain 2-IB concentrations were comparable in maternal animals (average concentration was 268 ng/g) and their fetuses (average concentration was 329 ng/g for the males and 369 ng/g for the females).
[0000]
TABLE 11B
2-IB concentration in brain sample
Concentration
Concentration
Concentration
maternal
pooled fetuses
pooled fetuses
animals (ng/g)
male (ng/g)
female (ng/g)
female 1
151
287 (n = 8)
474 (n = 3)
female 2
375
435 (n = 4)
317 (n = 8)
female 3
270
283 (n = 5)
329 (n = 4)
female 4
276
309 (n = 8)
356 (n = 7)
average (±SD)
268 (±92)
329 (±72)
369 (±72)
LLOQ was 20.0 ng/g and ULOQ was 5000 ng/g.
[0159] In general, 2-IB passage to the brain appeared to be relatively lower in maternal animals (average brain-to-plasma ratio was 0.03, ranging from 0.02 to 0.04) than in their fetuses (average brain-to-plasma ratio was 0.19, ranging from 0.15 to 0.21 for the males and 0.20, ranging from 0.15 to 0.22 for the females).
[0160] Bioanalytical results showed that all maternal animals and their fetuses were exposed to 2-IB after subcutaneous injections, with maternal animals showing 3-7 times higher plasma concentrations than their fetuses (average plasma 2-IB concentration was 10,039 ng/mL for maternal animals, and 1,765 ng/mL for the male and 1,903 ng/mL for the female fetuses). In addition, 2-IB concentrations could be measured in the brains of all maternal animals (average concentration was 268 ng/g) and their fetuses (average concentration was 329 ng/g for the male and 369 ng/g for the female fetuses). 2-IB passage to the brain appeared to be relatively lower in maternal animals (average brain-to-plasma ratio was 0.03) than in their fetuses (average brain-to-plasma ratio was 0.20). Based on the above-mentioned results, transfer of 2-IB over the placenta and the blood-brain barrier is confirmed after two subcutaneous injections in Wistar rats at a total dose level of 55 mg/kg.
Example 8
[0161] Solutions of 2-IB at the concentrations 0.6 mg/g, 0.75 mg/g and 1 mg/g in citrate buffers at a pH of 3.8, 4.0 and 4.2, respectively, were prepared to a final weight of 20 g as follows (buffer capacity target at pH 4.0 was 15 mM):
[0162] A citric acid 0.1 M solution and a sodium citrate dihydrate 0.1 M solution were each prepared in WFI. Citric acid solution was added to 2-IB weighed into a pre-weighed glass vial (taking into account water content as specified in the CoA of this batch (4.2% w/w)). WFI was added for dilution, and then sodium citrate dihydrate 0.1 M solution was added to adjust pH up to the required pH value. WFI was added up to a total weight of 20 g followed by pH measurement.
[0163] The 12 bulk solutions obtained were subsequently divided and stored in stability chambers at 5° C.±3° C. and 25° C.±2° C. for 3 days. All stored solutions were evaluated for pH and appearance at each time point (0, 1, 2, 3 days).
[0164] Table 20 shows the composition of the citric acid buffer formulations, and the intended and measured pHs before and after addition of WFI to a total formulation weight of 20 g.
Example 9
[0165] In a subsequent study, the stability of 2-IB citrate buffer solution formulations at pH 4±0.2 at a temperature at 15° C.±3° C. and 25° C.±2° C. was examined. 24B-citrate buffer formulations at 2-IB concentrations of 0 mg/ml (placebo), 0.75 mg/ml and 1 mg/ml in citrate buffer pH 3.8, 4.0 and 4.2 were prepared as described in Example 8. Each formulation was prepared to a final weight of 20 g (buffer capacity target was 15 mM at pH 4.0), and each was visually examined for appearance and pH determined. The solutions were divided and stored in stability chambers at 15° C.±3° C. and 25° C.±2° C. for 3 days. All stored solutions were evaluated for pH and appearance at time points T=0, 1, 2, and 3 days.
[0166] Table 21 presents the composition of each of the citric acid buffer foundations, and the intended and measured pH values before and after addition of WFI to a total formulation weight of 20 g. Appearance and pH data for each of the time points are presented as well.
Example 10
[0167] The solubility of 2-iminobiotin was assessed in a buffered 5% CAPTISOL® solution for pH values of 4.0-6.2. The formulations also included NaCl for adjustment of osmolality, and the citrate buffer concentration aimed for at pH 4.0 was 15 mM. The 2-IB concentrations of these solutions were 4.0, 2.0, 1.0, 0.75, and 0 mg/g (placebo) 2-IB.
[0168] Preparation of a citric acid 0.1 M solution and the citrate dihydrate 0.1 M solution is described in Example 8. A bulk solution of 25% CAPTISOL®—2.45% NaCl solution was prepared and used for further preparation of the formulations.
[0169] Each of the final bulk formulations was visually examined for appearance and pH determined. The solutions were divided and stored in stability chambers at 5° C.±3° C. and 25° C.±2° C. for 3 days. All stored solutions were evaluated for pH and appearance at time points T=0, 1, 2, and 3 days.
[0170] Tables 22 and 23 present the composition of the 2-IB citrate buffer solutions and the appearance and pH data.
Example 11
[0171] A short-term stability (STS) study of 2-IB in citrate buffer was performed (timepoints: T=0, 2 weeks, 4 weeks, and 6 weeks) on the following formulations:
[0172] Formulation 03-15 comprising: 0.75 mg/g 2-IB in citrate buffer pH 6.0, with 5% CAPTISOL® and 2.45% NaCl (for isotonicity) solution and
[0173] Formulation 02-5B comprising: 0.75 mg/g 2-IB in citrate buffer pH 4.0, with NaCl for isotonicity.
[0174] The following parameters were studied: visual appearance, pH, osmolality, assay, IDD, clarity, visible particles, and subvisible particles. The pH variation (0.1 units over 6 weeks at pH 6.0) was insignificant. There was no evidence that stability is problematic at any of the temperatures tested.
Example 12
[0175] A solubility study of dried 2-IB as compared to hydrated 2-IB was performed. Three formulations were prepared, based on formulation #02-5. The 07-1 formulation was obtained from 2-IB “as is” material (i.e., 2-IB taken straight from the vial) after drying. The 07-2 formulation was obtained from 2-IB fully hydrated material by leaving “as is” 2-IB material at 20° C./RH (70±5%). The 07-3 formulation was obtained from 2-IB “as is” material. The solutions were examined for appearance and pH. The water content of the dried material, the “as is” material, and the fully hydrated material was determined as 1%, 12%, and 18% respectively.
[0176] Table 12 below presents the amounts of the ingredients used for preparation of the formulations (07-1, 07-2, and 07-3), the time it took to dissolve the 2-IB material (used in each formulation) in the citric acid 0.1 M solution, the final pHs of the three formulations and their appearance.
[0000]
TABLE 12
07-1
07-2
07-3
2-IB conc.
0.75 mg/g
0.75 mg/g
0.75 mg/g
2-IB taken as:
dried
fully hydrated
“as is”
Theoretical amount of 2-IB, (g)
0.157
0.157
0.157
Water content (%)
1.3340
18.1020
11.8330
Water content (%), replicate
1.2470
18.1050
11.7900
Water content (%), average
1.2905
18.1035
11.8115
Dry 2-IB, %
98.71
81.90
88.19
Calculated amount of 2-IB based
0.1591
0.1917
0.1780
corrected for water content
Actual amount of 2-IB taken, (g)
0.1605
0.1915
0.1781
Citric acid 0.1M solution (g)
20.0
20.0
20.0
Actual citric acid 0.1M solution (g)
20.0
20.0
20.0
Time to dissolve 2-IB (min)
1.0
1.0
1.0
Sodium citrate dihydrate 0.1M
~10.0
~10.0
~10.0
solution (ca., g)
Actual sodium citrate dihydrate
23.1
23.7
23.5
0.1M solution (g)
Calculated water for injection to
160.0
160.0
160.0
add (up to 200 g)
Actual water for injection added (g)
160.0
160.0
160.0
Total amount of solution (g)
203.3
203.9
203.7
pH (theoretical)
4.0
4.0
4.0
pH (actual)
4.00
4.00
4.00
Appearance
Clear and
Clear and
Clear and
colorless
colorless
colorless
Example 13
[0177] A terminal sterilization study of two formulations of 2-IB in citrate buffer with or without CAPTISOL® was performed to determine which sterilization methods may be used without degrading 2-IB.
[0178] Four (4) buffered 2-IB formulations were prepared including placebo formulations lacking 2-IB. Each of these solutions was filtered through a 0.22 μm PES filter. The pH, osmolality, visual appearance, and 2-IB content were determined. The pH was also determined following titration of the 2-IB citric acid solution with the sodium citrate solution.
[0179] Each formulation was divided into 4×10 g portions. Each portion was distributed into a 20 ml glass vial. Each of the four samples was placed in the Tuttnauer steam sterilizer and autoclaved (Program 6 (for liquids, 121° C. for 15 minutes)). Following autoclaving, the samples were allowed to cool down to room temperature. A 5 g sample was taken from each of the four vials for determination of appearance, pH, and osmolality. The remaining 5 g of the formulation were employed for the assay.
[0180] Table 24 presents the materials and their amounts used for preparation of each of the four formulations, citrate buffer capacity, visual appearance, pH, and assay before and after terminal sterilization. The assay referred to in Table 24 refers to the stability of the solutions monitored by HPLC analysis. As demonstrated in Table 24, the formulations can be autoclaved without a significant decrease in 2-IB stability.
Example 14
[0181] A study was undertaken to assess the potential for in-vivo precipitation of two selected formulations. For this purpose, the In-Vitro Static Serial Model was used as described in Example 6.
[0182] Table 25 presents the amounts of the materials used for the 09-1, 09-1V, 09-2, and 09-2V preparations, their buffer capacities, and pH and appearance after titration of the 2-IB citric acid solution with the sodium citrate. Tables 26 and 27 present the appearance and pH values for dilutions of 09-1 and 09-1V in ISPB and dilutions of 09-1 in the vehicle. The appearance and pH results presented in Tables 26 and 27 indicate that for all dilutions performed, both preparations 09-1 and 09-2 do not show precipitation when diluted with Sorensen buffer mimicking physiological pH. Therefore, the risk of in-vivo precipitation of these formulations should be low. In addition, the pH change toward more physiological values is rapid, increasing in-vivo compatibility/safety.
Tables
[0183]
[0000]
TABLE 13
Overview of formulation, pH, 2-IB solubility/encapsulated and
stability in SBE-CD or HP-CD formulations.
2-IB Solubilized/
encapsulated
Visual inspection after
Formulation
Final pH
(mg/ml)
12 hours at 5° C.
2-IB in 40% CAPTISOL ®/WFI
6.8
4.2
No precipitation
2-IB in 20% CAPTISOL ®/WFI
6.7
2.4
No precipitation
2-IB in 10% CAPTISOL ®/WFI
6.5
1.5
No precipitation
2-IB in 5% CAPTISOL ®/WFI
6.5
1.0
No precipitation
2-IB in 2.5% CAPTISOL ®/WFI
6.3
0.7
No precipitation
2-IB in 40% CAPTISOL ®/50 mM
5.5
9.9
No precipitation
Citrate pH 5.0
2-IB in 20% CAPTISOL ®/50 mM
5.3
7.0
No precipitation
Citrate pH 5.0
2-IB in 10% CAPTISOL ®/50 mM
5.1
4.6
No precipitation
Citrate pH 5.0
2-IB in 5% CAPTISOL ®/50 mM
5.1
2.9
No precipitation
Citrate pH 5.0
2-IB in 2.5% CAPTISOL ®/50 mM
5.0
1.9
No precipitation
Citrate pH 5.0
2-IB in 40% CAPTISOL ®/50 mM
5.1
14.5
No precipitation
Citrate pH 4.0
2-IB in 20% CAPTISOL ®/50 mM
4.9
11.4
No precipitation
Citrate pH 4.0
2-IB in 10% CAPTISOL ®/50 mM
4.6
8.0
No precipitation
Citrate pH 4.0
2-IB In 5% CAPTISOL ®/50 mM
4.4
5.5
No precipitation
Citrate pH 4.0
2-IB In 2.5% CAPTISOL ®/50 mM
4.3
3.7
Small amount of
Citrate pH 4.0
precipitation
2-IB in 40% KLEPTOSE ®
6.7
1.2
No precipitation
HPB/WFI
2-IB In 20% KLEPTOSE ®
6.6
0.9
No precipitation
HPB/WFI
2-IB in 10% KLEPTOSE ®
6.5
0.6
No precipitation
HPB/WFI
2-IB in 5% KLEPTOSE ® HPB/WFI
6.5
0.5
No precipitation
2-IB In 2.5% KLEPTOSE ®
6.5
0.5
Precipitation
HPB/WFI
2-IB in 40% KLEPTOSE ® HPB/50
5.6
2.6
No precipitation
mM Citrate pH 5.0
2-IB in 20% KLEPTOSE ® HPB/50
5.3
2.1
No precipitation
mM Citrate pH 5.0
2-IB in 10% KLEPTOSE ® HPB/50
5.2
1.6
No precipitation
mM Citrate pH 5.0
2-IB in 5% KLEPTOSE ® HPB/50
5.1
1.2
No precipitation
mM Citrate pH 5.0
2-IB in 2.5% KLEPTOSE ® HPB/50
5.1
0.9
No precipitation
mM Citrate pH 5.0
2-IB in 40% KLEPTOSE ® HPB/50
5.0
5.6
No precipitation
mM Citrate pH 4.0
2-IB in 20% KLEPTOSE ® HPB/50
4.7
5.1
Precipitation
mM Citrate pK 4.0
2-IB in 10% KLEPTOSE ® HPB/50
4.5
4.1
Precipitation
mM Citrate pH 4.0
2-IB in 5% KLEPTOSE ® HPB/50
4.3
3.0
Precipitation
mM Citrate pH 4.0
2-IB In 2.5% KLEPTOSE ® HPB/50
4.2
2.5
Precipitation
mM Citrate pH4.0
[0000]
TABLE 14
Formulations of 2-IB based on SBE-CD at different pH
CAPTISOL ®,
Formulations
%
Citric acid, mM
Sodium citrate, mM
2-IB, mg/g
Ph
F429-02-001p002
10
0.6
0.0
1.5
6.0
F429-02-001p003
10
2.0
0.0
2.5
5.5
F429-02-001p004
10
6.6
1.5
3.9
5.0
F429-02-001p007
8
5.6
0.0
4.0
5.0
F429-02-001p005
10
15.0
0.2
7.0
4.5
F429-02-001p006
10
32.3
3.5
9.7
4.0
[0000]
TABLE 15
pH and osmolality of formulations after 6 weeks' storage at three different temperatures
pH
Osmolality, osm/kg
Sample
Storage
T = 0
T = 2 weeks
T = 4 weeks
T = 6 weeks
T = 0
T = 2 weeks
T = 4 weeks
T = 6 weeks
F429-02-001P002
5° C.
6.0
6.0
6.0
6.0
0.287
0.292
0.239
0.288
25° C.
6.0
6.0
6.0
0.290
0.288
0.290
40° C.
6.0
6.0
6.0
0.293
0.317
0.292
F429-02-001P003
5° C.
5.5
5.6
5.6
5.6
0.292
0.298
0.293
0.291
25° C.
5.6
5.6
5.6
0.296
0.293
0.292
40° C.
5.6
5.6
5.6
0.298
0.301
0.295
F429-02-001P004
5° C.
5.0
5.0
5.0
5.0
0.299
0.304
0.298
0.300
25° C.
5.0
5.0
5.0
0.302
0.300
0.299
40° C.
5.0
5.0
5.0
0.303
0.306
0.300
F429-02-001P005
5° C.
4.5
4.5
4.5
4.6
0.311
0.316
0.312
0.311
25° C.
4.5
4.5
4.5
0.314
0.314
0.313
40° C.
4.5
4.5
4.5
0.317
0.317
0.310
F429-02-001P006
5° C.
4.0
4.0
4.1
4.1
0.329
0.340
0.332
0.332
25° C.
4.0
4.0
4.0
0.332
0.330
0.327
40° C.
4.0
4.0
4.0
0.337
0.350
0.336
F429-02-001P007
5° C.
5.0
5.0
5.1
5.1
0.232
0.233
0.232
0.233
25° C.
5.0
5.0
5.1
0.231
0.233
0.231
40° C.
5.0
5.0
5.0
0.235
0.236
0.234
[0000]
TABLE 16
Purity and content of 2-IB in the six formulations after 6 weeks' storage at three different temperatures
F429-02-001p002
F429-02-001p003
F429-02-001p004
Purity
Content
Recovery
Purity
Content
Recovery
Purity
Content
Recovery
Storage
%
mg/ml
%
%
mg/ml
%
%
mg/ml
%
T = 0
96.9
1.59
100
99.0
2.60
100
99.1
4.02
100
2 weeks,
96.6
1.64
103
99.0
2.69
104
99.0
4.22
105
5° C.
2 weeks,
98.8
1.62
102
98.8
2.68
103
99.0
4.20
104
25° C.
2 weeks,
98.7
1.61
102
98.9
2.70
104
99.0
4.26
106
40° C.
4 weeks,
98.5
1.64
103
98.9
2.69
104
98.9
4.31
107
5° C.
4 weeks,
98.5
1.63
102
99.0
2.69
104
98.9
4.18
104
25° C.
4 weeks,
98.5
1.60
101
96.9
2.67
103
98.9
4.20
104
40° C.
6 weeks,
99.3
1.69
106
99.3
2.73
105
99.3
4.29
107
5° C.
6 weeks,
99.3
1.64
103
99.2
2.74
106
99.2
4.24
105
25° C.
6 weeks,
99.3
1.64
103
99.3
2.73
105
99.2
4.26
106
40° C.
F429-02-001p005
F429-02-001p006
F429-02-001p007
Purity
Content
Recovery
Purity
Content
Recovery
Purity
Content
Recovery
Storage
%
mg/ml
%
%.
mg/ml
%
%.
mg/ml
%
T = 0
99.1
7.17
100
99.1
10-01
100
99.1
4.03
100
2 weeks,
99.1
7.60
106
99.1
10.49
105
99.1
4.46
111
5° C.
2 weeks,
99.1
7.70
107
99.1
10.43
104
99.0
4.35
108
25° C.
2 weeks,
99.0
7.85
110
99.1
10.72
107
99.0
4.29
106
40° C.
4 weeks,
99.0
7.49
105
99.0
10.42
104
99.0
4.37
108
5° C.
4 weeks,
99.1
7.42
104
99.0
10.42
104
98.9
4.15
103
25° C.
4 weeks,
98.9
7.46
104
99.0
10.42
104
98.9
4.10
102
40° C.
6 weeks,
99.2
7.70
107
99.2
11.23
112
99.2
4.32
107
5° C.
6 weeks,
99.2
7.67
107
99.2
11.01
110
99.2
4.30
107
25° C.
6 weeks,
99.2
7.73
108
99.1
10.86
108
99.2
4.49
111
40° C.
[0000]
TABLE 17
Summary of stability study for 2-IB formulations without cyclodextrin
F1
F2
F3
F4
F5
F6
F7
F8
F9
2-IB (mg/g)
1
1
1
1
1
1
5
4
5
NaCl (%)
0.45
0.45
0.45
0.45
0.45
0.45
0.51
0.51
0.51
Glucose (%)
2.5
2.5
2.5
2.5
2.5
2.5
5
5
5
Citric buffer pH 4.0 (mM)
0
1
2.5
5
7.5
10
10
10
5
Appearance after
not
not
not
clear
clear
clear
not
not
not
preparation
clear
clear
clear
clear
clear
clear
Osmolality (mOsm)
313
pH
4.43
4.31
4.23
study: 1st day, 5° C.
ppt
ppt
ppt
study: 2nd day, 5° C.
ppt
ppt
ppt
study: 3rd day, 5° C.
ppt
ppt
ppt
F10
F11
F12
F13
F14
F15
F16
F17
F18
2-IB (mg/g)
3.5
3
3.5
3
4
5
2
2.5
3
NaCl (%)
0.73
0.73
0.73
0.51
0.51
0.51
0.73
0.73
0.73
Glucose (%)
2.5
2.5
2.5
5
5
5
2.5
2.5
2.5
Citric buffer pH 4.0 (mM)
10
10
5
15
15
15
15
15
15
Appearance after
not
not
not
clear
not
not
clear
clear
not
preparation
clear
clear
clear
clear
clear
clear
Osmolality (mOsm)
318
321
321
pH
4.66
4.40
4.49
study: 1st day, 5° C.
clear
clear
ppt
study: 2nd day, 5° C.
clear
clear
ppt
study: 3rd day, 5° C.
few
clear
ppt
part
[0000]
TABLE 18
Summary of stability study for 2-IB formulations with cyclodextrin
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
2-IB (mg/g)
2.5
2.5
2.5
2.5
2.5
3
3
3
3
3
NaCl (%)
0.73
0.73
0.73
0.73
0.73
0.73
0.73
0.73
0.51
0.51
CAPTISOL ® (%)
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
5
5
Citric buffer pH 4.0
15
(mM)
Citric acid (mM)
1.75
10
15
20
10
15
20
10
15
Citric buffer pH 3.5
15
(mM)
Sodium citrate (100
4
1.5
9.5
4
1.6
7.45
11.2
1
5.75
mM)
Appearance after
clear
clear
clear
clear
clear
clear
clear
clear
clear
clear
preparation
Total molarity (mM)
16.8
14
16.5
24.5
24
11.6
22.5
31.2
11
20.8
Osmolality (mOsm)
321
319
320
340
360
306
333
356
308
323
pH
4.01
3.99
4.00
4.00
4.00
4.00
4.00
4.00
4.01
4.00
study: 1st day, 5° C.
clear
clear
clear
clear
clear
clear
ppt
clear
clear
clear
study: 2nd day, 5° C.
ppt
clear
clear
clear
clear
clear
ppt
clear
clear
clear
study: 3rd day, 5° C.
ppt
clear
clear
clear
clear
few
ppt
clear
clear
clear
part.
F29
F30
F31
F32
F33
F34
F35
F36
F37
F38
2-IB (mg/g)
3
4
4
4
5
5
5
3
4
5
NaCl (%)
0.51
0.51
0.51
0.51
0.51
0.51
0.51
0.73
0.51
0.51
CAPTISOL ® (%)
5
5
5
5
5
5
5
2.5
5
5
Citric buffer pH 4.0
(mM)
Citric acid (mM)
20
10.8
15
20
14.2
15.3
20
2.75
5
Citric buffer pH 3.5
20
20
20
(mM)
Sodium citrate (100
10.3
0.25
1
4.8
5.15
0.25
mM)
Appearance after
clear
clear
clear
clear
clear
clear
clear
clear
clear
clear
preparation
Total molarity (mM)
30.3
11
16
24.8
14.2
15.3
25.2
20.2
22.8
25
Osmolality (mOsm)
345
307
307
326
307
309
333
328
326
330
pH
4.00
4.00
3.98
3.97
4.01
3.99
3.99
4.00
3.99
3.99
study: 1st day, 5° C.
clear
clear
clear
clear
ppt
clear
clear
clear
clear
ppt
study: 2nd day, 5° C.
clear
clear
clear
clear
ppt
clear
clear
few
clear
ppt
part.
study: 3rd day, 5° C.
clear
clear
clear
clear
ppt
few
ppt
ppt
clear
ppt
part.
ppt: precipitation;
few part: a few particles are visible
[0000]
TABLE 19
Three-day stability study results for formulation F30 (Table 19A) and formulation F34 (Table 19B).
T-1 st day
T-2 nd day
T-3 rd day
T-0
5° C.
25° C.
40° C.
5° C.
25° C.
40° C.
5° C.
25° C.
40° C.
Table 19A
2-IB assay
4.0
4.0
4.0
4.0
4.1
4.0
4.1
4.0
4.0
4.1
(mg/g)
pH
4.2
4.2
4.2
4.2
4.2
4.2
4.2
4.2
4.2
4.2
Appearance
Clear
Clear
Clear
Clear
Clear
Clear
Clear
Clear
Clear
Clear
solution
solution
solution
solution
solution
solution
solution
solution
solution
solution
Table 19B
2-IB assay
5.0
5.0
5.0
5.0
5.0
5.1
5.1
5.1
5.1
5.1
(mg/g)
pH
4.2
4.2
4.2
4.2
4.2
4.1
4.2
4.1
4.2
4.2
Appearance
Clear
Clear
Clear
Clear
Clear
Clear
Clear
Clear
Clear
Clear
solution
solution
solution
solution
solution
solution
solution
solution
solution
solution
[0000]
TABLE 20
Composition of 2-IB formulations (0, 0.6, 0.75, and 1.0 mg/g) in citrate buffer (pH = 4.0 ± 0.2), and
appearance and pH values for each formulation at time points T = 0, 1, 2, and 3 days stored in temperature
chambers at 5° C. ± 3° C. and 25° C. ± 2° C.
01-1
01-2
01-3
01-4
01-5
01-6
01-7
01-8
01-9
01-10
01-11
01-12
2-IB conc. (mg/g)
0
0
0
0.6
0.6
0.6
0.75
0.75
0.75
1.0
1.0
1.0
2-IB (95.8%), g
0
0
0
0.01
0.01
0.01
0.01
0.01
0.01
0.02
0.02
0.02
Citric acid 0.1M solution (g)
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
Sodium citrate dihydrate 0.1M
1.21
1.50
1.82
0.94
1.45
1.69
1.03
1.27
1.58
1.01
1.30
1.49
solutiamouon (g)
Water for Injection
Up to
Up to
Up to
Up to
Up to
Up to
Up to
Up to
Up to
Up to
Up to
Up to
20 g
20 g
20 g
20 g
20 g
20 g
20 g
20 g
20 g
20 g
20 g
20 g
Total molarity, mM
16.0
17.4
19.0
14.6
17.2
18.4
15.1
16.3
17.9
15.0
16.4
17.4
pH Target
3.8
4.0
4.2
3.8
4.0
4.2
3.8
4.0
4.2
3.8
4.0
4.2
pH obtained after titration (T-0)
3.81
4.00
4.20
3.78
3.99
4.19
3.81
3.99
4.19
3.80
4.00
4.20
STS: 1 st day, pH
5° C.
3.99
4.19
4.43
4.08
4.28
4.41
4.07
4.12
— 1
3.72
— 2
— 2
STS: 3 rd day, pH
3.83
4.02
4.22
3.79
4.08
4.22
3.80
4.03
— 2
3.82
— 2
— 2
STS: 1 st day, pH
25° C.
4.00
4.00
4.27
3.91
4.23
4.21
3.98
4.14
4.29
4.02
4.25
4.21
STS: 3 rd day, pH
3.81
4.02
4.22
3.91
4.08
4.28
3.80
4.11
4.13
3.92
4.08
4.15
STS: 1 st day, appearance
5° C.
clear
clear
clear
clear
clear
clear
clear
clear
ppt 2
clear
ppt 3
ppt 3
STS: 2 nd day,
clear
clear
clear
clear
clear
clear
clear
clear
ppt 3
clear
ppt 3
ppt 3
appearance
STS: 3 rd day, appearance
clear
clear
clear
clear
clear
clear
clear
clear
ppt 3
clear
ppt 3
ppt 3
STS: 1 st day, appearance
25° C.
clear
clear
clear
clear
clear
clear
clear
clear
clear
clear
clear
clear
STS: 2 nd day,
clear
clear
clear
clear
clear
clear
clear
clear
clear
clear
clear
clear
appearance
STS: 3 rd day, appearance
clear
clear
clear
clear
clear
clear
clear
clear
clear
clear
clear
clear
1 pH in vials with precipitation was not measured
2 ppt—needle-type precipitate
[0000]
TABLE 21
Amounts of ingredients used to prepare 2-IB formulations (0 (placebo), 0.75, and 1.0 mg/g) in citrate
buffer (pH = 4.0 ± 0.2), and appearance and ph values for each formulation at timepoints T = 0, 1, 2,
and 3 days stored in temperature chambers at 15° C. ± 3° C. and 25° C. ± 2° C.
02-1
02-2
02-3
02-4
02-5
02-6
02-7
02-8
02-9
2-IB conc. (mg/g)
0
0
0
0.75
0.75
0.75
1.0
1.0
1.0
2-IB (95.8%), g
0
0
0
0.0157
0.0157
0.0157
0.0209
0.0209
0.0209
Citric acid 0.1M
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
solution (g)
Sodium Citrate
1.07
1.26
1.56
0.82
1.03
1.34
0.73
0.96
1.33
dihydrate 0.1M
solution (g)
Water for Injection
Up to 20 g
Up to 20 g
Up to 20 g
Up to 20 g
Up to 20 g
Up to 20 g
Up to 20 g
Up to 20 g
Up to 20 g
Total molarity, mM
15.35
16.30
17.80
14.10
15.15
16.70
13.65
14.80
16.65
pH Target
3.8
4.0
4.2
3.8
4.0
4.2
3.8
4.0
4.2
pH obtained after
3.79
3.97
4.21
3.82
4.03
4.23
3.80
4.03
4.24
titration (T-0)
STS: 1 st day, pH
15° C.
3.81
4.04
4.23
3.81
4.07
4.22
3.82
4.05
4.29
STS: 2 nd day, pH
3.84
4.02
4.25
3.87
4.05
4.27
3.82
4.04
4.27
STS: 3 rd day, pH
3.81
4.02
4.27
3.83
4.04
4.24
3.83
4.05
4.28
STS: 1 st day, pH
25° C.
3.80
3.97
4.19
3.82
4.03
4.20
3.81
4.05
4.29
STS: 2 nd day, pH
3.83
4.05
4.25
3.84
4.04
4.27
3.85
4.02
4.25
STS: 3 rd day, pH
3.80
4.00
4.22
3.81
4.04
4.27
3.82
4.06
4.33
STS: 1 st day,
15° C.
clear
clear
clear
clear
clear
clear
clear
clear
ppt
appearance
STS: 2 nd day,
clear
clear
clear
clear
clear
clear
clear
clear
ppt
appearance
STS: 3 rd day,
clear
clear
clear
clear
clear
clear
clear
clear
ppt
appearance
STS: 1 st day,
25° C.
clear
clear
clear
clear
clear
clear
clear
clear
clear
appearance
STS: 2 nd day,
clear
clear
clear
clear
clear
clear
clear
clear
clear
appearance
STS: 3 rd day,
clear
clear
clear
clear
clear
clear
clear
clear
clear
appearance
[0000]
TABLE 22
Composition of 2-IB isotonic formulations (0.75, 1.0, 2.0, and 4.0 mg/g ) in citrate buffer (pH = 4.0-6.2),
and appearance and pH values for each formulation at time points T = 0, 1, 2, and 3 days stored at 5° C. ± 3° C. and 25° C. ± 2° C.
03-1
03-2
03-3
03-4
03-5
03-6
03-7
03-8
03-9
10-03
03-11
03-12
13-03
03-14
15-03
16-03
2-IB conc., mg/g
4.0
4.0
4.0
2.0
2.0
2.0
2.0
2.0
1.0
1.0
1.0
1.0
1.0
0.75
0.75
0.75
2-IB (95.8%), g
0.084
0.084
0.084
0.042
0.042
0.042
0.042
0.042
0.021
0.021
0.021
0.021
0.021
0.016
0.016
0.016
Citric acid 0.1M
2.3126
1.9184
1.4089
1.906
1.3898
0.9029
0.5036
0.2966
1.915
1.4181
0.9071
0.5216
0.3167
0.8936
0.5131
0.3133
solution (g)
25% CAPTISOL ®/
4.1625
3.9998
3.9897
4.0215
3.9907
3.9945
4.0165
3.9808
4.0079
4.0274
4.1164
4.0249
4.0381
3.9893
4.0238
4.0385
2.45% NaCl stock
solution, (g)
Sodium Citrate
0
0.4639
ppt
1.375
2.1573
2.4214
3.6295
ppt
2.0182
2.4845
3.0597
4.1459
3.6235
3.242
4.474
3.9582
dihydrate 0.1M
solution (g)
Water for
2.5201
1.7929
Ppt
1.7143
1.5042
1.7132
0.8506
ppt
1.1265
1.1116
0.9796
0.3312
1.0627
0.8159
0
0.8276
Injection (g)
Total molarity,
11.26
11.91
7.04
16.41
17.74
16.62
20.67
1.48
19.67
19.51
19.83
23.34
19.70
20.68
24.94
21.36
mM
pH Target
4.0
4.5
5.0
4.5
5.0
5.5
6.0
6.2
4.5
5.0
5.5
6.0
6.2
5.5
6.0
6.2
pH obtained after
3.93
4.50
ppt
4.49
5.09
5.52
ppt
ppt
4.53
5.01
5.52
6.01
6.23
5.52
6.02
6.23
titration (T-0)
STS: 1 st day,
5° C.
4.04
ppt
ppt
4.52
5.14
ppt
ppt
ppt
4.59
5.05
5.53
6.02
ppt
5.55
6.02
6.21
pH
STS: 2 nd
4.03
ppt
ppt
4.54
5.11
ppt
ppt
ppt
4.55
5.00
5.50
5.96
ppt
5.49
5.98
6.19
day, pH
STS: 3 rd
4.10
ppt
ppt
4.57
ppt
ppt
ppt
ppt
4.58
5.04
5.50
5.95
ppt
5.52
5.99
6.17
day, pH
STS: 1 st day,
25° C.
4.02
4.53
ppt
4.52
5.10
5.51
ppt
ppt
4.54
5.03
5.48
5.97
6.20
5.51
5.97
6.17
pH
STS: 2 nd
4.06
4.58
ppt
4.58
5.15
ppt
ppt
ppt
4.53
5.03
5.52
5.98
6.20
5.52
5.99
6.18
day, pH
STS: 3 rd
4.08
4.58
ppt
4.57
5.13
ppt
ppt
ppt
4.57
5.02
5.49
5.95
6.14
5.51
5.93
6.18
day, pH
Osmolality
RT
293
299
ppt
300
304
309
ppt
ppt
309
312
326
333
325
320
337
329
obtained
after
titration
(T-0)
STS: 3rd
5° C.
293
ppt
ppt
300
ppt
ppt
ppt
ppt
308
312
328
332
ppt
321
337
330
day,
osmolality,
mOsm
STS: 3rd
25° C.
290
297
ppt
300
302
ppt
ppt
ppt
308
313
327
335
328
317
336
329
day,
osmolality,
mOsm
Appearance
RT
clear
clear
ppt
clear
clear
clear
ppt
ppt
clear
clear
clear
clear
clear
clear
clear
clear
obtained
after
titration
(T-0)
STS: 1st
5° C.
clear
ppt
ppt
clear
clear
ppt
ppt
ppt
clear
clear
clear
clear
ppt
clear
clear
clear
day,
appearance
STS: 2nd
clear
ppt
ppt
clear
clear
ppt
ppt
ppt
clear
clear
clear
clear
ppt
clear
clear
clear
day,
appearance
STS: 3rd
clear
ppt
ppt
clear
ppt
ppt
ppt
ppt
clear
clear
clear
clear
ppt
clear
clear
clear
day,
appearance
STS: 1st
25° C.
clear
clear
ppt
clear
clear
clear
ppt
ppt
clear
clear
clear
clear
clear
clear
clear
clear
day,
appearance
STS: 2nd
clear
clear
ppt
clear
clear
ppt
ppt
ppt
clear
clear
clear
clear
clear
clear
clear
clear
day,
appearance
STS: 3rd
clear
clear
ppt
clear
clear
ppt
ppt
ppt
clear
clear
clear
clear
clear
clear
clear
clear
day,
appearance
[0000]
TABLE 23
Composition of 2-IB placebo isotonic formulations in citrate
buffer (pH = 4.0-6.2) with CAPTISOL ® points T = 0,
1, 2, and 3 days stored at 5° C. ± 3° C. and 25° C. ± 2° C.
03-1
03-2
03-3
03-4
03-5
03-6
2-IB conc., mg/g
0
0
0
0
0
0
2-IB (95.8%), g
0
0
0
0
0
0
Citric acid 0.1M solution (g)
2.3681
1.8622
1.4556
0.8859
0.5515
0.3351
25% CAPTISOL ®/2.45%
4.1152
3.9825
3.9939
3.9852
3.8414
3.9901
NaCl stock solution, (g)
Sodium Citrate dihydrate
1.8553
2.4737
3.5027
3.9749
5.6267
5.0957
0.1M solution (g)
Water for Injection
1.6782
1.7153
1.1384
1.2175
0.0597
0.5445
Total molarity, mM
21.12
21.6795
24.7915
24.304
30.891
27.154
pH Target
4.0
4.5
5.0
5.5
6.0
6.2
pH obtained after titration
4.04
4.51
5.03
5.48
5.95
6.16
(T-0)
STS: 1 st day, pH
5° C.
4.02
4.52
5.04
5.50
5.97
6.18
STS: 2 nd day, pH
4.11
4.59
5.09
5.52
5.97
6.17
STS: 3 rd day, pH
4.10
4.56
5.08
5.51
5.97
6.18
STS: 1 st day, pH
25° C.
4.06
4.54
5.06
5.53
6.02
6.21
STS: 2 nd day, pH
4.11
4.58
5.09
5.52
5.99
6.16
STS: 3 rd day, pH
4.12
4.58
5.08
5.52
5.98
6.19
Osmolality
RT
316
312
326
331
342
347
obtained after
titration (T-0)
STS: 3 rd day,
5° C.
314
312
326
331
341
342
osmolality, mOsm
STS: 3 rd day,
25° C.
314
313
328
331
344
345
osmolality, mOsm
Appearance
RT
clear
clear
clear
clear
clear
clear
obtained after
titration (T-0)
STS: 1 st day,
5° C.
clear
clear
clear
clear
clear
clear
appearance
STS: 2 rd day,
clear
clear
clear
clear
clear
clear
appearance
STS: 3 rd day,
clear
clear
clear
clear
clear
clear
appearance
STS: 1 st day,
25° C.
clear
clear
clear
clear
clear
clear
appearance
STS: 2 nd day,
clear
clear
clear
clear
clear
clear
appearance
STS: 3 rd day,
clear
clear
clear
clear
clear
clear
appearance
[0000]
TABLE 24
Materials and their amounts used for preparation of each of the four
formulations 08-1, 08-2, 08-1P, and 08-2P, citrate buffer capacity, visual appearance, pH, and
assay before and after terminal sterilization. Water for irrigation is a sterile, hypotonic,
nonpyrogenic irrigating fluid entirely composed of Sterile Water for Injection USP.
08-1
08-1P
08-2
08-2P
2-IB conc.
0.75 mg/ml
0.75 mg/ml
0.75 mg/ml
0.75 mg/ml
Theoretical amount of 2-IB (g)
0.0345
0.0345
Water content, %
14.57
14.57
Amount of 2-IB (actual, g)
0.0402
0.0404
Citric acid 0.1M solution (theoretical, g)
4.4
4.05
0.679
0.590
Actual citric acid 0.1M solution (g)
4.4117
4.0468
0.6927
0.5916
Sodium citrate dihydrate 0.1M solution (theoretical, g)
2.2~
2.2~
~5.3
~5.0
Actual sodium citrate dihydrate 0.1M solution (g)
2.8465
3.1900
6.6017
6.9156
4.5% NaCl stock solution, (theoretical, g)
8.8
8.8
4.5% NaCl stock solution, (actual, g)
8.7941
8.8272
25% CAPTISOL ®/2.45% NaCl stock solution (theoretical,
8.8
8.8
g)
25% CAPTISOL ®/2.45% NaCl stock solution (actual, g)
8.8090
8.8511
Water for irrigation (g)
Up to 44 g
Up to 44 g
Up to 44 g
Up to 44 g
Actual water for irrigation added (g)
17.6077
18.7046
18.7120
17.6075
Total formulation (g)
43.9392
44.0253
44.0012
43.9909
Theoretical buffer capacity, mM
15.15
15.15
15.00
15.00
Actual buffer capacity, mM
16.50
16.45
16.58
17.06
pH Target
4.0
4.0
6.0
6.0
pH obtained after titration (T-0)
4.0
4.0
6.0
6.0
Appearance before sterilization
Clear and colorless
Appearance after sterilization
Clear and colorless
pH before sterilization
4.01
4.01
6.04
6.05
pH following sterilization
4.05
4.06
6.09
6.12
Osmolality before sterilization
310
313
309
308
Osmolality after sterilization
314
311
306
306
Assay before sterilization
99.6%
ND
99.1%
ND
Assay after sterilization
96.6%
ND
98.8%
ND
[0000]
TABLE 25
Ingredient amounts used for preparing 09-1 formulations and 09-1V
(vehicle (placebo) of 09-1), 09-2 and 09-2v (vehicle (placebo) of 09-2) solutions (including
buffer capacities, and pH and appearance after titration of the 2-IB citric acid solution with
sodium citrate.
Formulation No.
09-1
09-1V (Placebo)
09-2
09-2V (Placebo)
2-1B conc.
0.75 mg/g
0.00
0.75 mg/g
0.00
Theoretical amount of 2-IB (g)
0.0345
0.00
0.0345
0.00
Weighed amount of 2-IB (g)
0.0347
—
0.0346
—
Water content, %
6.072
—
6.072
—
Water content, g
0.0021
—
0.0021
—
Amount of 2-IB (actual, g)
0.0326
—
0.0325
—
Citric acid 0.1M solution
4.4
20.44
0.679
2.946
(theoretical, g)
Actual citric acid 0.1M solution
4.4408
20.47
0.6843
2.947
(g)
4.50% NaCl stock solution,
8.8
44.00
—
—
(theoretical, g)
4.50% NaCl stock solution,
8.8102
44.00
—
—
(actual, g)
25% CAPTISOL ®/2.45% NaCl
—
—
8.8
44.00
stock solution (theoretical, g)
25% CAPTISOL ®/2.45% NaCl
—
—
8.8629
44.022
stock solution (actual, g)
Sodium citrate dihydrate 0.1M
1.80~
11.00~
~4.0
~17.00
solution (theoretical, g)
Actual sodium citrate dihydrate
3.5734
17.8140
9.5472
31.8830
0.1M solution (g)
Water for injection (g)
Up to 44.00
Up to 220.00
Up to 44.00
Up to 220.00
Water for injection (actual, g)
43.9591
220.02
44.029
220.042
Theoretical buffer capacity, mM
15.15
15.15
15.00
15.00
Actual buffer capacity molarity,
18.23
17.40
23.24
15.83
mM
pH Target
4.0
4.0
6.0
6.0
pH obtained after titration
4.17
4.06
6.17
6.09
Appearance after titration
Clear without
Clear without
Clear without
Clear without
precipitation
precipitation
precipitation
precipitation
[0000]
TABLE 26
Appearance and pHs of 09-1 formulations and 09-1V dilutions with
ISPB and with the vehicle.
Appearance
Appearance
Appearance
Diluting
Formulations
Dilution
Fold-
right after
after water
following
Agent
to be diluted
no.
Dilution
mixing
bath
centrifuging
pH
ISPB
09-1
1
0.5
Clear
Clear
Clear
6.78
Without
Without
Without
6.81
2
0.25
Precipitation
Precipitation
Precipitation
7.20
Colorless
Colorless
Colorless
7.19
3
0.125
7.33
7.30
4
0.0625
7.34
7.42
5
0.03125
7.40
7.43
6
0.01563
7.44
7.45
7
0.007875
7.47
7.45
09-1V
1
0.5
Clear
Clear
Clear
6.85
Without
Without
Without
6.84
2
0.25
Precipitation
Precipitation
Precipitation
7.17
Colorless
Colorless
Colorless
7.14
3
0.125
7.36
7.33
4
0.0625
7.39
7.41
5
0.03125
7.42
7.45
6
0.01563
7.46
ND
7
0.007875
7.43
ND
Vehicle
09-1
1
0.5
Clear
Clear
Clear
4.17
Without
Without
Without
4.13
2
0.25
Precipitation
Precipitation
Precipitation
4.13
Colorless
Colorless
Colorless
4.11
3
0.125
4.09
4.11
4
0.0625
4.11
4.11
5
0.03125
4.09
4.07
6
0.01563
4.13
4.13
7
0.007875
4.12
4.09
[0000]
TABLE 27
Appearance and pHs of 09-2 and 09-1V dilutions with ISPB and of
09-2 with the vehicle.
Appearance
Appearance
Appearance
Diluting
Formulations
Dilution
Fold-
right after
after water
following
Agent
to be diluted
no.
Dilution
mixing
bath
centrifuging
pH
ISPB
09-2
1
0.5
Clear
Clear
Clear
7.33
Without
Without
Without
7.33
2
0.25
Precipitation
Precipitation
Precipitation
7.32
Colorless
Colorless
Colorless
7.39
3
0.125
7.46
7.39
4
0.0625
7.46
7.43
5
0.03125
7.47
7.46
6
0.01563
7.42
7.43
7
0.007875
7.45
ND
09-2V
1
0.5
Clear
Clear
Clear
7.31
Without
Without
Without
7.34
2
0.25
Precipitation
Precipitation
Precipitation
7.43
Colorless
Colorless
Colorless
7.41
3
0.125
7.41
7.40
4
0.0625
7.44
7.43
5
0.03125
7.47
7.43
6
0.01563
7.45
7.39
7
0.007875
7.43
7.40
Vehicle
09-2
1
0.5
Clear
Clear
Clear
6.23
Without
Without
Without
6.25
2
0.25
Precipitation
Precipitation
Precipitation
6.21
Colorless
Colorless
Colorless
6.16
3
0.125
6.10
6.14
4
0.0625
6.18
6.16
5
0.03125
6.16
6.17
6
0.01563
6.16
6.17
7
0.007875
6.09
6.10
|
The disclosure relates to improving the aqueous solubility of 2-iminobiotin. In a particular aspect, the disclosure pertains to formulations suitable for administration of 2-iminobiotin to mammals suffering from disorders or conditions that benefit from that administration.
| 0
|
This is a Continuation of International Application PCT/EP02/03801, with an international filing date of Apr. 5, 2002, which was published under PCT Article 21(2) in German, and the disclosure of which is incorporated into this application by reference.
FIELD OF AND BACKGROUND OF THE INVENTION
The invention relates to a method for generating an AC voltage in a system frequency range from a DC input voltage in which the DC input voltage, pulse-width modulated, is connected to the primary winding of a transformer at a higher switching frequency than the system frequency.
The invention also relates to a voltage converter for converting a DC input voltage to an AC output voltage in the system frequency range using a transformer. Selectively connected to a primary winding of the transformer is the DC input voltage, pulse-width modulated via a switching device which is driven by a drive circuit at a higher switching frequency than the system frequency.
In order to generate an AC voltage in the system frequency range, for example 117 V/60 Hz or 230 V/50 Hz, from a DC input voltage of, for example, 12 or 24 V, two stages are usually carried out according to the prior art, for example as explained below:
In a first stage, an intermediate circuit voltage of 310 V is generated by means of a step-up converter from the low DC input voltage of 12 V. A flyback converter or forward converter is used for this purpose, using pulse-width modulation in a frequency range above the audible range, for example 20 kHz or more. The intermediate circuit voltage is regulated to ensure that it is constant. This high DC voltage is then converted by means of a full bridge rectifier to obtain the desired AC voltage, pulse-width modulation again being used at a switching frequency of 20 kHz or more. The envelope of the stepped voltage obtained here forms the system frequency output voltage. It is clear to those skilled in the art that this two-stage method necessarily leads to greater losses and decreased efficiency. Inductors are required in both converter stages, a transformer being required in at least one stage in order to provide the DC isolation that is usually required between the input and the output. These inductors and the required intermediate circuit capacitor are disadvantageous in terms of costs.
If the DC input voltage of, for example, 12 V is converted directly to a 50 Hz voltage then this requires an expensive 50 Hz transformer to achieve the desired 117/230 V on the output side.
OBJECTS OF THE INVENTION
One object of the invention is to provide a method and a voltage converter with which the overall complexity is reduced and with which no transformers operable at the system frequency are required.
SUMMARY OF THE INVENTION
This object is achieved with a method of the type mentioned initially in which, according to the invention, two pulse-width modulated square-wave pulse trains of opposite polarity are applied to the primary winding. Each pulse train is modulated so as to correspond to one half-cycle of the AC voltage to be generated. The pulses of the pulse train in each case are shifted with respect to pulses of the other pulse train such that the pulses of one pulse train fall into the gaps in the other pulse train. The pulses of the two pulse trains are rectified on the secondary side of the transformer such that only one pulse train of pulses of one polarity is still present. Owing to their pulse-width modulation, these pulses correspond to successive half-cycles of the AC voltage to be generated. The polarity of the pulse train obtained after rectification is reversed periodically at double the frequency of the AC voltage to be generated such that a pulse train is obtained which is a pulse-width modulated representation of the AC output voltage with respect to amplitude, frequency and polarity.
The invention dispenses with a complex high-voltage intermediate circuit having an expensive intermediate circuit capacitor. Since the switch-over is carried out on the secondary side in the system frequency range, the required switching elements are dimensioned with respect to these low frequencies.
In some cases it may be necessary or expedient to subject the pulse train obtained to low-pass filtering in order to obtain the AC output voltage (e.g., a sinusoid).
In a preferred embodiment of the invention, the primary winding of the transformer is split into two halves. The DC input voltage is connected (in a corresponding manner to the pulse-width modulated square-wave pulse trains of opposite polarity) in each case to one winding half or to the other, with reverse polarity. It is therefore sufficient, in practice, to have two controlled switches on the primary side.
This object is also achieved using a voltage converter of the type mentioned initially in which, according to the invention, the switching device and the drive circuit are designed to apply two pulse-width modulated square-wave pulse trains of opposite polarity from the DC input voltage to the primary winding. Each pulse train is modulated so as to correspond to one half-cycle of the AC voltage to be generated, and the two pulse trains are shifted with respect to one another such that the pulses of one pulse train fall into the gaps in the other pulse train. A rectifier is connected downstream of the secondary winding of the transformer, at whose output only one pulse train of pulses of one polarity is still present. Owing to their pulse-width modulation, these pulses correspond to successive half-cycles of the AC voltage to be generated. A controlled polarity reversal switch is arranged downstream of the rectifier in order to reverse the polarity of the pulse train downstream of the rectifier at twice the frequency of the AC voltage to be generated, such that a pulse train is obtained which is a pulse-width modulated representation of the AC output voltage with respect to amplitude, frequency and polarity.
The advantages which can be achieved using this voltage converter have already been explained in conjunction with the method.
Here too, it is more appropriate to obtain the AC output voltage from this pulse train using an internal and/or a load-side low-pass filter.
In a preferred embodiment, the primary winding of the transformer is split into two halves, and the switching device has two controlled switches by means of which the DC input voltage can be applied alternately to one winding half and to the other, with reverse polarity. It is advisable, particularly with a resistive load, for the low-pass filter to be formed from an inductance in a series path downstream of the polarity reversal switch and the load.
In practice, for example in the case of loads in the form of motors, the invention provides for the low-pass filter to be at least partially included in an inductive load.
One expedient variant provides for the polarity reversal switch to comprise a bridge circuit which has a controlled switch in each of its four arms.
It is particularly advantageous if the rectifier and the polarity reversal switch are combined in a rectifying switch having a bridge structure, each bridge arm having two back-to-back series-connected diodes, and each diode being bridged by a switching transistor so that, by alternately driving one switching transistor in each bridge arm at twice the system frequency, one and the other diodes of the bridge arm alternately forms the active arm of the bridge, as a result of which the pulse train which is pulse-width modulated with respect to the amplitude, frequency and polarity of the AC output voltage is obtained. In this manner, the secondary-side rectification and switching can take place in a single bridge.
In order to solve the problem of DC isolation, it is favorable if each switching transistor is driven via a light-emitting diode to provide DC isolation.
Cost-effective solutions for relatively large numbers of voltage converters can be achieved if the rectifying switch is in the form of an integrated circuit, thereby simplifying fabrication and reducing manufacturing costs.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention including further advantages is explained in more detail below with reference to exemplary embodiments which are illustrated in the drawing, in which:
FIG. 1 shows a simplified outline circuit diagram of a voltage converter according to the invention,
FIGS. 2A-2F show simplified signal waveforms, not to scale, which occur when carrying out the method according to the invention,
FIG. 3 shows a further circuit for a voltage converter according to the invention,
FIG. 4 shows the details of a rectifier switch used in the circuit shown in FIG. 3 , and
FIGS. 5A and 5B show two switching states of the rectifier switch shown in FIG. 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a transformer UET having a primary winding W 1 , comprising two winding halves W 11 , W 12 , and a secondary winding W 2 . The positive pole of a DC input voltage U E , for example +12 V, is applied to the center of the primary winding.
Primary winding W 1 is connected to the negative pole of the DC input voltage via a first controlled switch S 1 , connected to the beginning winding half W 11 , and via a second controlled switch S 2 , connected to the end winding half W 12 . The two controlled switches S 1 , S 2 , in this case field-effect transistors, can be driven by a drive circuit AST as described in more detail below.
On the secondary side, the secondary winding W 2 produces the secondary voltage U sec . A bridge rectifier GLR is connected downstream of the winding W 2 . The GLR is followed by a polarity reversal switch UPS comprising four controlled switches S 31 . . . S 34 . These switches are also controlled by the drive circuit AST, so that firstly S 31 and S 32 and secondly S 33 and S 34 are alternately closed or opened. A series inductor L is positioned between the output of the polarity reversal switch UPS and a load connected to the converter.
The method according to the invention will now be explained in more detail with reference to FIGS. 2A-2F .
Two pulse-width modulated square-wave pulse trains of opposite polarity are applied to the primary winding W 1 , each pulse train being modulated so as to correspond to one half-cycle of the AC voltage to be generated. In this case, the pulses of the two pulse trains are in each case shifted with respect to one another such that the pulses of one pulse train fall into the gaps in the other pulse train.
FIG. 2F shows the AC output voltage U A to be generated which is of a frequency of, for example, 50 Hz. FIGS. 2A and 2B show the drive pulses for the two controlled switches S 1 , S 2 . FIG. 2C shows the resultant secondary voltage U sec of the transformer, whose waveform also corresponds to that of the primary voltage of the transformer. The opposite polarity of the pulse trains is achieved here by connecting the DC input voltage U E alternately to one of the two winding halves W 11 , W 12 . With an integral primary winding W 1 , four controlled switches would have to be used to achieve this opposite polarity.
The switching takes place at a higher frequency than the system frequency, for example at 100 kHz, which means that the transformer need have only small dimensions and mass and the secondary-side filtering should have minimal complexity. It is therefore clear that the illustrations shown in FIGS. 2A and 2B should only be regarded as schematic representations since here the switching frequency has been selected to be substantially lower for reasons of clarity.
The combined pulse train shown in FIG. 2C is then rectified using the rectifier GLR, resulting in the pulse train shown in FIG. 2D as the output voltage U g of the rectifier, this pulse train now having only pulses of one polarity. Since this pulse train now corresponds to successive sinusoidal half-cycles of the output voltage to be generated, the polarity needs to be reversed in time with a frequency which is twice the output frequency, i.e. at 100 Hz. This polarity reversal is done by the polarity reversal switch UPS, so that a voltage U L as shown in FIG. 2E is generated at the output of the switch UPS. This voltage U L is a pulse train which is pulse-width modulated with respect to the amplitude, frequency and polarity of the AC output voltage. The desired output voltage is obtained from this voltage U L after low-pass filtering.
If the load LAS is purely resistive, the low-pass filtering or integration is provided by the series inductance L. With regard to the high clock frequency of 100 kHz or more, in practice special filtering means can be dispensed with since, for example in the case of motor loads, an inductive component is contained in the load, or, on the other hand, for example incandescent lamps have so much inertia that special filtering can be dispensed with.
With reference to FIGS. 3 to 5 B, another variant of a voltage converter will now be described in which the rectifier and the polarity reversal switch are combined to form a unit on the secondary side of the transformer, this unit also being in the form of an integrated circuit.
On the primary side of the transformer, the circuit is the same as that shown in FIG. 1 . On the secondary side, the secondary winding W 2 of the transformer is followed by an integrated rectifier switch IGS and this is followed by a low-pass filter TPF, to whose output the load LAS can be connected.
The rectifier switch IGS, whose design is shown in more detail in FIG. 4 , is driven by the drive circuit AST at three inputs x, y, z, its inputs being given the reference symbols r and s and its outputs the reference symbols u and v.
As can be seen from FIG. 4 , the rectifier switch IGS is in the form of a bridge. Each bridge arm has two back-to-back series-connected diodes D 1 , D 2 ; D 3 , D 4 ; D 5 , D 6 and D 7 , D 8 . Each diode is bridged by a switching transistor T 1 . . . T 8 . It should be noted here that the diodes can be the parasitic diodes intrinsic to, for example, MOSFET transistors, although the forward-biased voltage drop across the diodes should be kept very low by suitable doping.
Preferably, the transistors T 1 . . . T 8 are driven with optical DC isolation with the aid of light-emitting diodes LD 1 . . . LD 8 . There is no need for each switching transistor to have an associated light-emitting diode. For example, one light-emitting diode can be used to drive a plurality of transistors which switch simultaneously.
In order to obtain a signal corresponding to the desired sinusoidal output voltage from the rectified pulse-width modulated signal shown in FIG. 2D , the rectifier switch IPS must be switched correspondingly.
The connection “x” is the common anode of the light-emitting diodes on the drive-circuit side, and is connected to the positive supply voltage of the drive circuit AST via a series resistor (not shown).
If the connection “z” of the drive circuit is connected to ground, the light-emitting diodes LD 2 , LD 3 , LD 5 and LD 8 are active and the corresponding transistors T 2 , T 3 , T 5 and T 8 are switched on. These switched-on transistors bridge the corresponding diodes D 2 , D 4 , D 5 and D 8 and an equivalent circuit is produced as shown in FIG. 5 A. Only the diodes D 1 , D 4 , D 6 and D 7 act as rectified elements and this results in the positive half-cycle having a voltage waveform corresponding to the output voltage U A .
If the connection “y” of a drive circuit is connected to ground, the light-emitting diodes LD 1 , LD 4 , LD 6 and LD 7 are active and the corresponding transistors T 1 , T 4 , T 6 and T 7 are switched on. These switched-on transistors bridge the corresponding diodes D 1 , D 4 , D 6 and D 7 and an equivalent circuit is produced as shown in FIG. 5 B. Only the diodes D 2 , D 3 , D 5 and D 8 act as rectifying elements and this results in the negative half-cycle having a voltage waveform corresponding to the output voltage U A .
Since the controlled bridge rectifier is switched at a low frequency, no particularly stringent demands are placed on the switching frequency of the optically coupled switching elements.
The switching must take place at the zero crossing of the AC voltage, but this is known by the drive circuit AST and can be derived from the PWM frequency as an integer division ratio, or is rigidly linked to this frequency.
Although the invention has been described in connection with generation of a single-phase AC voltage, it should be clear to those skilled in the art that appropriate modification also allows the generation of a 3-phase AC voltage, for example.
The AC output voltage will generally be at a frequency of 50 Hz or 60 Hz, although the term “system frequency” should not be taken to mean only these values. Other output frequencies are also possible, for example a system frequency of 400 Hz, as is customary for vehicle electrical systems. The frequency of the output voltage may be switched continuously or in steps, as required.
The sound frequency of the pulse-width modulation is expediently over 20 kHz, preferably in the region of 100 kHz, especially since at such high frequencies the low-pass filtering means are kept to a minimum or can even be completely dispensed with, since this filtering can take place in the load as long as it has, for example, inductive and resistive components. Correspondingly inert loads, such as incandescent lamps, do not require any special low-pass filtering, either.
One major advantage of the invention is that, owing to the pulses which are applied alternately to the positive and negative poles of the primary side of the transformer, saturation and thus thermal losses can be avoided.
The above description of the preferred embodiments has been given by way of example. From the disclosure given, those skilled in the art will not only understand the present invention and its attendant advantages, but will also find apparent various changes and modifications to the structures and methods disclosed. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the invention, as defined by the appended claims, and equivalents thereof.
|
A method and apparatus for generating an AC voltage in a system frequency range from a DC input voltage. Two opposite-pole, pulse-width modulated (PWM) rectangular pulses having a high switching rate are applied to the primary winding of a transformer. Every pulse is modulated to correspond to a half-wave of the AC voltage to be generated. On the secondary side of the transformer, the impulses of both PWM pulse trains are rectified to create a pulse train of a single polarity, the pulse width modulation of which corresponds to subsequent half-waves of the AC voltage to be generated. The pulse train so obtained is periodically commutated at double the frequency of the AC voltage to be generated so that a PWM signal representative of the AC output voltage is obtained with respect to amplitude, frequency, and polarity.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application Ser. No. 60/074,360, filed Feb. 10, 1998.
BACKGROUND OF THE INVENTION
This invention relates generally to the field of rigid disc drives, and more particularly, but not by way of limitation, to a glide test head assembly for use in testing magnetic disc recording media surface characteristics.
Disc drives of the type known as “Winchester” disc drives or hard disc drives are well known in the industry. Such disc drives record digital data on a plurality of circular, concentric data tracks on the surfaces of one or more rigid discs. The discs are typically mounted for rotation on the hub of a brushless DC spindle motor. In disc drives of the current generation, the spindle motor rotates the discs at speeds of up to 10,000 RPM.
Data are recorded to and retrieved from the discs by an array of vertically aligned read/write head assemblies, or heads, which are controllably moved from track to track by an actuator assembly. The read/write head assemblies typically consist of an electromagnetic transducer carried on an air bearing slider. This slider acts in a cooperative hydrodynamic relationship with a thin layer of air dragged along by the spinning discs to fly the head assembly in a closely spaced relationship to the disc surface. In order to maintain the proper flying relationship between the head assemblies and the discs, the head assemblies are attached to and supported by head suspensions or flexures.
The actuator assembly used to move the heads from track to track has assumed many forms historically, with most disc drives of the current generation incorporating an actuator of the type referred to as a rotary voice coil actuator. A typical rotary voice coil actuator consists of a pivot shaft fixedly attached to the disc drive housing base member closely adjacent to the outer diameter of the discs. The pivot shaft is mounted such that its central axis is normal to the plane of rotation of the discs. An actuator housing is mounted to the pivot shaft by an arrangement of precision ball bearing assemblies, and supports a flat coil which is suspended in the magnetic field of an array of permanent magnets, which are fixedly mounted to the disc drive housing base member. On the side of the actuator housing opposite to the coil, the actuator housing also typically includes a plurality of vertically aligned, radially extending actuator head mounting arms, to which the head suspensions mentioned above are mounted. When controlled DC current is applied to the coil, a magnetic field is formed surrounding the coil which interacts with the magnetic field of the permanent magnets to rotate the actuator housing, with the attached head suspensions and head assemblies, in accordance with the well-known Lorentz relationship. As the actuator housing rotates, the heads are moved radially across the data tracks along an arcuate path.
As the physical size of disc drives has decreased historically, the physical size of many of the disc drive components has also decreased to accommodate this size reduction. Similarly, the density of the data recorded on the magnetic media has been greatly increased. In order to accomplish this increase in data density, significant improvements in both the recording heads and recording media have been made.
For instance, the first rigid disc drives used in personal computers had a data capacity of only 10 megabytes, and were in the format commonly referred to in the industry as the “full height, 5¼″ format. Disc drives of the current generation typically have a data capacity of over a gigabyte (and frequently several gigabytes) in a 3½″ package which is only one fourth the size of the full height, 5¼″ format or less. Even smaller standard physical disc drive package formats, such as 2½″ and 1.8″, have been established. In order for these smaller envelope standards to gain market acceptance, even greater recording densities must be achieved.
The recording heads used in disc drives have evolved from monolithic inductive heads to composite inductive heads (without and with metal-in-gap technology) to thin-film heads fabricated using semi-conductor deposition techniques to the current generation of thin-film heads incorporating inductive write and magneto-resistive (MR) read elements. This technology path was necessitated by the need to continuously reduce the size of the gap in the head used to record and recover data, since such a gap size reduction was needed to reduce the size of the individual bit domain and allow greater recording density.
Since the reduction in gap size also meant that the head had to be closer to the recording medium, the quest for increased data density also lead to a parallel evolution in the technology of the recording medium. The earliest Winchester disc drives included discs coated with “particulate” recording layers. That is, small particles of ferrous oxide were suspended in a non-magnetic adhesive and applied to the disc substrate. With such discs, the size of the magnetic domain required to record a flux transition was clearly limited by the average size of the oxide particles and how closely these oxide particles were spaced within the adhesive matrix. The smoothness and flatness of the disc surface was also similarly limited. However, since the size of contemporary head gaps allowed data recording and retrieval with a head flying height of twelve microinches (0.000012 inches, 12μ″) or greater, the surface characteristics of the discs were adequate for the times.
Disc drives of the current generation incorporate heads that fly at nominal heights of only about 2.0μ″, and products currently under development will reduce this flying height to 1.5μ″ or less. Obviously, with nominal flying heights in this range, the surface characteristics of the disc medium must be much more closely controlled than was the case only a short time ago.
In current disc drive manufacturing environments, it is common to subject each disc to component level testing before it is assembled into a disc drive. One type of disc test is referred to as a “glide” test, which is used as a go/no-go test for surface defects or asperities, or excessive surface roughness. A glide test typically employs a precision spin stand and a specially configured glide test head including a piezo-electric sensing element, usually comprised of lead-zirconium-titanate (PbZrTi 3 ), also commonly known as a “pzt glide test head”. The glide test is performed with the pzt glide test head flown at approximately half the flying height at which the operational read/write head will fly in the finished disc drive product. For instance, if the disc being glide tested is intended for inclusion in a disc drive in which the operational heads will fly at 2.0μ″, the glide test will typically be performed with the pzt glide test head flying at 1.0μ″. If the glide test is completed without contact between the pzt glide test head and any surface defects, then the disc is passed on the assumption that there will be no contact between the operational heads and the discs during normal operation with a nominal head flying height twice that of the pzt glide test head flying height.
A variant of the glide test, often used by disc media manufacturers, is sometimes referred to as a “glide avalanche” or GA test. In GA testing, a pzt glide test head is first flown at a greater than normal flying height above the disc surface. This initial increased flying height is commonly achieved by rotating the disc under test at a greater than normal speed, thus increasing the linear velocity between the disc and the test head, and increasing the strength and thickness of the air bearing supporting the test head above the disc surface.
The rotational speed of the disc under test is then gradually reduced until contact between the test head and disc occurs, at which point the current flying height is recorded. Correlation of a series of such test sequences at varying radii on the disc can be used by the disc media manufacturer as an indication of overall disc surface characteristics.
It is also common practice in the industry to provide a textured “landing zone” on the disc surface, on which the read/write head of the disc drive will come to rest during “power-off” or “sleep” conditions. Since the glide avalanche test simulates the loss of power to rotate the disc, the glide avalanche test is also frequently used by design engineers developing textured landing zones to study the landing characteristics of head assemblies on various types of landing zone textures.
The read/write head assemblies incorporated in disc drive products are commonly designed to provide rapid take-off of the head assemblies as the discs accelerate from stopped to operational speed to minimize frictionally-induced wear, and typical pzt-glide test heads also include air bearing structures with the same rapid take-off characteristics.
One technique frequently used to lower the linear velocity between discs and head assemblies at which head take-off occurs is to provide the air bearing surfaces of the head assemblies with a positive crown, or slightly convex surface. As is known to those of skill in the art, a positive crown on the air bearing surfaces of a head assembly causes the hydrodynamic pressure between the heads and the discs to increase rapidly with the increase in linear velocity between the heads and discs, and thus enables the head assemblies to begin to fly at a much lower linear velocity than would heads with perfectly planar air bearing surfaces.
It is also common practice in the industry to utilize such positive crowns on the air bearing surfaces of glide test heads.
However, when such glide test heads are used for the glide avalanche test described above, the low linear velocity necessary to bring about contact between the test head and the disc may also result in instability of the flying attitude of the test head at the time of contact, and subsequent ambiguity in the validity of the glide avalanche test results.
A need exists, therefore, for a glide avalanche test head assembly which is capable of stable flight at lower flying heights to enable reliable glide avalanche testing on discs including the extremely smooth surfaces of the current generation of disc media products.
SUMMARY OF THE INVENTION
The present invention is a glide test head assembly optimized for glide avalanche testing. The glide test head assembly of the present invention includes air bearing surfaces formed with a negative crown, or slightly concave surface. The negative crown of the air bearing surfaces of the inventive glide test head lowers the hydrodynamic pressure between the glide test head assembly and a spinning disc for given disc rotational speeds, enabling the glide test head assembly to fly at a lower heights at a greater linear velocity, and thus with increased stability. The increased flying stability of the inventive glide test head assembly improves the correlation between true flying height and disc/head contact detection for glide avalanche testing.
The manner in which the present invention is implemented, as well as other features, benefits and advantages of the invention, can best be understood by a review of the following Detailed Description of the Invention, when read in conjunction with an examination of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a disc drive in which discs, which can be tested using the glide test head of the present invention, are utilized.
FIG. 2 is a simplified functional block diagram of a prior art test system in which the glide test head of the present invention can be integrated.
FIG. 3 is a simplified bottom perspective view of a typical prior art glide test head.
FIG. 4 is a simplified top perspective view of a typical prior art glide test head.
FIG. 5 is a simplified side elevation view of the prior art glide test head of FIGS. 3 and 4.
FIG. 6 is a graph showing the correlation between flying height and piezo element output for a typical prior art glide test head.
FIG. 7 is a simplified side elevation view of the glide test head of the present invention.
FIG. 8 is a simplified functional block diagram of a test system, similar to the prior art test system of FIG. 2, which has been modified to include the glide test head of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings and specifically to FIG. 1, shown is a plan view of a disc drive 100 in which the present invention is particularly useful. The disc drive 100 includes a base member 102 to which all other components are directly or indirectly mounted and a top cover 104 (shown in partial cutaway) which, together with the base member 102 , forms a disc drive housing which encloses delicate internal components and isolates these components from external contaminants.
The disc drive includes a plurality of discs 106 which are mounted for rotation on a spindle motor shown generally at 108 . The discs 106 include on their surfaces a plurality of circular, concentric data tracks, the innermost and outermost of which are shown by dashed lines at 110 , on which data are recorded via an array of vertically aligned head assemblies (one of which is shown at 112 ). The head assemblies 112 are supported by head suspensions, or flexures 114 , which are attached to actuator head mounting arms 116 . The actuator head mounting arms 116 are integral to an actuator bearing housing 118 which is mounted via an array of precision ball bearing assemblies (not designated) for rotation about a pivot shaft 120 .
Power to drive the actuator bearing housing 118 in its rotation about the pivot shaft 120 is provided by a voice coil motor (VCM) shown generally at 122 . The VCM 122 consists of a coil (not separately designated) which is supported by the actuator bearing housing 118 within the magnetic field of an array of permanent magnets (also not separately designated) which are fixedly mounted to the base member 102 , all in a manner well known in the industry. Electronic circuitry (partially shown at 124 , generally, and partially carried on a printed circuit board (not shown)) to control all aspects of the operation of the disc drive 100 is provided, with control signals to drive the VCM 122 , as well as data signals to and from the heads 112 , carried between the electronic circuitry 124 and the moving actuator assembly via a flexible printed circuit cable (PCC) 126 .
It will be apparent to one of skill in the art that the proper operation of the disc drive 100 will depend in large part to the existence of a controlled, precise relationship between the head assemblies 112 and the discs 106 . Therefore, it is common in the industry to test each of the discs 106 included in the disc drive 100 before the discs 106 are assembled into a disc drive 100 .
FIG. 2 is a simplified functional block diagram of a typical prior art test unit 130 used to test and map the surface of recording discs as components before the discs are assembled into disc drive units. The test unit 130 includes a precision spin stand 132 which further includes a spin motor 134 on which the disc 106 is mounted for rotation and testing.
The test unit 130 also typically includes a linear actuator 136 which is used to controllably move a test head 138 , mounted on a head suspension 140 , on a linear path across a radius of the disc 106 . Actuator control logic 142 is also included in the test unit 130 and provides the control signals on signal path 144 needed to move the test head 138 and monitors, via signal path 146 , the position of the test head 138 during testing of the disc 106 . In a typical test unit of the current art, the actuator supports and controls a second test head for simultaneous testing of the second disc surface. For purposes of clarity, the figure shows only a single test head 138 .
The test unit 130 also includes spin motor control logic 148 which is used to accelerate the spin motor 134 to its intended testing speed by passing motor drive signals on path 149 . It is common practice in the industry to vary the speed of the spin motor 134 as the test head 138 is moved across the disc radius to provide a constant linear velocity between the test head 138 and the area of the disc being tested. That is, as the test head 138 is moved inward, the speed of the spin motor is increased proportionally to maintain a constant linear velocity, and thus maintain a constant flying height for the test head 138 .
The spin stand 132 also includes a spin motor position encoder 150 which provides a position dependent reference signal. This reference signal is carried over signal path 152 to the spin motor control logic 148 where it is used to assist in the control of the speed of the spin motor 134 . The reference signal is also passed via signal path 154 to defect mapping logic 156 , where it is utilized, along with the actuator position signal passed via signal path 158 by the actuator control logic 142 , to maintain a constant calculation of the radial and circumferential portion of the disc 106 that is located under the test head 138 .
During the testing operation, a disc 106 is mounted on the spin motor 134 and the spin motor 134 is brought up to operational speed by the spin motor control logic 148 . Once the spin motor 134 is at the proper speed, the actuator control logic 142 causes the actuator 136 to move the test head 138 into cooperative arrangement with the surface of the disc 106 . The test head 138 is then stepped across the spinning disc 106 at a rate selected to cause the test head 138 to pass over every portion of the disc surface. As the head is stepped across the disc surface, the spin motor control logic 148 varies the spin motor speed to maintain a constant relative linear velocity between the test head 138 and the disc area being tested as noted above.
A defect on the disc surface will cause the test head 138 to generate a defect signal which is passed to the defect mapping logic 156 via signal path 159 . Recognition of the defect signal by the defect mapping logic 156 results in the current radial and circumferential location of the test head 138 relative to the disc 106 being recorded. Once the test head 138 has passed over the entire usable radial extent of the disc 106 , all detected and recorded defects are correlated to produce a defect map of the entire disc surface.
Test units of the type described above and which can be modified to include and implement the present invention are available from several sources. A typical test unit of this type is the model number MSA 450, manufactured by Cambrian Systems, Inc., a subsidiary of Phase Metrics Corporation, located in Westlake Village, Calif.
FIGS. 3 and 4 are, respectively, simplified bottom and top perspective views of a typical prior art glide test head 160 . The glide test head consists of a slider body 162 which is typically formed from a stable ceramic material, such as aluminum oxide/titantium carbide. Features of the slider body 162 are commonly formed using the processes of machining, ion etching and precision lapping.
The glide test head 160 is of the type sometimes referred to as a “catamaran” slider configuration, since it includes a pair of laterally displaced rails 164 . The rails 164 include air bearing surfaces 166 , which interact with a thin layer of air dragged along by the spinning disc to fly the glide test head 160 at a desired fly height above the surface of the disc being tested. As is known to those of skill in the art, the flying height is determined, in part, by the geometry of the air bearing surfaces, and the flying attitude of the slider body is a function of the geometry of the air bearing surface, as well as the head suspension ( 140 in FIG. 2) used to support the glide test head 160 .
At the leading edge of the air bearing surfaces 166 the rails 164 also typically include beveled regions 168 which are included to aid in the rapid establishment of the air bearing between the slider body 162 and the spinning disc.
While other forms of slider bodies are known in the art, such as tri-pad sliders and negative pressure air bearing sliders, the scope of the present invention is not envisioned as being limited by the specific form of air bearing elements included in the slider body 162 . The catamaran form of FIGS. 3 and 4 has been chosen for illustrative purposes only, due to its familiarity and simplicity.
FIGS. 3 and 4 show that the slider body 162 also includes a laterally extending wing 170 which is used to mount a piezoelectric crystal, or piezo element 172 . The reason that the slider body 162 must include the wing 170 for mounting the piezo element 172 is that that portion (shown at 174 , generally, in FIG. 4) of the slider body 162 above the rails 164 is used to attach the head suspension ( 140 in FIG. 2) used to support the glide test head 160 .
The piezo element 172 can be seen in the figures to include attached signal wires 176 . During operation, such as in a test system similar to that of FIG. 2, any contact between the air bearing surfaces 166 and a surface asperity on the disc under test will result in vibration or ringing of the entire slider body 162 . This excitation of the slider body 162 is conveyed to the piezo element 172 which responds to this excitation by outputting electrical signals on the signal wires 176 . These electrical signals are passed to appropriate detection logic (such as the defect mapping logic 156 of FIG. 2 ). If, as noted in the discussion of FIG. 2 above, the occurrence of the output of the piezo element 172 is correlated to the position of the actuator and the rotational position of the disc under the glide test head, a defect map of the disc under test can be generated.
FIG. 5 is a simplified side elevation view of the prior art glide test head assembly of FIGS. 3 and 4. As can be seen in the figure, the air bearing surfaces 166 of the glide test head 160 have a positive crown, or convex surface. In actual glide test heads, the amount of convexity of the air bearing surface is up to approximately 2μ″. The amount of positive crown has been greatly exaggerated in FIG. 5 for illustrative purpose only.
Having a positive crown allows the prior art glide test head 160 to begin flying at a lower linear velocity than would be possible if the air bearing surfaces 166 were to be flat, and thus reduces the amount of time that the glide test head 160 would be in contact with the surface of the disc, if the glide test head 160 were in contact with the disc when the disc starts to accelerate to it operational rotational speed. This capability is important in operational read/write heads incorporated into disc drives that are of the “contact start/stop” type, i.e., those disc drives which allow the heads to come to rest on the disc surface when power to the disc drive is lost, or during power-conserving “sleep” conditions. However, at the initial low take-off speed, the flying attitude of the head is relatively unstable, allowing the attitude of the head to vary in both the pitch and roll axes. While this instability is of little significance in the operational read/write heads of a disc drive, such instability is detrimental in glide avalanche testing.
It will be recalled from earlier discussion of glide avalanche testing that the test is typically performed by having the test head flying at a higher-than-normal flying height, due to higher-than-normal disc rotational speed. The speed of disc rotation is then reduced gradually until contact occurs between the test head and the disc.
If the glide avalanche test head has a positive crown, as does the prior art glide test head 160 of FIG. 5, the disc rotational speed will have to be reduced to a point where the stability of the flying attitude of the test head suffers before contact with the disc is to be expected. This reduced stability causes the reliability of the glide avalanche contact inception to be questionable, especially on the extremely smooth discs of the current generation.
FIG. 6 is a graphic representation of the output of the piezo element 172 of the prior art glide test head 160 of FIG. 5, showing the relationship between the piezo element output, in volts on the vertical axis, versus the flying height of the glide test head, in μ″ on the horizontal axis. This graphic representation is a idealization of the oscilloscope picture that can be obtained during a glide avalanche test with the prior art glide test head 160 of FIG. 5 .
As can be seen in FIG. 6, the piezo element output peaks at approximately 5.5 volts at an apparent flying height of less than 0.5μ″. However, with the positive crown on the air bearing surfaces of the prior art glide test head 160 of FIG. 5, this result includes certain ambiguities. Specifically, it is not certain whether the contact that caused the piezo element output is a result of a surface irregularity on the disc, or is caused by the unstable flying attitude of the glide test head 160 itself. That is, as the pitch and roll attitude of the glide test head 160 become unstable at the low linear velocity needed to bring the glide test head 160 into proximity with the disc surface being tested, the “rocking” of the glide test head in its pitch and roll axes can cause portions of the glide test head 160 to be much closer to the disc surface than would be expected if the flying attitude of the glide test head were known to be stable at this relatively low linear velocity.
It is the ambiguity of the glide avalanche test results that the present invention is directed to alleviating.
FIG. 7 is a simplified side elevation view, similar to FIG. 5, of the glide test head 180 of the present invention.
As can be seen in FIG. 7, the inventive glide test head 180 also includes a laterally-extending wing 170 on which is mounted a piezo element 172 , as in the prior art glide test head 160 of FIG. 5 .
The air bearing surface 182 of the inventive glide test head 180 , however, can be seen to have a negative crown, or concave shape. Once again, as in FIG. 5, the amount of negative crown or concavity has been greatly exaggerated for illustrative purposes, and the actual amount of negative crown incorporated in the air bearing surfaces 182 of the glide test head 180 of the present invention is actually envisioned as being on the order of 0.5-2μ″.
The effect of the negative crown on the operation of the glide test head of the present invention will be appreciated by one of skill in the art upon reading this disclosure. That is, just as a positive crown on the air bearing surfaces caused the prior art glide test head 160 of FIG. 5 to begin flying at a lower linear velocity than normal, the negative crown on the air bearing surfaces 182 of the glide test head 180 of the present invention causes it to begin flying at a much higher-than-normal linear velocity, and allows it to fly a much lower flying heights at higher linear velocities. This, in turn, means that the glide test head 180 of the present invention, if used in the glide avalanche test described above, will fly closer to the disc surface at a higher linear velocity and will thus fly with a much more stable attitude at these lower flying heights than can the prior art glide test head 160 of FIG. 5 .
Therefore, if the graphical representation of the piezo element output shown in FIG. 6 were to be obtained from the glide test head 180 of the present invention, it can be assumed with a very high degree of confidence that the contact between the glide test head 180 and the disc that is reflected in the output of the piezo element is, indeed, indicative of a surface irregularity on the disc being tested, rather than an indication of instability in the flying attitude of the glide test head 180 itself.
FIG. 8 is a simplified functional block diagram of a test system 190 , similar to the prior art test system 130 of FIG. 2, which has been modified to include the glide test head 180 of the present invention, and supporting electronic circuitry.
The test system 190 of FIG. 8 can be seen to include a precision spin stand 132 and spin motor 134 for supporting and rotating a disc 106 to be tested, as did the prior art test system 130 of FIG. 2 . The test system 190 also includes a linear actuator 136 , as in the prior art, and, although it is not shown in FIG. 8, actuator control logic for controlling the motion and detecting the position of the actuator 136 , similar to the actuator control logic 142 of FIG. 2, would also be included in the test system 190 .
The test system 190 also includes spin motor control and speed detection logic 192 that transmits motor drive signals to the spin motor 134 on path 194 . Associated with the spin motor 134 is a spin motor position detection element 196 which transfers information concerning the rotational position of the spin motor 134 to the spin motor control and speed detection logic on path 198 .
The spin motor control and speed detection logic 192 will also include a precision clock circuit 200 whose output is combined with the spin motor position information on path 198 by motor speed determination circuitry 202 . That is, the rotational position of the spin motor 134 is compared to the output of the precision clock circuit 200 by the motor speed determination circuitry 202 to develop a motor speed output on path 204 .
The piezo element 172 , which is a physical part of the glide test head 180 , as shown by dashed line 206 , will react to any contact between the glide test head 180 and the disc 106 by outputting an electrical contact detection signal on the lead connections 176 . This contact detection signal is passed to glide avalanche test logic 208 .
The glide avalanche test logic includes known parametric information about the glide test head 180 , such as the flying height versus linear velocity characteristics of the glide test head 180 .
Glide avalanche testing of the disc 106 is accomplished by first bringing the spin motor 134 with the disc 106 mounted thereon up to a selected rotational speed that is great enough to fly the glide test head at a first known fly height above the disc 106 . This first known fly height is higher than the height of any expected surface irregularities on the disc surface.
The linear actuator is then moved, in a manner well known in the art, to bring the glide test head 180 over the disc surface to place the glide test head at a known radial position at the first known fly height.
The speed of the spin motor 134 is then gradually reduced until the first contact between the glide test head 180 and the disc 106 occurs. This contact causes the piezo element 172 of the glide test head 180 to output the contact detection signal to the glide avalanche test logic 208 on lead connections 176 .
In the glide avalanche test logic 208 , the contact detection signal causes the spin motor speed signal on path 204 to be sampled, and compared with the known flight parameters of the glide test head 180 , to determine the flying height at which the contact between the glide test head 180 and the disc 106 occurred.
FIG. 8 also shows that the glide avalanche test logic 208 includes an output 210 which can be in the form of a drive signal for an oscilloscope, to provide a graphic representation of the glide avalanche test results, such as the graphic representation of FIG. 6, or in the form of digital data for transfer to a statistical data base for later analysis, or in the form of drive signals to a visual display.
It will also be appreciated by one of skill in the art that the above steps can be repeated with the glide test head 180 positioned at various radii of the disc 106 , should such further testing be desired.
In summary, the present invention provides a glide test head 180 with air bearing surfaces 182 formed with a negative crown, or convexity. The negative crown of the air bearing surfaces 182 of the glide test head 180 of the present invention allows the glide test head 180 of the present invention to fly at lower flying heights at higher linear velocities than can prior art glide test heads with either no air bearing crown characteristics or with positive crown characteristics. Because the glide test head 180 of the present invention is capable of lower flying heights at higher linear velocities, it also flies with greater attitude stability than can prior art glide test heads at low flying heights, increasing the reliability of test results obtained during glide avalanche testing with the glide test head of the present invention.
From the foregoing, it is apparent that the present invention is particularly well suited and well adapted to achieve the functionality set forth hereinabove, as well as possessing other advantages inherent therein. While a particular configuration of the present invention has been disclosed as an example embodiment, certain variations and modifications which fall within the envisioned scope of the invention may be suggested to one of skill in the art upon reading this disclosure. Therefore, the scope of the present invention should be considered to be limited only by the following claims.
|
A glide test head assembly optimized for glide avalanche testing. The glide test head assembly of the present invention includes air bearing surfaces formed with a negative crown, or slightly concave surface. The negative crown of the air bearing surfaces of the inventive glide test head lowers the hydrodynamic pressure between the glide test head assembly and a spinning disc for given disc rotational speeds, enabling the glide test head assembly to fly at a lower heights at a greater linear velocity, and thus with increased stability. The increased flying stability of the inventive glide test head assembly improves the correlation between true flying height and disc/head contact detection for glide avalanche testing.
| 6
|
REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 08/927,347 filed on Sep. 11, 1997 now U.S. Pat. No. 5,980,531, and which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
This invention relates to the field of stent deployment devices of the type for delivering and deploying a stent to a treatment site in a vessel of a living organism, more particularly, an animal or human. The device of the present invention includes two balloons, one being compliant and used for stent deployment at a relatively low pressure, and the other being non-compliant and available for post-deployment stent expansion at a relatively high pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall view of a stent delivery apparatus useful in the practice of the present invention.
FIG. 2 is an enlarged view partly in section of detail 2 of FIG. 1 showing the manifold-lumen fluid paths at the proximal end.
FIG. 3 is an enlarged section view of a distal end of the apparatus of FIG. 1 showing the lumen-balloon fluid paths with the balloons shown in respective deflated conditions with an outer sleeve and guide wire omitted.
FIG. 4 is a section view along line 4 — 4 of FIG. 3, except with the inner balloon shown inflated and the stent omitted.
FIG. 5 is a simplified section view of the distal end of the apparatus of FIG. 3 shown in an initial condition ready for insertion into a vessel with the outer sleeve shown in section and extended over a stent.
FIG. 6 is a view similar to FIG. 5 except with the outer sleeve retracted and the outer balloon inflated and in section showing stent deployment.
FIG. 7 is a view similar to FIG. 6 except with the inner balloon inflated with parts cut away showing post-deployment stent expansion.
FIG. 8 is a simplified section view of a vessel with a stenosis.
FIG. 9 is a simplified section view of the vessel and stenosis of FIG. 5 with a stent deployed via inflation of the outer balloon corresponding to FIG. 6 .
FIG. 10 is a simplified section view of the vessel and stenosis of FIG. 5 with the stent expanded after deployment using the inner balloon corresponding to FIG. 7 .
FIG. 11 is a graph of the distention characteristics for certain materials suitable for the outer balloon.
FIG. 12 is a graph of the distention characteristics for certain materials suitable for the inner balloon.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the Figures, and most particularly to FIGS. 1, 2 and 3 , a stent delivery system or medical device 10 may be seen. System or device 10 includes a three lumen catheter 12 preferably formed of a polymer or combination of polymers such as polyamide, polyester, polyimide, or the like and carries a slidable sleeve 14 on the exterior thereof System 10 also includes a valve body or manifold 16 preferably formed of a relatively rigid conventional polymer material, such as polycarbonate. Manifold 16 is secured to catheter 12 in a conventional fluid-tight manner and has ports 18 , 20 , and 22 in communication with respective lumens of catheter 12 . Port 18 is in fluid communication with lumen 24 ; port 22 is in fluid communication with lumen 26 ; and port 20 is in communication with lumen 28 , with port 20 and lumen 28 preferably adapted to receive a conventional guide wire 30 . As shown in FIG. 1, outer sleeve 14 extends to a region near the proximal end of assembly 10 and is thus retractable by manipulation of the proximal end of sleeve 14 , either directly or through the use of an enlarged portion such as a finger loop 15 . Sleeve 14 may be formed of a polyolefin such as polyethylene or polypropylene; a fluorinated polymer such as polytetrafluoroethylene or fluoroethylene propylene; a polyamide such as nylon, or other suitable material, as desired, and may be homogeneous or may be formed from more than one kind of polymer. For example, use of more than one kind of polymer allows sleeve 14 to be formed with a distal remainder including the proximal portion having a durometer of about 70D to about 80D.
Referring now also to FIGS. 3-7, system 10 also includes a first or inner balloon 32 , a second or outer balloon 34 and an expandable stent 36 . The first, or inner, balloon 32 is preferably formed from a non-compliant material, and the outer balloon 34 is preferably formed from a compliant type material.
As use herein, a “non-compliant” material balloon will exhibit a diameter change of about 10 percent or less (preferably 3 to 10 percent) when its internal pressure changes from 4 atmospheres to 13 atmospheres and a “compliant” material balloon will exhibit a diameter change of about 11 percent or more (preferably 11 to 20 percent) when its internal pressure changes from 4 atmospheres to 13 atmospheres.
Each of balloons 32 , 3 4 are preferably formed with a “memory” so that when deflated or depressurized, they will return to a rolled or “folded” state (known as “rewrap”) as indicated in the figures. Stent 36 is preferably a non-self deploying or balloon-expandable type stent, such as depicted in U.S. Pat. No. 4,733,665.
FIG. 3 shows the assembly with both balloons deflated, but with the sleeve 14 retracted and with the stent 36 ready for deployment. Lumen 24 is in fluid communication with the interior of inner balloon 32 via a skive 41 . Lumen 26 is in fluid communication with the region between inner balloon 32 and the interior of outer balloon 34 via a second skive 43 . A first pair of radiopaque marker bands 38 , 40 are preferably positioned to indicate the location and extent of first balloon 32 and an anticipated post-deployment location and length of stent 36 . A second pair of bands 42 , 44 may be used to indicate the location and extent of the second balloon 34 and a predeployed location and length of stent 36 . As may be seen in the figures, the first balloon 32 is positioned radially inward of the stent 36 and has a working section 33 having a length 37 substantially equal to the axial length of the stent 36 when the stent is in a deployed condition (as shown in FIGS. 6 and 7) and the second balloon 34 has a working section 35 having a length substantially equal to or greater than the non-deployed length of the stent 36 , as indicated most particularly in FIG. 5 . It is to be understood that the non-self-deploying stent 36 useful in the practice of the present invention may “shrink” or reduce in axial length by as much as 15 to 20 percent or more (of the non-deployed length) when deployed to the design diameter or condition for the stent. Such axial shrinkage occurs because the filaments or elemental sections of the stent 36 are typically not extensible, but rather move from a generally axial orientation to a more radial (helical) orientation.
Because of this property of the stent, it is useful to define a working section for each balloon in relation to the length of the stent when the balloon is disposed within the stent for expansion against the stent. Thus, the working section of the outer balloon will be substantially equal to the length of a collapsed or non-deployed stent, while the working section of the inner balloon will preferably be substantially equal to the length of the post-deployed or expanded stent, after it is enlarged by inflation of the outer balloon, but before any further radial enlargement by the inner balloon. Stated more generally, the working section of a balloon is preferably about equal to the length of the stent as it exists immediately prior to the stent being acted upon (urged radially outward) by that balloon. Making the outer balloon working section equal to the length of the non-deployed stent will ensure that the stent is deployed along its full axial length, while making the working section of the inner balloon equal to the length of the deployed stent will avoid direct contact between the inner balloon and the vessel during post-deployment expansion of the stent and will cause the inner balloon to fully engage the deployed stent for post-deployment “processing” (i.e., “setting” or further enlargement) of the stent. Because of the higher pressures utilized in post-deployment expansion, direct contact between the inner balloon and the vessel could result in over-expansion of the vessel in the regions beyond the axial ends of the stent if the inner balloon were permitted to be longer than the post-deployment length of the stent. Having the inner balloon substantially shorter than the length of the deployed stent may result in an undesirable condition wherein the stent protrudes into the vessel at one or both ends thereof.
As an example, and not by way of limitation, the stent may be 20 mm long before deployment and 15.4 mm long after deployment. For such a stent, the present invention will preferably have a working section for the inner balloon of 15.4 mm and a working section for the outer balloon of 20 mm or more.
In the practice of the present invention, the stent delivery system is manipulated until the stent is located radially inward of a stenosis in a vessel to be treated, preferably using radiopaque marker bands. The sleeve 14 is then retracted using finger pull 15 until the stent 36 is exposed as shown in FIG. 3 . The outer balloon 34 is inflated to deploy the stent, as shown in FIG. 6 . The outer balloon 34 is then deflated and the inner or first balloon is then inflated (as shown in FIG. 7) to “set” or fix the stent 36 in place. The inner balloon is then deflated and the stent delivery system (less the stent 36 ) is removed from the vessel, leaving the stent in place. The outer balloon is preferably of a softer and tougher material than the inner balloon, protecting the inner balloon from damage.
The inner balloon, being non-compliant, will also enable a stenosis enlargement procedure, as illustrated by FIGS. 8, 9 , and 10 . In FIG. 8, a simplified view of a stenosis 46 interior of a vessel 48 is shown. The stent 36 is shown deployed in FIG. 9 . However, even after deployment using the outer balloon 34 , the stenosis may protrude at least partially radially into the interior bore of the vessel 48 . Inflating the inner balloon 32 will urge the stenosis 46 radially outward, substantially restoring the interior diameter of the stenosis to the diameter of the bore of the vessel, as shown in FIG. 10 . Using the inner balloon 32 to accomplish this radial enlargement of the stenosis bore typically will entail higher pressures than used to deploy the stent, and thus will utilize the non-compliant character of the inner balloon to hold the diameter more constant over a greater pressure range than would be the case with a compliant inner balloon. It is to be understood that the outer balloon is preferably used to deploy the stent at relatively low inflation pressures and the inner balloon is preferably used to either “set” or shape the stent using relatively high pressures, but without over-enlarging the radial dimension of the deployed stent. It is to be further understood, however, that post-deployment inflation of the inner, non-compliant balloon 32 will typically result in further, limited, expansion of the stent 36 , and consequent similar expansion of the vessel region 48 radially outward of the stent 36 . In the practice of the present invention, it may be desirable to utilize a laminated balloon construction, particularly for the inner balloon 32 . Such a laminated structure may include an exterior nylon layer, for example, and a PET (polyethylene terepthalate) inner layer, combining the puncture resistance and improved rewrap memory of the nylon with the non-compliant high pressure capability of the PET.
Referring now to FIGS. 11 and 12, the distention curves for various materials for certain compliant and non-compliant balloons may be seen. In FIG. 11, two example compliant materials for the outer balloon are shown. Curve 50 illustrates the diameter change versus pressure for a polyethylene polymer, and curve 52 represents nylon 12. In FIG. 12, various example non-compliant materials are illustrated: curve 54 is for a PET material, and curves 56 , 58 , and 60 show the distention characteristic for PET/PA 12 laminate construction, (where PE is polyethylene, PET is polyethylene terephthalate, PA refers to a polyamide material and PA12 refers specifically to nylon 12). Curve 56 is for a two layer laminate having an internal PET layer laminated to an external PA layer wherein the PET/PA thickness ratio is 75/25; curve 58 is for 50% PET, 50% PA; and curve 60 is for 25% PET, 75% PA. Suitable wall thicknesses for the PET/PA laminated structure are from about 0.00037″ to about 0.00084″ overall. Although the curves shown are for layer ratios of 75/25%, 50/50%, and 25/75%, it is to be understood that other layer thickness ratios (such as 60% PET/40% PA) are suitable as well. For illustrative purposes, the following table gives approximate percentage diameter changes over a 4-13 atmosphere pressure range for various representative polymeric materials that are commercially available:
TABLE I
Compliant %
Non-compliant %
PE
18
PET
7
Nylon 12
13
75% PET/25% PA12
5
50% PET/50% PA12
8
25% PET/75% PA12
10
Generally a variety of polymer types could be used as either the compliant or non compliant material. One skilled in the art could formulate a polymer type so that the polymer would have the right characteristics. Examples of the polymer types that could be used include the below listed materials. Suitable materials for the balloons are as follows.
Various nylons (depending upon how they are formulated) can be incorporated into either the compliant or non-compliant balloon (alone or in a blend or in a laminated structure), specifically: Grilamid L25 (available from EMS of Zurich, Switzerland); Vestamide 2101 F or Vestamide 1801 F (available from H_ls America Inc. of Piscataway, N.J.).
For the non-compliant material, several applicable PET homopolymers are: ICI 5822C (available from ICI Americas, P.O. Box 630, Cardell plant, Fayetteville, N.C., 28302) and Shell Traytuf 1006.
For the compliant material, the following are representative of acceptable polymers:
Source
Thermoplastic Polyether Blockamide
7033 Pebax
Elf Atochem
6333 Pebax
5533 Pebax
Rigid Polyurethane
2510 Isoplast
Ashland
Polyester Elastomer
72D Hytrel HTR8276
DuPont
82D Hytrel HTR8280
63D Hytrel HTR8279
45D Hytrel HTR8278
Polyurethane
63 D Pellethane
Dow
55 D
75 D
Polyethylene
2247A Dowlex
Dow
2938 Dowlex
Although a number of materials have been listed above, it is to be understood that the compliant and non-compliant balloons can be prepared from a wide range of thermoplastic and or thermosetting polymer resins having the desired compliant or non-compliant characteristics.
A method of using the stent deployment device 10 is as follows. The stent deployment device 10 is inserted into a vessel and maneuvered to position the distal region at a treatment site. The sheath 14 is then retracted such that the stent 36 is presented to the treatment site. The outer balloon 34 is then inflated to deploy the stent 36 and then deflated to rewrap the outer balloon. The inner balloon is then inflated to expand or “set” the stent in the vessel at the treatment site, after which the inner balloon is deflated to rewrap the inner balloon, and the device 10 is eventually withdrawn from the vessel.
The invention is not to be taken as limited to all of the details thereof as modifications and variations thereof may be made without departing from the spirit or scope of the invention.
|
A stent delivery device having a pair of balloons at a proximal end of a catheter and having separate lumens for selectively inflating the respective balloons. The outer balloon is relatively compliant and the inner balloon is relatively non-compliant. A central lumen is provided for a guide wire. A stent is carried by the delivery device within an axially retractable sheath at the distal end of the catheter and is deployed by retraction of the sheath and inflation of the compliant balloon, and the stent is subsequently expanded by inflation of the non-compliant balloon.
| 0
|
STATEMENT REGARDING FEDERAL RIGHTS
This invention was made with government support under Contract No. W-7405-ENG-36 awarded by the U.S. Department of Energy. The government has certain rights in the invention.
FIELD OF THE INVENTION
The present invention relates generally to continuous air monitors, and, more particularly, to an apparatus that provides for automated filter change-out in a continuous air monitor.
BACKGROUND OF THE INVENTION
The Canberra Instrument Company, Inc. currently produces the Alpha Sentry CAM, and the Canberra Aquila Technologies Group currently produces the alpha-ECAM for the radiological air monitoring community. The present invention is an apparatus that provides for automated filter change in continuous air monitors (CAMs); including, the Alpha Sentry CAM and the Alpha Environmental Continuous Air Monitor (ECAM) utilizing the Quick Change Filter Cartridge (QCFC) filter holder.
The fact that the Alpha Sentry CAM and the ECAM use the Quick Change Filter Cartridge for handling filters created a unique opportunity to design a simple retrofit filter changing apparatus for these CAMs. The QCFC not only holds and positions the filter in the CAM head, it also provides the porous filter backing disk, so once the filter is inserted into the cartridge and the cap pressed on, all handling, positioning, or sealing requirements are taken into account except for insertion of the cartridge into the CAM head.
The user is enabled to pre-load a number of filter cartridges with pre-cut filter paper and insert them in the subject invention. Following initiation of the filter change process, all subsequent filter changes are executed automatically under the control of the embedded controller or PC in the CAM or ECAM. The user can initiate filter change just as is currently provided for in the CAM/ECAM user interface program, or by the detection of a condition such as unacceptably low flow using the built-in flow meter signal, at which time a filter change sequence would begin. In either circumstance, the actual process of used filter cartridge extraction and storage, and insertion of a fresh filter, would be carried out by the present invention without user handling. Thus, the present invention makes possible autonomous filter change outs at remote sites using the built-in network communication capability of the monitor.
Various objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
SUMMARY OF THE INVENTION
In accordance with the purposes of the present invention, as embodied and broadly described herein, the present invention includes an apparatus and corresponding method for automatically changing out a filter cartridge in a continuous air monitor. The apparatus includes: a first container sized to hold filter cartridge replacements; a second container sized to hold used filter cartridges; a transport insert connectively attached to the first and second containers; a shuttle block, sized to hold the filter cartridges that is located within the transport insert; a transport driver mechanism means used to supply a motive force to move the shuttle block within the transport insert; and, a control means for operating the transport driver mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
FIG. 1 is a pictorial illustration of one embodiment of a CAM filter cartridge that the present invention can be used to replace automatically.
FIG. 2 is a pictorial illustration of one embodiment of a feed container used to store replacement CAM filter cartridges.
FIG. 3 a is a pictorial illustration of a top loading feed container embodiment.
FIG. 3 b is a pictorial illustration of a bottom loading feed container embodiment.
FIG. 4 is a pictorial illustration of a one-piece bottom loading feed container.
FIG. 5 is a pictorial illustration of an embodiment of a shuttle block.
FIGS. 6 a and 6 b are pictorial illustrations of an embodiment of a latching mechanism.
FIG. 7 is a pictorial illustration of a transport insert.
FIG. 8 is a flow chart describing the method of removing a spent cartridge and replacing it with a fresh cartridge.
FIG. 9 is a pictorial illustration of another embodiment of a feed container.
FIGS. 10 a and 10 b are pictorial illustrations of another embodiment of a shuttle block and feed container.
DETAILED DESCRIPTION
The present invention was created to meet an expressed need for automated filter changing capability, where remote environmental settings or adverse conditions may make filter changing a costly and time-consuming process. The present invention makes it possible to reduce the support time requirement in a monitored facility or environmental monitored network by allowing a week's or a month's supply of filters (depending on dust loading conditions) to be set up at one time.
FIG. 1 shows one embodiment of a CAM filter cartridge that is used for collecting radiological air samples. In this embodiment, a filter cartridge 10 is round with beveled edges that allow proper centering under a detector within a CAM during mechanical handling. However, any shape configuration may be used for filter cartridge 10 , so long as the shape does not interfere with smooth handling during mechanical operations. Generally, air monitor filters used in real-time monitoring applications exhibit a circular geometry, ranging in size from 1″ to 8″.
FIG. 2 shows one embodiment of feed container 20 , which is sized appropriately to hold replacement filter cartridges 10 . Replacement filter cartridges 10 are stacked within feed container 20 , where the vertical dimension of feed container 20 is the only limiting factor on the number of cartridges that may be stored. Also, shown is latch 45 , which separates one filter cartridge 10 from the stack of cartridges at a time for transport into an attached CAM.
Referring now to FIG. 3 a , feed container 20 is connectively attached in a gravity feed position to transport insert 50 . Transport insert 50 is an enclosed rectangular tray (metal or plastic) sized to fit into and connectively attach to CAM 5 . Transport insert 50 serves as a guide element for cartridge shuttle block 40 , located within insert 50 , and provides a moving platform chassis on which the operations of loading, shuttling, and discharging filter cartridges 10 occurs. Discharge container 30 is also connectively attached to transport insert 50 , and serves the function of holding replaced filter cartridges 10 until collected by personnel.
FIG. 3 b shows another embodiment of the present invention, where feed container 20 is placed below transport insert 50 and spring 25 is used to supply the upward motive force to load new replacement cartridges into cartridge shuttle block 40 .
Feed container 20 is used for loading and staging of replacement filter cartridges 10 and discharge container 30 is used for accumulation of discharged filter cartridges 10 . Both feed container 20 and discharge container 30 are of suitable diameter to accept filter cartridges for used in automated filter changes. Note that in an alternative embodiment, feed container 20 and discharge container 30 may be manufactured as one piece, as shown in FIG. 4 .
FIG. 5 shows an embodiment of shuttle block 40 used to capture and transfer used and replacement cartridges 10 . This embodiment would be used for replacement cartridges 10 that exhibit a circular design. Other embodiments may be fashioned for other cartridge 10 geometries. Shuttle block 40 may comprise any suitable material (i.e., metal or plastic) sized to fit within transport insert 50 , with a defined central opening to accept and capture filter cartridges 10 .
FIG. 6 a shows an embodiment of a latching mechanism that functions to capture and stage cartridges 10 in feed container 20 during the loading process, such that only one cartridge 10 is inserted into radiation monitor 5 at a time. Latch piece 45 is mounted on block piece 44 to facilitate a spring-loaded approach to insertion and recovery of latch piece 45 from between cartridges in feed container 20 . In this embodiment, latch 45 includes two finger projections 41 that slide between successive cartridges 10 in feed container 20 and hold non-selected stack of cartridges 10 from moving, while the selected cartridge 10 is loaded into shuttle block 40 into CAM 5 .
Referring now to FIG. 6 b , backpiece 49 is secured to transport insert 50 , and springs 48 push latch piece 45 towards feed container 20 as shuttle block 40 moves towards CAM 5 . When shuttle block 40 is moving back towards discharge container 30 , pins 42 that protrude down through holes 46 into the interior of transport insert 50 , are engaged by formed pieces 39 (reference FIG. 5 ) on the back of shuttle block 40 . Thus, as shuttle block 40 continues movement towards discharge container 30 , latch piece 45 is pushed away from feed container 20 , allowing the stack of replacement cartridges to moved down by the pull of gravity, and thereby readying another cartridge 10 for replacement use.
FIG. 7 shows an embodiment of transport insert 50 . As previously stated, shuttle block 40 (not shown) is located within transport insert 50 and is coupled to transport driver mechanism means 60 , which may be, as in this embodiment, motor 62 with pulley 64 and belt 66 . Other motive means may be used as driver mechanism, to include a screw drive driven by a stepper motor or digital pulse control of a small motor or servomotor. Motor 60 is typically controlled using microprocessor 65 , or other suitable electrical/mechanical control means known to those skilled in the art, to achieve proper positioning of shuttle block 40 during operation. Slots 52 allow pins 42 (reference FIG. 6 a/b ) to extend down to make contact with shuttle block 40 .
FIG. 8 is a flow chart describing the method of removing a spent cartridge and replacing it with a fresh cartridge:
In Step 100 , a computer program interrupt generated by a flow sensor signal, programmed elapsed time signal, or user command signals microprocessor 65 to initiate a filter change out operation. The interrupt is usually based on a flow sensor measurement of reduced volumetric flow below a user-defined low-flow level, but also is frequently initiated by a user-initiated filter change command.
In Step 110 , microprocessor 65 initiates disengagement of used filter cartridge 10 from CAM 5 , typically this is performed by removing a vacuum condition within CAM 5 that holds cartridge 10 in place.
In Step 120 a signal from controlling microprocessor 65 initiates movement of shuttle block 40 that contains used/spent filter cartridge 10 from CAM 5 along transport insert 50 until shuttle block 40 reaches discharge container 30 . During this movement, shuttle block 40 , engages pins 42 , and pushes latch piece 45 away from feed container 20 , allowing the stack of replacement cartridges to move down.
In Step 130 , once centered over discharge container 30 , used filter cartridge 10 simply drops into discharge container 30 from shuffle block 40 .
In Step 140 , a signal is sent to the microprocessor to reverse movement of shuttle block 40 . The signal may be generated by any means known to those skilled in the art, for example from a limit switch, optical rotation encoder, or a computer program that logs the progress of shuttle block 40 .
In Step 150 , shuttle block 40 moves back towards CAM 5 , and springs 48 provide the motive force to slide latch piece 45 back to, and insert in, feed container 20 , thereby isolating a replacement cartridge from the stack of replacement cartridges.
In Step 160 the isolated replacement cartridge moves into shuttle block, either by gravity feed or some other motive force like a spring.
In Step 170 shuttle block 40 moves along transport insert 50 and into CAM 5 , providing a fresh filter cartridge for use. Note that an infra-red LED beam interrupt system could be used to detect filter movement out of the stack in the cartridge feed tube. The interrupt system would indicate that the stack supply has been exhausted (providing a “stack empty” signal), and in addition, it would take care of the situation where a cartridge got stuck in the process of loading, in which case an “service error” signal would be generated.
Finally, in Step 180 , microprocessor 65 initiates engagement of replacement filter cartridge 10 , typically by creating a vacuum condition within CAM 5 .
FIGS. 9 , 10 a , and 10 b show another embodiment for selecting a replacement cartridge from a stack of fresh cartridges. In this embodiment, spring loaded latch 75 , located on shuffle block 70 swivels, depending on the direction of motion of shuttle block 70 . As shuttle block 70 moves towards feed container 60 , latch 75 is in the upright position shown in both FIGS. 9 and 10 b . As latch 75 moves into and through feed container 60 towards CAM 5 , latch 75 pushes a replacement cartridge out of feed container 60 and over opening 55 , where the replacement cartridge drops down into shuttle block 70 . Shuttle block 70 then continues on, as in the first embodiment, into CAM 5 . Feed container 60 includes lip feature 62 that holds cartridges 10 in feed container 60 , serving the same function as latch piece 45 ( FIG. 6 a ) in the previous embodiment. Notch 64 allows the passage of latch 75 through feed container 60 , while latch 75 is in the upright position.
When moving a used/spent cartridge towards discharge container 30 , shuttle block 70 must move under feed container 60 . In order to perform this operations, latch 75 is designed with a curved surface that contacts the replacement stack of cartridges 10 in feed container 60 and swivels towards shuttle block 70 and below feed container 60 , in order to allow shuttle block 70 to move freely below feed container 60 . Once latch 75 exits from beneath feed container 60 , spring 77 provides the motive force to push latch 75 back into the upright position.
The foregoing description of the invention has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching.
The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled 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 appended hereto.
|
An apparatus and corresponding method for automatically changing out a filter cartridge in a continuous air monitor. The apparatus includes: a first container sized to hold filter cartridge replacements; a second container sized to hold used filter cartridges; a transport insert connectively attached to the first and second containers; a shuttle block, sized to hold the filter cartridges that is located within the transport insert; a transport driver mechanism means used to supply a motive force to move the shuttle block within the transport insert; and, a control means for operating the transport driver mechanism.
| 1
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an electric compressor in which an electric motor portion and a compressor portion are integrated and, in particular, to an electric compressor in which a drive circuit portion for supplying electric power to the electric motor portion is integrated with the compressor portion.
[0003] 2. Description of the Related Art
[0004] Attempts have been made to integrate a refrigerant compressor, for an air-conditioning system mounted in an automobiles, with an electric motor for rotatably driving the refrigerant compressor via a common rotating shaft, and to integrate a drive circuit portion, such as an inverter for supplying power to the electric motor, with the electric motor, in order to reduce the amount of wasted space and the size and weight of the overall structure, by using, in conjunction, as many components as possible, to facilitate installation of the compressor in a vehicle where there is not enough space, to simplify the arrangement of the transmission shaft, wiring, piping and the like linking the various components, and to reduce the cost.
[0005] When integrating a refrigerant compressor and electric motor in this way, as a means for cooling the electric motor, in which overheating is a problem due to the density of installation, a method of guiding a low temperature intake refrigerant, consisting mainly of gas returning to the refrigerant compressor from the evaporator during the refrigeration cycle, and cooling the inside of the electric motor by circulating this gas through the electric motor, can be performed. For this purpose, in the prior art, a passage for circulating the intake refrigerant, formed between the stator of the electric motor and the housing enclosing this, is normally provided uniformly surrounding the rotating shaft of the electric motor.
[0006] Consequently, where a heat radiating body such as a drive circuit portion including an inverter is integrated with part of the periphery of the housing of the electric motor and with other heat radiating bodies disposed in proximity thereto, due to heat emitted from the heat radiating bodies of the drive circuit portion and the like, part of the electric motor attached or in proximity thereto suffers from a localized rise in temperature because it cannot be sufficiently cooled, the temperature around the rotating shaft of the electric motor becomes non-uniform, and oscillation problems or the like occur due to differences in the minute space between the stator and armature as a result of localized heat expansion differences, resulting in a non-uniform magnetic field being generated by the stator and rotational imbalance, thus reducing efficiency. Also, because the drive circuit components such as the inverter and the like are not sufficiently cooled by indirect cooling alone from the inside of the electric motor by means of intake refrigerants returning to the compressor, there is a problem of a reduction in the durability of the drive circuit components.
SUMMARY OF THE INVENTION
[0007] The present invention, in light of the above problems of the prior art, has as its object, in the case of integrating an electric motor, a compressor driven thereby, and a drive circuit portion for supplying power to the electric motor, to guide a fluid that is introduced into the compressor to the electric motor, to uniformly cool the electric motor by circulating it therethrough, and to sufficiently cool the electric motor drive circuit portion integrally attached to a portion of the housing of the electric motor, thereby simultaneously solving the problems generated by non-uniform and insufficient cooling.
[0008] In the electric compressor of the present invention, in which an electric motor portion, a drive circuit portion including an inverter for operating the electric motor portion, and a compressor portion driven by the electric motor portion for compressing a fluid are integrated, in order to circulate the fluid taken in by the compressor portion prior to compression, as a cooling medium through the electric motor portion, a plurality of cooling medium passages are provided in the electric motor portion, among which those cooling medium passages provided in the vicinity of the drive circuit portion can have a greater endothermic capacity than that of the cooling medium passages provided in other portions. The drive circuit portion mentioned here includes a portion that is installed directly on to the electric motor housing, i.e. at least the electric motor housing side portion of the casing of the drive circuit portion is integrated with the electric motor housing.
[0009] In order to increase endothermic capacity, such methods as increasing the cross sectional area of the cooling medium passages or increasing the surface area of the cooling medium passages can be used. Other methods for increasing the endothermic capacity of the cooling medium passages include imparting different flow rates between the plurality of the cooling medium passages and imparting different temperatures to the circulating cooling medium; when imparting a difference in temperature, a method of the circulating a cooling medium, whose temperature has been increased by being circulated through the cooling medium passages in those portions where the endothermic capacity increases, through the cooling medium passages in those portions where the endothermic capacity is not required to be increased can, for example, be used.
[0010] In either case, as heat radiating bodies that increase the endothermic capacity of the cooling medium passages and which correspond to those portions of the cooling medium passages whose cross sectional area or surface area is to be increased, not only is there the drive circuit portion, but also heat radiating bodies such as an internal combustion engine mounted in the vehicle, for example.
[0011] In this way, the endothermic capacity of portions of the cooling medium passages corresponding to heat radiating bodies such as the drive circuit portion of the electric motor portion and the internal combustion engine disposed in proximity thereto can be increased, thereby avoiding the problem of a localized temperature rise in part of the electric motor portion, non-uniform temperature states around the rotating shaft of the electric motor portion, and partial heat expansion differences that result in vibrations and the like due to differences in the minute spaces between the stator and armature, as well as the problem of an irregular magnetic field generated by the stator resulting in rotational imbalance and a reduction in efficiency. Also, a reduction in the durability of the drive circuit portion itself due to insufficient cooling can be prevented.
[0012] A specific method for increasing the surface area of the cooling medium passages is to make a surface of the cooling medium passages an uneven surface. This uneven surface may be formed only on one surface of the cooling medium passages. The cooling medium passages may be disposed parallel to the rotating shaft of the electric motor portion, or may be imparted differences in endothermic capacity by disposing part of the plurality of cooling medium passages in a non-linear winding pattern.
[0013] When the electric compressor of the present invention is used as a refrigerant compressor for an automotive air-conditioning system, a refrigerant taken into the refrigerant compressor and returning from the evaporator during the refrigeration cycle can be used as the cooling medium to be circulated through the cooling medium passages. The effects of the present invention can thereby be maximized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a sectional view illustrating the concept of the overall structure of the electric compressor common to all of the embodiments.
[0015] [0015]FIG. 2 is a block diagram of a refrigeration cycle illustrating a case where the electric compressor of the present invention is used.
[0016] [0016]FIG. 3 is a cross sectional side view showing a first embodiment of the main portions of the electric compressor.
[0017] [0017]FIG. 4 is a cross sectional side view showing a second embodiment.
[0018] [0018]FIG. 5 is a cross sectional side view showing a third embodiment.
[0019] [0019]FIG. 6 is a cross sectional side view showing a fourth embodiment.
[0020] [0020]FIG. 7 is a cross sectional side view showing a fifth embodiment.
[0021] [0021]FIG. 8 is a cross sectional side view showing a sixth embodiment.
[0022] [0022]FIG. 9 is a cross sectional side view showing a seventh embodiment.
[0023] [0023]FIG. 10 is a cross sectional side view showing an eighth embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] By reference to the attached drawings, the preferred embodiments of the present invention will be explained in detail. FIG. 1 illustrates the overall structure of the electric compressor common to eight specific embodiments of the present invention, relating to the main components of the electric compressor, shown in FIGS. 3 to 10 , and FIG. 2 shows, in abbreviated form, the structure of a refrigeration cycle common to all of the embodiments, in a case where the electric compressor of the embodiments of the present invention is used as a refrigerant compressor in a refrigeration cycle of an air-conditioning system mounted in a vehicle such as an automobile.
[0025] In FIG. 1, the electric compressor 1 of the embodiments, for example, an air-conditioning system mounted in a vehicle, comprises a compressor portion 2 comprising a compressor such as a scroll type compressor or swash plate type compressor used as a refrigerant compressor, an electric motor portion 3 , integrated with the compressor portion 2 on the axis of a common rotating shaft not shown in the drawing, for rotatably driving the compressor portion 2 , and a drive circuit portion 5 integrally attached to part of the peripheral surface of the housing 4 of the electric motor portion 3 and containing an inverter or the like for supplying power to the electric motor portion 3 . However, the present invention is not characterized by the specific structures of the compressor portion 2 and the drive circuit portion 5 , nor by the form, structure and the like of the electric motor portion 3 itself, therefore most of the internal structures thereof have been omitted in the attached drawings.
[0026] In order to cool the electric motor portion 3 from the inside, an intake port 6 for receiving fluid (in this case a vaporized refrigerant) to be compressed in the compressor portion 2 is provided at the end portion of the electric motor portion 3 opposite the compressor portion 2 . Meanwhile, an exhaust port 7 for discharging the fluid to be compressed in the compressor portion 2 is provided in part of the compressor portion 2 itself. Consequently, the refrigerant (intake refrigerant) to be compressed in the compressor portion 2 enters through the intake port 6 and flows into the housing 4 of the electric motor portion 3 in the direction of the arrow, is compressed in the compressor portion 2 after cooling the interior of the electric motor portion 3 , and is discharged as a compressed refrigerant (discharge refrigerant) through the exhaust port 7 to the exterior of the electric compressor 1 . The housing 4 of the electric motor portion 3 , the casing 8 enclosing the drive circuit portion 5 for maintaining a waterproof quality, and the like, are produced from an aluminum alloy having suitable thermal conductivity.
[0027] In the case of the refrigeration cycle of the air-conditioning system shown in FIG. 2, although the electric compressor 1 is disposed in the vicinity of the engine 9 (internal combustion engine) to drive the vehicle, it is not directly driven by the crank shaft of the engine 9 , but is driven by power supplied to the drive circuit portion 5 from a battery charged by a generator (not shown in the drawing) attached to the engine 9 . The refrigerant compressed in the compressor portion 2 of the electric compressor 1 is discharged from the exhaust port 7 and flows into a condenser 10 , which is a first heat exchanger, and radiates the heat produced during compression to the external atmosphere to liquefy the refrigerant. The liquid refrigerant is decompressed while passing through a throttle 11 such as an expansion valve, and flows in a gas/liquid mixture state into an evaporator 12 , which is a second heat exchanger, to cool the air inside the vehicle when it is vaporized.
[0028] Stated briefly, the structural features of the electric compressor of the present invention can be said to reside in the form or structure, in cross section, of the electric motor portion 3 shown along the line A-A in FIG. 1. That is, the cross section A-A is the relevant part of the present invention, the form or structure thereof varying as explained below to distinguish the eight embodiments shown in FIGS. 3 to 10 . Consequently, the structures of the embodiments are all the same except for these variations.
[0029] A first embodiment relating to the relevant part (cross section A-A) of the electric compressor of the present invention is shown in FIG. 3. Although this is a structure common to all of the embodiments, the electric motor portion 3 has a mainly ring-shaped stator portion 13 fixedly supported by a cylindrical surface formed inside the housing 4 of the electric motor portion 3 , and a mainly cylindrical rotor portion 15 rotatably supported by a central rotating shaft 14 so that there is a slight gap between it and the inner peripheral surfaces of the stator portion 13 , which has a comb-like shape. The rotating shaft 14 connects to a drive shaft, not shown in the drawing, of the compressor portion 2 on the same axis. Coils 16 are wound into slots (grooves) on the inner periphery of the stator portion 13 . These coils 16 produce a rotating magnetic field moving in a predetermined direction on the fixed stator portion 13 , by a three-phase alternating current (for example) supplied from the inverter housed in the drive circuit portion 5 , and rotate the rotor portion 15 together with the magnetic field. The rotational speed of the rotating magnetic field can be freely controlled by changing the frequency of the three-phase alternating current applied to the coils 16 from the inverter.
[0030] As the electric motor portion 3 radiates heat from the coils 16 and the core that is the stator portion 13 and from the rotor portion 15 , it is necessary to cool these parts to eliminate this heat. Therefore, a plurality of refrigerant passages are formed in groove shapes in the axial direction of the rotating shaft 14 around the peripheral surface of the stator portion 13 , these refrigerant passages connecting at one end to the intake port 6 described above, and connecting at the other end to an inlet of the compressor portion 2 , not shown in the drawing.
[0031] However, in the electric compressor 1 of the embodiment shown in the drawing, the drive circuit portion 5 including an inverter is attached to a portion 4 a of the housing 4 of the electric motor portion 3 , and because the inverter and the like also radiate heat, the temperature of the electric motor housing 4 in the vicinity of the portion 4 a attached to the drive circuit portion 5 increases in comparison to a portion 4 b in the electric motor housing 4 located opposite the portion 4 a attached to the drive circuit portion 5 . Consequently, unless the portion 4 a attached to the drive circuit portion 5 is cooled more strongly than the opposite portion 4 b, the overall temperature of the electric motor housing 4 cannot be equalized.
[0032] Thus, in the first embodiment of the present invention shown in FIG. 3, as well as increasing the cross sectional area of a plurality of first refrigerant passages 17 formed in the stator portion 13 in the vicinity of the portion 4 a connected to the drive circuit portion 5 to increase the heat transfer surface area thereof, thus increasing the endothermic capacity and amount of refrigerant circulating through these portions, the cross sectional area and heat transfer surface area of a plurality of second refrigerant passages 18 formed in the stator portion 13 toward the portion 4 b opposite the portion 4 a are made relatively small, consequently decreasing the endothermic capacity thereof. Thus, among the low temperature refrigerant (mainly gas) returning to the compressor portion 2 of the electric compressor 1 from the evaporator 12 , the amount circulating in the first refrigerant passages 17 is more than the amount circulating in the second refrigerant passages 18 , therefore the amount of heat absorbed by the refrigerant circulating in the first refrigerant passages 17 is greater than the amount of heat absorbed by the refrigerant circulating in the second refrigerant passages 18 , as a result of which the temperature of the stator portion 13 is substantially uniform across its entire periphery and is cooled to a balanced state. Not only can the previously described problems resulting from irregular cooling thereby be avoided, but the inverter of the drive circuit portion 5 can also be sufficiently cooled and operated without the possibility of deterioration.
[0033] [0033]FIG. 4 shows a second embodiment of the present invention. The second embodiment is a further development of the first embodiment, and is characterized in that, as the first refrigerant passages 17 in the vicinity of the portion 4 a attached to the heat radiating drive circuit portion 5 are formed from grooves on the cylindrical inner wall of the electric motor housing 4 and the cylindrical outer peripheral surface of the stator portion 13 , by forming a plurality of protrusions (folds) on both surfaces of the first refrigerant passages 17 along the axial direction of the rotating shaft 14 , or an uneven surface 19 comprising a plurality of protrusions or the like formed on both surfaces, the surface area of the portion 4 a of the electric motor housing 4 close to the drive circuit portion 5 and portions where the stator portion 13 comes into contact with the refrigerant, i.e. the heat transfer surface area, is increased and the endothermic capacity of the first refrigerant passages 17 can be made higher than that of the second refrigerant passages 18 . It is thereby possible to further increase the effects of the first embodiment.
[0034] When it is not necessary to increase the endothermic capacity of the first refrigerant passages 17 to the extent of the second embodiment, an uneven surface 19 comprising protrusions or the like in portions corresponding to the first refrigerant passages 17 can be formed in the inner wall of the electric motor housing 4 as in the third embodiment shown in FIG. 5, or an uneven surface 19 can be formed in the bottom surface of the grooves forming the first refrigerant passages 17 on the stator portion 13 side as in the fourth embodiment shown in FIG. 6.
[0035] Also, when the electric compressor 1 is directly connected to a heat radiating body having a large shape and thermal capacity such as the engine 9 , as in the refrigeration cycle example shown in FIG. 2, the electric compressor 1 receives not only heat radiated from the drive circuit portion 5 including the inverter, but it also receives heat conducted directly from the engine 9 . Even if the electric compressor 1 is not directly connected to the engine 9 but is rather disposed in the vicinity of the engine 9 , it still absorbs radiant heat emitted from the engine 9 , resulting in non-uniform temperature distribution due to localized temperature increases in the electric compressor 1 , and not only do the same problems as in the cases described above occur, but due to an overall temperature rise in the electric compressor 1 there is a possibility of heat damage occurring.
[0036] When there are these kinds of concerns, by increasing the cross sectional area and heat transferring area of not only the first refrigerant passages 17 which receive heat from the drive circuit portion 5 , but also third refrigerant passages 20 formed in a portion 4 c which receives radiant heat or heat conducted from the engine 9 , and consequently increasing the flow rate of refrigerants in these portions and the endothermic capacity attained by this increase in flow rate over the amount in the second refrigerant passages 18 , as in the fifth embodiment shown in FIG. 7, the endothermic capacity of these portions is increased. Specifically, 21 is a mount for attaching the electric compressor 1 to the engine 9 (the lower portion not shown in FIG. 7) and supporting it, and comprises through holes 22 for integrating the electric compressor 1 and for inserting bolts to attach the electric compressor 1 to the engine 9 . The lower surface of the mount 21 is a contact surface 21 a (attachment surface) and contacts the engine 9 . In this case 4 b indicates a portion distanced from both the previously described portions 4 a and 4 c in the electric motor housing 4 .
[0037] [0037]FIG. 8 is a sixth embodiment of the present invention. The sixth embodiment is a further development of the fifth embodiment and is characterized by providing uneven surfaces 19 on the cylindrical inner wall of the electric motor housing 4 and the bottom surfaces of the grooves of the cylindrical outer periphery of the stator portion 13 forming the first refrigerant passages 17 in the vicinity of the portion 4 a to which the casing 8 of the drive circuit portion 5 that radiates heat is attached and the third refrigerant passages 20 formed in the vicinity of the portion 4 c that receives heat from the engine 9 . This increases the surface area of the portions 4 a and 4 c of the electric motor housing 4 close to the drive circuit portion 5 and engine 9 , and the surface area of the stator portion 13 in contact with the refrigerant, i.e. the heat transfer surface area, and increases the endothermic capacity of the first refrigerant passages 17 and third refrigerant passages 20 over that of the second refrigerant passages 18 . The effects of the fifth embodiment can thereby be increased even further.
[0038] When it is not necessary to increase the endothermic capacity of the first refrigerant passages 17 and third refrigerant passages 20 to the extent of the sixth embodiment, an uneven surface 19 can be formed in the bottom surface of the grooves provided for forming the first refrigerant passages 17 and third refrigerant passages 20 on the stator portion 13 side as in the seventh embodiment shown in FIG. 9, or an uneven surface 19 can be formed in portions corresponding to the first refrigerant passages 17 and third refrigerant passages 20 in the inner wall of the electrical motor housing 4 as in the eighth embodiment shown in FIG. 10.
[0039] In the embodiments shown in the drawings, although the refrigerant passages 17 , 18 and 20 are formed as grooves in the axial direction on the cylindrical outer surface of the stator portion 13 , these are no more than simple examples and, where necessary, can be formed as narrow grooves in the axial direction in the cylindrical inner surface of the electric motor housing 4 , for example. Needless to say, these refrigerant passages 17 , 18 and 20 can also be formed in a shape other than a linear shape, for example as non-linear winding-shaped grooves.
|
In an electric compressor, in which an electric motor and a compressor driven thereby are integrated, in order to prevent a reduction in the durability of the electric motor and the like due to heat conducted from heat radiating bodies such as drive circuits, a fluid, prior to being taken into the compressor portion, is circulated through the electric motor portion as a medium for cooling. In this case, a plurality of cooling medium passages for example are provided parallel to the axis of rotation, and the endothermic capacity of passages formed in the vicinity of heat radiating bodies is made greater than the endothermic capacity of passages formed in other portions.
| 5
|
FIELD OF THE INVENTION
This invention relates generally to seating structures and more particularly to seating structures having support surfaces formed from resilient fabric without the need for underlying springs or cushion support structures.
BACKGROUND
Traditional seating structures such as for use in a vehicle, office environment or residential setting are formed from relatively thick urethane foam buns mounted on semi-flexible spring wire constructions. These foam buns are, in turn, typically covered with an aesthetically pleasing fabric cover for contacting the user. As will be readily appreciated, the use of such a multiplicity of components (i.e. springs, cushions and covers) all of which are attached to a frame gives rise to a relatively complicated assembly practice.
In order to reduce the number of components in seating structures and to reduce the bulk thereof, it has been proposed to provide thin profile seats, including thin seats using elastomeric seat backing material. For example, in U.S. Pat. No. 2,251,318 to Blair et al, solid rubber tape or strips reinforced by fabric are stretched over a seat frame. In U.S. Pat. No. 4,545,614 to Abu-Isa et al., (incorporated by reference) a thin profile vehicle seat is disclosed in which a multiplicity of side by side elastomeric filaments made from a block copolymer of polytetramethylene terephthalate polyester and polytetramethylene ether are stretched across a vehicle seat frame. U.S. Pat. No. 4,869,554 to Abu-Isa et al., issued Sep. 26, 1989 (incorporated by reference) discloses a thin profile seat in which elastomeric filaments like that of the U.S. Pat. No. 4,545,614 are woven together to form a mat. The mat was prestretched to at least 5 percent elongation and attached to a seat frame. U.S. Pat. No. 5,013,089 to Abu-Isa et al., (incorporated by reference) discloses a seat assembly having an elastomeric filament suspension and a fabric cover. The filament suspension and the fabric cover are integrated by having the elastomeric filaments and the fabric knitted together to provide a low profile finished seat or backrest.
The present invention provides a seating structure wherein the support surfaces (i.e. the seat and backrest) comprise a weft insertion knitted which can be formed in a single operation on one knitting machine. The fabric has an aesthetic side suitable for contacting the user of the seating structure. The structure of the fabric is such that it also has a performance side to provide the user with resilient support during repeated use. The present invention therefore represents a useful advancement over the state of the art.
OBJECTS AND SUMMARY
In light of the foregoing, it is a general object of the present invention to provide a seating structure having webbed support surfaces formed from a single knitted fabric structure.
It is an object of the present invention to provide a seating support structure having a webbed support surface formed from warp knit fabric wherein the fabric undergoes easy initial elongation in the weft direction while having relatively limited elongation in the warp direction.
It is a further object of the present invention to provide a seating structure having a webbed support surface displaying sufficient vertical ride upon use to provide comfort to the user while avoiding overextension of the support surface.
It is yet a further object of the present invention to provide a seating structure having a webbed support surface formed from a warp knit fabric with weft insertion wherein one side of the fabric yields desired structural performance characteristics while the opposite side is aesthetically pleasing.
In that respect it is a feature of the present invention to provide a seating structure having a webbed support surface formed from a warp knit fabric with weft insertion of an elastomeric yarn, wherein the warp stretch is substantially linear over a full range of applied stress from zero pounds to breaking and elongation of the filling has two substantially linear components wherein a first substantially linear high elongation component operates over the range of zero to about 10 pounds applied force and a second linear component operates over the range of about 10 pounds applied force to breaking.
Other objects, advantages and features of the invention will, of course, become apparent upon reading the following detailed description and upon reference to the drawings below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a seating structure according to the present invention.
FIG. 2 is a needle bed point diagram illustrating a potentially preferred construction of the fabric used in the support surface of the seating structure of the present invention.
FIGS. 3-5 are needle bed point diagrams illustrating the components in the potentially preferred construction of the fabric as shown in FIG. 2.
FIG. 6 is a view of the aesthetic side of the potentially preferred fabric for use in the support surface of the seating structure of the present invention.
FIG. 7 is a view of the performance side of the potentially preferred fabric for use in the support surface of the seating structure of the present invention.
DESCRIPTION
While the invention will be described in connection with certain preferred embodiments and procedures, it is to be appreciated that we do not intend to limit the invention to such embodiments and procedures. On the contrary, we intend to include all alternatives, modifications and equivalents as may be included within the true spirit and scope of the invention as defined by the appended claims.
Turning now to the drawings, in FIG. 1 there is shown a seating structure 10 according to the present invention such as may be used in an automobile, an office chair or a home environment. While the actual design of the seating structure 10 may be varied depending on environment of use and aesthetic preferences, in general the seating structure will preferably include a seating frame 12, a seating support web 14, a back frame 16 and a back support web 18. In the illustrated and preferred embodiment, the seating support web 14 and the back support web 18 are disposed in tension over the seating frame 12 and back frame 16 respectively without the need for added cushions or other support structures, although it is contemplated that such support structures could be utilized if desired.
As will be appreciated by those of skill in the art, the seating support web 14 and back support web 18 should be constructed to provide a so called "vertical ride" when a load is applied in the form of an occupant so that a feeling of support and comfort is provided. This feature in seating structures has historically been provided by the use of springs and cushions which compress in known repeatable fashion when loads are applied.
While some degree of movement is important to the impartation of comfort, such movement should also not be so extreme as to negate the feeling of support. Accordingly, it is important that any seating support structure have a limited degree of movement when loads are applied. As will be understood, the use of spring structures has historically been used in this function since the spring compression effectively limits movement when loads are applied.
In order to provide a seating structure which has these desirable operational features while avoiding the need to use previously available complex support structures and still providing an aesthetically pleasing appearance, the present invention utilizes a weft-insertion fabric (FIG. 2) to form the seating support web 14 and back support web 18. As illustrated in the point diagrams FIGS. 3-5, this weft-insertion fabric preferably includes three components.
In the illustrated and preferred embodiment the components of the weft-insertion fabric are an elastomeric monofilament yarn 30 in the warp, a highly elastomeric filament yarn 32 wrapped for aesthetics and inserted in the weft and a knit filament yarn 34 which is used to tie the warp yarn and the weft-inserted yarn together at their intersections.
The face or aesthetic side of the resultant fabric is illustrated in FIG. 6, and the rear or performance side of the resultant fabric is illustrated in FIG. 7. In the illustrated and potentially preferred embodiment, the elastomeric monofilament yarns 30 are 2500 denier ELAS-TER™ monofilament yarn believed to be available from Hoechst Celanese Corporation whose business address is I-85 at Road 57, Spartanburg, S.C. 29303. The wrapped filament yarns 32 which are inserted in the weft preferably comprise a highly elastomeric core 40 formed from a material such as is available under the trade designation SPANDEX™ or the like. As shown, this elastomeric core 40 is preferably wrapped with an aesthetically pleasing yarn 42. One preferred composite of wrapped filament yarn 32 for weft insertion is available from World Elastic whose business address is believed to be 231 Pounds Avenue SW, Concord, N.C. 28025. The knit filament yarn 34 is preferably a solution dyed polyester of between about 100 and 250 denier and more preferably about 150 denier such as are well known to those of skill in the art although alternative materials may be utilized.
In the potentially preferred final fabric configuration, the elastomeric monofilament yarn 30 will be disposed at about 12 to about 32 ends per inch and more preferably 16 to 24 ends per inch and the weft-inserted wrapped filament yarns will be inserted at about 16 to about 40 picks per inch and more preferably 22 to 30 picks per inch.
In an important aspect of the present invention, it has been found that the use of a warp knit weft-insertion fabric as described above provides exceptional comfort and support in the support webs of the seating structure 10 without the need for any supplemental supports or resilient load carrying members. Tensile testing of this weft-insertion fabric according to ASTM D-5034 indicates that elongation in the warp direction is substantially linear up to failure. Specifically, such elongation has been measured to be in the range of between about 2 pounds force per percent elongation and about 4 pounds force per percent elongation.
In contrast to the linear stress strain relationship existing from initiation to failure in the warp direction, tensile tests in the weft direction indicate two separate linear regions. Specifically, the weft insertion configuration described above yields elongations of between about 25 and about 65 percent at a load of 10 pounds (i.e. 0.4 to 0.17 pounds force per percent elongation) followed by a relatively gradual linear region of elongation between about 10 pounds force and breaking with ratios of between about 2 and about 4 pounds force per percent elongation.
It can thus be appreciated that the use of weft-inserted fabrics as described above as the seating support web 14 and the back support web 18 in a seating structure 10, provides for initial limited displacement upon loading due to the elongation in the weft direction followed by steady support after such initial loading due to both the warp and the weft being in a region of linear elongation up to breaking. Moreover, the use of the weft-inserted fabric as described provides for an aesthetically pleasing surface by itself with no additional cover.
In accordance with the present invention, a useful seating structure can be formed by stretching a weft-inserted fabric as described over a seating frame and back frame without the need for any additional padding, springs or other support structures. Such seating structures thus represent an important and significant advancement over the present art.
|
A seating structure including fabric support webs is provided. The seating structure includes a webbed support surface formed from a warp knit fabric with weft insertion of an elastomeric yarn. The stretch in the warp is substantially linear over a full range of applied stress from zero pounds to failure. The stretch in the weft has two substantially linear components wherein the first linear component operates over the range of zero to about 10 pounds applied force and the second linear component operates over the range of 10 pounds applied force to failure.
| 3
|
BACKGROUND OF THE INVENTION
The task of harvesting nuts has always been a tiresome job since it requires picking up nuts from the ground under the nut trees. The back-breaking nature of the job has been the motivation for many past inventors to devise machines to do the job. In general these have been large cumbersome machines self-propelled or towed behind a tractor with belt conveyors to receive nuts swept from the ground and deliver the nuts to other portions of the machine for cleaning, sorting, classifying and bagging. Typical of such machines are those disclosed in U.S. Pat. Nos. 2,679,133; 3,148,493; 4,364,222; 3,387,442; 3,475,889; 3,530,655; 3,579,969; and 3,591,948. These machines are all large production harvesters that might be used for a farm having hundreds of acres of nut trees. No one appears to have considered how to provide a harvester for a small producer who cannot afford to buy a large machine.
It is an object of this invention to provide a manually operable nut harvester. It is another object of this invention to provide a nut harvester that can be rolled over the ground to pick up nuts on the ground, and to deposit them in a collection bag. It is another object to provide a harvester for pecans that can be pushed over the ground like a lawn mower to pick up and bag the pecans. Still other objects will become apparent from the more detailed description which follows.
BRIEF SUMMARY OF THE INVENTION
This invention relates to a nut harvesting apparatus comprising a frame having a front, a back, and two sides, a lateral axle extending from one to the other of said sides, a plurality of ground engaging nut collecting wheels individually rotatably mounted on side-by-side said axle, said frame including handle bar means at said back to be pushed by a person walking behind said frame, a bag support at said front adapted to support an open collection bag thereon for receiving harvested nuts therein; and a nut stripping means to remove nuts from said wheels and direct them into said open bag; each said nut collecting wheel being a thin structure approximately the thickness of the largest diametrical dimension of the nuts being collected and having a radially outwardly projecting wall member having a radial height outwardly of said rim at least as large as the said largest diametrical dimension of said nut and being adapted in combination with the wall member of the next adjacent wheel to clamp said nut therebetween; said stripping means being a comb-like member having a comb back extending across the front of said wheel adjacent said bag support and comb teeth projecting laterally from said comb back extending into the spaces between said projecting wall members on adjacent wheels.
In specific and preferred embodiments the wall member is a row of spaced flexible spokes projecting radially outwardly from the rim; or alternatively the wall member is a solid thin, flexible wall extending radially outwardly from the rim. Preferably the flexible spokes made to be replaceable if broken by being formed in two telescoping portions that have a male-female connection means. In still another preferred embodiment there is included a trash stripper similar to and outwardly from the nut stripper to serve the purpose of stripping away trash, twigs, etc. from the nuts being collected.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed to be characteristic of this invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which:
FIG. 1 is a perspective view of the nut harvesting apparatus of this invention;
FIG. 2 is a perspective view of the journal member of this apparatus;
FIG. 3 is an end elevational view of the roller member, the nut stripper, the bag support and a bag as used to pick up nuts in the apparatus of this invention;
FIG. 4 is a perspective view of a portion of the apparatus showing the interaction of the nut and trash strippers and the roller member;
FIG. 5 is an enlarged elevational view of the spoke-like members on one embodiment of the wheel units of this invention;
FIG. 6 is an end elevational view of a second embodiment of the wheel units of this invention;
FIG. 7 is a front elevational view, partly in cross-section of the wheel units of the second embodiment of the invention; and
FIG. 8 is an enlarged cross-sectional view taken at 8--8 of FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
The features of this invention are best understood by reference to the attached drawings.
In FIG. 1 there is shown the assembled nut harvester having a roller assembly 20, mounted on an axle 26 through a pair of journal members 27. Attached to the journal members 27 are a handle 28, a collection bag support 29, a nut stripper 30, and a trash stripper 58. The apparatus is pushed from behind by means of handle 28 which causes roller assembly 20 to roll over the ground picking up nuts 46 on the ground and which become caught in the roller assembly 20 as at 44, and remain in roller assembly 20 as it rolls forward until the nuts are contacted by teeth 36 of nut stripper 30 which pry the nuts loose and allow them to tumble over back 35 of nut stripper 30 into open end 34 of bag 33 on bag support 29 to be part of a collection of nuts 40 inside bag 33. Handle 28 is shown as including hooks 32 On Which a supply of empty bags 31 is hung for use when required. The hooks and supply of empty bags are not important to this invention and may be eliminated, if desired, or replaced by other means to hold empty bags on handle 28.
In FIG. 2 there is shown one of journal members 27 which function as key support members for the entire harvester assembly. Two journal members 27 are needed for each apparatus in order to support other parts of the apparatus. An axle 26 is needed for roller assembly 20 and it passes through hub 23 of each journal member 27. Roller assembly 20 comprises a plurality of thin wheel units 21 placed side-by-side contiguously on axle 26 and are able to rotate around axle 26 separately and independently from each other. Each wheel unit (as seen in FIG. 3) has an outer rim 24 and a central hub 23 connected by internal spokes 22, or alternatively, may be connected by a solid disc between rim 24 and hub 23). A central bore in hub 23 forms a bearing for axle 26. Projecting outwardly from rim 24 is a flexible wall, which in the embodiment of FIGS. 1-5 is a circumferential row of spaced flexible spokes 25. The row of spokes 25 lie in a plane defined by the centerline of rim 24 and the center of the wheel unit 21A at the center of hub 23. FIG. 3 shows schematically how wheel 20 rolling in direction 43 toward pecans 46 on the ground picks up pecans 44 between adjacent spokes 25 with teeth 65 of trash stripper 58, as seen in FIG. 4, removing twig 67 and nut stripper 30 removing pecan 44 by teeth 36 and catching the pecans 40 in bag 33 on support 29.
The width of rim 24 is approximately the same as the smallest diametral dimension of the nuts being harvested. For pecans, which are oval in shape, this dimension would be the small overall dimension of the nut. For walnuts, which are approximately spherical, the dimension would be the diameter of the nut. It is, of course, to be understood that there is nothing critical in this definition because the spokes 25 are flexible and the wheel units 21 are not tightly pressed together. It is only necessary that the play between adjacent wheel units 21, the flexibility of spokes 25, and any other looseness in the structure be sufficient to allow nuts to be jammed between adjacent spokes 25 tightly enough to be restrained there until removed from the roller assembly 20 by the nut stripper 30. If more pressure between adjacent wheel units is desirable bungee cords may be wrapped around internal spokes 22 of several of the wheel units 21 in roller assembly 20. A desirable and preferred feature of spokes 25 is that shown in FIG. 3 where each spoke 25 has two spaced spherical knobs around the spoke. Outer knob 47 is at the tip of the spoke, and inner knob 48 is spaced inwardly from the tip by a distance about the size of the largest dimension of the nut. The actual dimensions of spokes 25 are not critical, but the overall length of each spoke 25 beyond rim 24 should be from about 1-3 times the maximum overall diametral dimension of the nuts being collected, and the distance between knobs 47 and 48 about one fifth of the length of spoke 25. Spokes 25 may be about 0.1 to about 0.25 inch in diameter and about 1-4 inches in length for most applications. Knobs 47 and 48 have diameters from about 1.1 to 1.25 times the diameter of spoke 25. Spokes are slightly flexible so as to accommodate various sizes of the nuts, but sufficiently stiff to be able to retain a nut between two or more adjacent spokes. Preferably spokes 25 are integral with rim 24. Each of the spokes 25 has a base portion 59 larger in diameter than shank portion 62 or tip portion 63. Thus, portions 62 and 63 are more flexible than base portion 59 and if a spoke 25 becomes permanently bent or broken, usually it will be at the intersection 70 or thereabove. Rather than replacing an entire wheel unit 21, one may instantly repair defective spoke 25 with replacement spoke 25A by clipping off the defective spoke 25 at intersection 70 and positioning replacement spoke 25A with its recess 61 over base portion 59 and forcing spoke 25A toward axle 26 until intersection 70 engages the bottom of the recess 61, i.e., note that the bottom 71 of spoke 25A does not engage the rim 24. The fit between recess 61 and base portion 59 affords a friction lock and inhibits any easy or inadvertent removal thereof during use of the apparatus. The replacement spoke 15A in all respects is identical to spoke 25 with respect to shank portion 62, tip portion 63 and knobs 47 and 48. The base portion 59A, in which recess 61 is located, by necessity is larger in diameter than base portion 59 since such base portion 59 tightly fits within recess 61.
Similarly collection bag support 29 is shown as U-shaped tubing with the ends of the tubing slidable into recesses 38 of journal members 27. Bag support member 29 is merely an internal support for a bag such that the open end 34 of the bag 33 will be adjacent recesses 38 and adjacent nut stripper 30 to be able to catch nuts freed from roller assembly 20.
Nut stripper 30 is a large comb-like structure with a comb back shaft 35 and comb teeth 36 pointed toward roller member 20. Teeth 36 are pivotally attached to shaft 35 which, in turn, is seated in recesses 37 in journal member 27. Each tooth 36 is positioned between adjacent rows of spokes 25 on adjacent wheel units 21 at an inclined angle upward so as to force nuts clamped between adjacent rows of spokes 25 to be pried loose therefrom and allowed to tumble freely over shaft 35 and into open end 34 of bag 33 on bag support member 29.
An additional preferred feature on journal member 27 is barb 41 which helps to hold bag 33 onto support member 29. In FIG. 2 there are shown an upper barb 41 and a lower barb 41. If the collection bag 33 has strap handles (as is the case of plastic bags in many grocery stores) the straps may be looped over barbs 41 to hold them in place. If the bags are burlap or other fabric, it may be convenient to push a hole in the bag where barbs 41 are located so as to hold the bag 33 in place. Other means than barbs 41 may be used to keep an open bag 33 on support 29, e.g., spring clamps, ties, etc.
Another embodiment of wheel unit 21 is shown in FIGS. 6-8. Wheel units in FIGS. 1-5 are labeled as 21A, while wheel units in FIGS. 6-8 are labeled 21B for purposes of distinction. The only distinguishing feature between units 21A and 21B is the structure of the upstanding wall member which contacts the nuts being collected. In wheel unit 21A the wall member is a row of spaced spokes 25 along the centerline of rim 24. In wheel units 21B (FIGS. 6-8) the wall member is a solid continuous thin wall 50 on the centerline of rim 24. Wall 50 is also slightly flexible as are spokes 25. Wall 50 has a small outer circumferential bead 55 extending outwardly on both sides of wall 50 at the outer edge of wall 55 and a small inner circumferential bead 54 extending outwardly on both sides of wall 50 about half way between the outer edge of wall 50 and rim 24. There also are a plurality of spaced tangential beads 51 on both sides of wall 50 extending from rim 24 to the outer edge of wall 50. The direction of tangential beads 51 is such that as wheel unit 21B rotates in the direction of arrow 53 beads 51 will tend to guide nut 56 outwardly, toward the outer edge of wheel unit 21B in the direction of arrow 57 when contacted by teeth 36 of nut stripper 30.
Preferably the entire harvester is made of polypropylene or polyvinylchloride (PVC), although it may be made of aluminum or other plastic materials. The harvester is easily dismantled into its various component parts for storage or repair.
While the invention has been described with respect to certain specific embodiments, it will be appreciated that many modifications and changes may be made by those skilled in the art without departing from the spirit of the invention. It is intended, therefore, by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention.
|
A rolling apparatus to be pushed by hand to roll over ground where nuts have fallen, pick up the nuts, and collect them in a bag; the apparatus including a roller assembly of a plurality of thin wheel units each having a flexible wall member which contacts the ground and is spaced from the wall member of the next adjacent wheel unit so as to clamp nuts between adjacent walls and carry the clamped nuts around the roller assembly to a comb-like stripper which pries the nuts from the wall members and guides them into a collection bag or other collection devices.
| 0
|
BACKGROUND OF THE INVENTION
The present invention relates to delivery chutes and in particular to a delivery chute for use in a sorting machine having a horizontal conveyor.
Horizontal conveyor sorting machines are well known and are described in such patents as U.S. Pat. Nos. 4,077,620, 4,147,252 and 4,527,792.
A particular use for such sorting machines is to sort pieces of mail, including mail referred to as "flats" which generally are envelopes and magazines having a large height and width as compared to their thickness.
In some such mail sorting machines there are up to 100 discharge outputs from the machine as the objects are sorted as they move along a horizontal conveyor. Two machines utilized in particular are referred to as the FSM881 and the FSM775 by the United States Postal Service.
Discharge chutes are provided on these sorting machines to guide the flat to a stationary container positioned below each discharge chute. The chutes, however, do not positively guide and orient the flat, but only provide a guided free fall of the flat after it has been diverted from the conveyor. The only constant is the entering velocity of the flat which is approximately 72 inches per second. Variables affecting the movement of the flat after it has been diverted from the conveyor include the weight, size, aspect ratio, static electricity, surface friction effects against the chute, stiffness of the flat and aerodynamic characteristics of the flat. Even the effects of humidity may change the coefficient of friction of the flat. Considering these variables, different trajectories and rotations occur along the chute path. The chute itself is a short spiral sheet, curving and descending along a vertical axis.
An intercepting diverter is provided at each discharge station, positioned near the bottom of the conveyor channel in which the flats are carried. Generally the diverter is positioned below transport push rods which push the individual flats along the fixed support surfaces of the conveyor. When the diverter is rotated in toward the feed path, the next flat is forced to turn through a small angle toward the guide chute. The diverter imparts a retarding force to the flat, and since the flat center of gravity generally is above the diverter, a torque is applied to the flat, beginning a rotation. A secondary effect occurs as the flat leaves the transport and moves off of the horizontal supporting surface of the conveyor. The leading edge of the flat is no longer supported, allowing it to fall and causing rotation of the flat. The rotational energy imparted to the flat is a function of the length of the flat, its weight and velocity. The analysis of rotation concludes that the significant parameter is the aspect ratio of the flat dimensions (height to length). Flats with small aspect ratios (height exceeding length) will have a smaller rotational velocity. This analysis assumes the center of gravity of the flat coincides with the center of area.
As the flat falls along the chute, its contact with the chute also affects the rotation of the flat, but probably in an indeterminate way, allowing for the variability of the flat characteristics. The curve in the chute increases the normal contact force due to centripetal effects, increasing drag and slowing the velocity of the flat. The aforementioned factors result generally in an unedged, disheveled stack of flats, many with loss of the original orientation on the transport path. The flats are discharged from the chute approximately 90° from their direction of travel along the conveyor and are received in rectangular boxes which are set on the floor spaced laterally from the conveyor to accommodate the lateral movement of the flat moving along the chute and its airborne travel after leaving the chute. A distant edge of the box is required to be elevated to prevent or reduce over shooting of the box by the airborne flats.
It would be advantageous, therefore, to provide a transport chute which maintains the orientation of objects diverted from a horizontal conveyor such that all of the objects deposited into the output stack will have the same orientation to each other as they did on the horizontal conveyor.
SUMMARY OF THE INVENTION
The present invention provides a discharge chute for a horizontal conveyor which will positively direct objects diverted from the conveyor and guide them to a point of collection where they will be deposited in a consistent orientation relative to their orientation on the conveyor. This discharge chute also permits a more compact placement of the collection boxes relative to the conveyor.
The chute includes a bottom edge guide plate which is positioned adjacent to the diverter plate to provide vertical support for the object for a short distance after diversion from the conveyor occurs. A curved and sloped panel is provided to intercept the object which has been diverted from the conveyor. Along a lateral outboard edge of the curved panel is an end stop which will arrest the horizontal movement of the object. This end stop, in some embodiments, may include an energy absorbing device such as a cushion pad. A short length discharge slide extends from the lower edge of the curved panel to direct the objects vertically and horizontally to the point of collection. The objects are deposited at the point of collection by moving in a direction approximately 180° from their direction of travel on the conveyor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an end elevational view of a horizontal conveyor incorporating an orientation chute according to the principles of the present invention.
FIG. 2 is a side elevational view of the conveyor and orientation chute of FIG. 1.
FIG. 3 is a plan view of the conveyor and orientation chute of FIG. 1.
FIG. 4 is a perspective view of the conveyor and orientation chute of FIG. 1 illustrating an object entering the chute.
FIG. 5 is a perspective view of the conveyor and orientation chute of FIG. 1 illustrating the object engaging the end stop.
FIG. 6 is a perspective view of the conveyor and orientation chute of FIG. 1 illustrating the object leaving the slide portion of the chute and entering the collection receptacle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the FIGURES there is illustrated a chute generally at 10 for directing objects such as an envelope 12 as it is diverted from a horizontal conveyor 14 to a collection bin 16. Although an envelope is illustrated, the invention is not limited to use with envelopes, or even mail flats. The invention can be used with any horizontal conveyor which is conveying objects having a relatively flat bottom edge and a height and width greater than a thickness, as carried along the conveyor.
A conveyor with which this invention has particular utility has a fixed horizontal support surface 20 along which the objects 12 slide as they are pushed by a pusher finger 22. A diverter plate or gate 24 is selectively pivotable into the feed path of the conveyor 14 to divert one of the objects 12 being transported on the conveyor. The object 12 is diverted at a small angle to the flow path on the conveyor 14 so the feed speed is relatively undiminished as the object leaves the conveyor. A bottom edge guide plate 26 is provided adjacent to the diverter plate 22 to provide vertical support to the object 12 as it is diverted from the conveyor 14. The bottom edge guide plate 26 has an upstanding wall 28 and a horizontal floor 30 which combine to guide the object 12 as it moves off the conveyor 14. The floor 30 provides the vertical support. The wall 28 may be curved to accommodate the diverting movement of the object from the conveyor.
A curved and sloped panel 32 is used to intercept the object 12 as its inertia carries it away from the conveyor 14. Preferably the panel 32 is positioned at an angle from vertical (FIG. 2) so that it will provide both horizontal and vertical support for the object 12. If a shallow angle is selected, centrifugal force will cause the object 12 to rise as it moves horizontally along the panel 32. If a steep angle is selected, gravitational force will overcome the centrifugal force and the object 12 will descend as it moves horizontally along the panel 32. Preferably an angle is selected in which centrifugal and gravitational forces are in balance, thus permitting the object 12 to move horizontally without rising or falling. In early tests, Applicant has preliminarily determined that an angle of approximately 20° provides such a result with certain objects such as magazines and large envelopes.
The current panel 32 extends upwardly above the level of the pusher finger 22 to provide support for the full height of the object 12 being conveyed. Since the finger 22 extends horizontally into the space occupied by the panel 32, a notch 33 is provided in the panel to accommodate passage of the finger past the panel.
A lateral end 34 of the panel 32 is provided with an end stop 36 which projects perpendicularly from the panel a distance greater than the thickness of the objects 12 being conveyed. Although in the preferred embodiment the end stop 36 is a rigid member, in some applications an energy absorbing end stop 37 may be utilized such as a cushion pad or other energy absorbing mechanism. The end stop 36 incorporates a return flange 40 to prevent objects for inadvertently bridging over the end stop.
The curve of the panel 32 does not necessarily have a constant radius in the preferred embodiment. The initial part of the curve matches the angle of the diverter plate 24 in its intercepting position. Preferably the panel has a continuous, but perhaps not constant, curve such that the objects 12, when they reach the end stop 36 are moving approximately perpendicular to the direction of travel they had when they were intercepted on the conveyor 14.
A discharge slide 38 extends from a bottom edge 40 of the curved panel 32 to guide the objects 12 down to the collection receptacle 16. The discharge slide 38 may be a separate member from the curved panel 32 or may be a continuation of that panel. Preferably the slide 38 has a shallower vertical angle than the panel 32 so that the objects 12 will be given a new horizontal velocity as they slide down into the receptacle 16. Thus a bottom edge 41 of the object 12 as it was moving along the conveyor 14 and the curved panel 32 will now become the leading edge as the object moves along the slide 38. The slide 38 causes the objects 12 to change horizontal direction, again preferably by 90° such that the direction the objects move as they enter the collection receptacle 16 is approximately 180° from that which they had when they were moving along the conveyor 14.
In the embodiment illustrated, the receptacle 16 is a flats carrier which is a rectangularly shaped box. The long side 44 of the box 16 is placed perpendicular to the feed path of the conveyor 14 and parallel to an end of the discharge slide 38. The initial bottom and subsequent leading edge of the object 12 will then fall into the box 16 parallel and adjacent to the far long wall 43 of the box.
As shown in FIGS. 4, 5 and 6, the sequence of operation is as follows:
In FIG. 4, the diverter plate 24 is rotated into the flow path of the conveyor 14 and a flat 12 is intercepted and diverted onto the bottom edge guide plate 26. At this point, the flat 12 is still being propelled forward at a velocity of 72 inches per second by means of the pusher finger 22 bearing against the trailing edge of the flat. The bottom edge guide plate 26 provides vertical support and guidance for the flat for a predetermined distance, for example, 6 inches, to prevent premature rotation of the flat upon its entry into engagement with the curved panel 32.
In FIG. 5, the flat 12, moving under its own inertia, slides across the polished surface of the curved panel 32 in an attitude that maintains the bottom edge 41 of the flat approximately horizontal. As mentioned above, the curved panel 32 is inclined backwards at an angle of approximately 20° from vertical to minimize the effect of gravitational forces that would normally result in premature rotation of the flat 12 if the curved panel incorporated a steeper incline. The horizontal motion of the flat 12 is stopped when its leading edge impacts the fixed position of the end stop 36 attached to the end 34 of the curved panel 32. In some applications, particularly where more massive objects are being conveyed, or where higher conveying speeds are utilized, i.e. where the momentum of the objects are high, force absorbing means 37 may be used in association with the end stop to assist in rapidly slowing down the object to a stop at the end stop 36.
At the instant of impact with the end stop 36, the velocity of the flat 12 has dissipated to less than 72 inches per second and the attitude of the flat is approximately 90° to the original transport path. The bottom edge 41 of the flat is parallel to a long edge 44 of the receptacle 16 which is located in a fixed position directly below the curved panel 32. If the flats have rotated about a horizontal axis as they move across the curved panel 32, engagement with the end stop 36 will realign or straighten them since impact by a leading corner will cause a counter rotation of the flat into the end stop until the momentum is dissipated. A slight bounce back of certain types of objects upon impact with the end plate 36 is preferred so as not to inhibit the secondary motion of gravity sliding that assures proper orientation of the object stacking in the receptacle 16. Once the object's inertial horizontal motion has been stopped by the end stop 36, the object gravity falls down the slide 38 with a newly directed slight horizontal motion directly into the receptacle 16 as shown in FIG. 6, and stacks one on top of another in a proper and consistent oriented fashion.
Since the motion of the object 12 as it leaves the conveyor 14 is maintained essentially horizontal until it engages the end stop 36, the collection receptacle can be elevated above the floor 45 by a distance of approximately 20 to 30 inches (when the invention is employed with U.S. postal machines FSM775 or FSM881). This enhances removal of filled boxes either manually (being in an improved ergonometric condition--raised off the floor) or automatically (by allowing for space below the receptacles for an automatic conveying system).
The present invention thus provides enhanced guidance and orientation of items being discharged from a horizontal conveyor without any powered mechanisms and without extensive modifications of an existing conveyor.
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 we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art.
|
An orientation chute is provided for a sorting machine which has a horizontal conveyor. The chute positively guides the objects as they leave the conveyor such that the relative orientation of successive objects leaving the container is maintained as the objects are deposited at a point of collection. A curved panel is used to intercept the objects as they leave the conveyor and to redirect them toward a stop member which stops their horizontal inertial velocity. The panel is sloped from the vertical to balance gravitational and centrifugal forces to maintain the object essentially horizontally as it moves across the panel. Once the object is stopped, it falls under the force of gravity along a slide portion of the chute to be deposited in a collection container.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The following co-assigned application is included herein by reference:
Docket # Serial # Filing Date Inventors Title TI-19552 08/291636 Aug. 17, 1994 Jain Enhancement in Throughput and Planarity During CMP Using a Dielectric Stack Containing HDP- SiO 2 Films
FIELD OF THE INVENTION
[0002] This invention relates to interconnection layers for microelectronic devices, and more particularly to planarization of insulated interconnection layers.
BACKGROUND OF THE INVENTION
[0003] Integrated circuits such as those found in computers and electronic equipment may contain millions of transistors and other circuit elements fabricated on a single crystal silicon chip. To achieve a desired functionality, a complex network of signal paths must be routed to connect the circuit elements distributed on the surface of the chip. Efficient routing of signals across a chip becomes increasingly difficult as integrated circuit complexity grows. To ease this task, interconnection wiring, which not too many years ago was limited to a single level of metal conductors, on today's devices may contain as many as five (with even more desired) stacked interconnected levels of densely packed conductors. Each individual level of conductors is typically insulated from adjacent levels by an interlevel dielectric (ILD) such as a silicon dioxide
[0004] Conductors typically are formed by depositing one or more layers of conductive film over an insulated substrate (which usually contains vias, or through holes, allowing the conductive film to contact underlying circuit structure where electrical connections are needed). Portions of the conductive film are selectively etched away using a mask pattern, leaving a pattern of separate conductors with similar thickness and generally rectangular cross-section on the substrate. Usually, after patterning, the conductors are covered with an ILD before additional conducting layers are added.
[0005] Ideally, a completed ILD has a planar upper surface. This ideal is not easily achieved and in multilayer conductor schemes, the inherent topography of the underlying conductors is often replicated on the ILD surface. After several poorly planarized layers of ILD with imbedded conductors are formed, problems due to surface topography that adversely affect wiring reliability are likely to occur, e.g., uneven step coverage or via under/overetching.
[0006] To overcome such problems, several methods are in common use for ILD planarization. Chemical mechanical planarization (CMP) abrasively polishes the upper surface of the ILD to smooth topography. Another approach is the etchback process, which generally requires depositing a sacrificial spin-on layer which smooths topography (such as photoresist) over the ILD. The sacrificial layer is etched away, preferably with an etchant which etches the ILD material at a similar rate. Done correctly, the etchback reduces high spots on the ILD layer more than it reduces low spots, thus effecting some level of planarization. Both of these methods can be expensive, time-consuming, and generally require a thick initial ILD deposition, since a top portion of the ILD is removed during planarization.
[0007] SUMMARY OF THE INVENTION
[0008] The present invention provides interconnect structures and methods for increased device planarity. A typical interconnection level contains conductors of several different widths. Conductors which will carry a small current during operation may be layed out using a minimum width established in the design rules for a specific fabrication process. Other conductors which must carry larger current or conform to other design requirements (e.g. alignment tolerances) may be layed out with larger widths. Generally, the largest conducting regions, such as power bus lines and bondpads, are formed on the topmost conducting level, where planarization is not a great concern.
[0009] It has now been found that certain ILD deposition processes may naturally planarize conductors (i.e. create a planar ILD upper surface over the conductor edge) narrower than a critical width. Given a specific conductor height, desired ILD deposition depth, and desired planarity, the critical width may be determined for such processes, usually by experimentation. The present invention exploits this property on a conducting level where it is desired to construct a variety of conductors, some of which require a width greater than the critical width. It has now been found that a network of integrally-formed conducting segments may be used to form a conductor which improves ILD deposition planarity and provides a large conductive cross-section. This is apparently the first use of a reticulated (i.e. meshlike) conductor structure to improve ILD planarity. Although such a conductor may require more surface area on the substrate (as compared to a non-reticulated conductor of equivalent length and resistivity), such conductors generally populate a small fraction of the overall area on a given level. In at least one embodiment using reticulated conductors, the ILD planarizes during deposition, thus obviating the need for a CMP or etchback step after deposition. In an alternate embodiment, CMP polish time may be reduced dramatically.
[0010] In accordance with the present invention, a method is described herein for constructing a planarized dielectric over a patterned conductor and adjacent regions on a semiconductor device. This method comprises depositing a layer of conducting material on a substrate, and removing the layer of conducting material in a circumscribing region, thereby defining a location for and peripheral walls for a conductor. The method further comprises removing the layer of conducting material from one or more regions within the circumscribing region to form internal walls for the conductor (both removing conducting material steps are preferably performed simultaneously). The current-carrying capability for the conductor is thereby divided amongst two or more integrally-formed conducting segments of smaller minimum horizontal dimension than the overall conductor width. The method may further comprise forming an insulating layer over the conductor and the substrate, preferably by a method which selectively planarizes features in order of smallest to largest, based on minimum horizontal dimension (and more preferably by a method of simultaneous chemical vapor deposition and back-sputtering).
[0011] An insulating seed layer may be deposited prior to a back-sputtered deposition, as well as a conventional CVD overlayer (i.e. without significant back-sputter) deposited after a back-sputtered deposition. Alternately, a selectively planarizing deposition may be deposited as a spin-coated dielectric. The conducting segments may be formed at a size and/or spacing equivalent to minimum design rules for the semiconductor device. The device may be chemical mechanical polished after deposition, e.g. to further enhance planarity.
[0012] A method is described herein for forming a planarized insulated interconnection structure on a semiconductor device. This method comprises depositing a first layer of conducting material on a substrate, and removing sections of the first layer in a predetermined pattern to form a plurality of conducting regions. At least one of the conducting regions is formed as a reticulated conductor, comprising a set of conducting segments integrally-formed to provide multiple conducting paths between opposing ends of the conductor. The method further comprises depositing at least one insulating layer over the conducting regions and substrate by a method of simultaneous deposition and back-sputtering (preferably CVD and back-sputtering, preferably using constituent gasses silane, O 2 and argon). The method may further comprise chemical mechanical polishing of the insulating layer. The method may further comprise depositing and patterning a second layer of conducting material over the insulating layer.
[0013] The present invention further comprises a metallization structure on a semiconductor device, comprising a plurality of first conducting regions formed on a substrate. At least one of the first conducting regions is a non-reticulated conductor, and at least one of the first conducting regions is a reticulated conductor, comprising a set of conducting segments (preferably formed at a size and/or spacing equivalent to minimum design rules for the device) integrally-formed to provide multiple conducting paths between opposing ends of the reticulated conductor. The structure further comprises one or more insulating layers overlying the first conducting regions and the substrate and providing a top surface which is locally (measured within a 10 μm radius) planar to at least 3000 Å. The structure may further comprise a plurality of second conducting regions formed over the insulating layers, at least one of the second conducting regions electrically connected to at least one of the first conducting regions through the insulating layers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] This invention, including various features and advantages thereof, can be best understood by reference to the following drawings, wherein:
[0015] [0015]FIGS. 1 and 2A- 2 C show, respectively, a plan view and cross-sectioned elevations taken along section line 2 A- 2 A, of a prior art method of planarizing an ILD.
[0016] FIGS. 3 A- 3 D show cross-sectioned elevations of a method of constructing a planarized ILD;
[0017] [0017]FIG. 4 shows a plan view of a prior art slit structure used to prevent cracking of a passivation layer due to stresses incurred during resin mold packaging;
[0018] [0018]FIGS. 5 and 6 show, respectively, a plan view and a cross-sectioned elevation taken along sectin line 6 - 6 of a conductor/ILD embodiment of the invention;
[0019] FIGS. 7 - 11 show plan views of various embodiments of a reticulated conductor which may be usable in the invention: and
[0020] [0020]FIGS. 12 and 13 show, respectively, a plan view and a cross-sectioned elevation taken along section line 13 - 13 of two conducting levels illustrative of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] It has long been the practice in semiconductor design to form patterned conductors of different widths. For example, widths are often adjusted based on current-carrying requirements for a given conductor, such that reliability problems (e.g. electromigration) may be avoided. Where low currents are expected, conductor size is however limited to a minimum width specific to a given device and/or semiconductor fabrication process. FIG. 1 shows a plan view of two conductors (e.g. of Al 0.5% Cu alloy) formed on a substrate 20 (e.g. with a top SiO 2 insulating layer), conductor 22 representing a large conductor of twice minimum width (much larger conductors usually exist on a given circuit layout) and conductor 24 representing a minimum width conductor. FIG. 2A shows a cross-sectioned elevation of the same conductors. FIG. 2B shows the conductors after deposition of an ILD 26 by a known method (e.g. PETEOS, or plasma-enhanced tetraethylorthosilicate, deposition) which forms a generally conformal layer having rectangular ridges 33 and 34 overlying conductors 24 and 22 . These ridges usually require planarization by one of the previously described methods before another conducting layer can be layed over ILD 26 , resulting in improved planarization as shown in FIG. 2C.
[0022] An ILD silicon dioxide deposition technique has now been developed which improves planarization over such conductors, herein referred to as high density plasma (HDP) deposition. HDP deposition comprises, for example, the following steps: a wafer (containing the substrate) is mounted in a reaction chamber such that backside helium cooling may be used to control temperature; the chamber is then evacuated to 7 millitorr, and a mixture of 68 sccm O 2 and 100 sccm Ar are supplied to the chamber; 2500 W of source rf power are used to create a plasma (which also heats the wafer), and the temperature of the wafer is stabilized at approximately 330C by backside cooling; after 50 seconds of operation, 50 sccm silane is also introduced into the chamber, causing a silane oxide to deposit on the wafer (shown as seed layer 30 in FIG. 3A); after 56 seconds of operation, 1600 W of bias power is applied to initiate back-sputtering; at this point, net deposition rate drops to 40 Å/sec, as some of the oxide being deposited sputters back off During such an HDP deposition, it is believed that back-sputtering preferentially affects oxide along the top edges of a conductor, eventually building a triangular cross-section ridge along such a conductor.
[0023] [0023]FIG. 3B illustrates one possible ILD cross-section after deposition of an HDP ILD 32 approximately to the depth of conductors 22 and 24 . Ridge 33 over conductor 24 has a generally triangular cross-section and a very low net deposition rate by this point. In contrast, ridge 34 has not yet formed a triangular peak and is still growing at roughly the same rate as ILD being deposited over the substrate areas.
[0024] If HDP deposition is continued as shown in FIG. 3C, ridge 34 peaks even as the bases of ridges 33 and 34 are swallowed by the HDP deposition growing from the substrate. This forms an ILD with planarization superior to that of the prior art PETEOS example of FIG. 2B. Ridge 34 is less planarized than ridge 33 which formed over a minimum width conductor. This trend may be generalized: i.e., for a given deposition depth narrower conductors are better planarized by the HDP deposition than wider conductors. Thus for a given deposition thickness and maximum desired deviation from planarity, a critical width may be determined such that conductors narrower than the critical width are sufficiently planarized by HDP deposition alone. For instance, it has been found that for a conductor thickness of 7500 Å and an HDP oxide thickness of 10000 Å, conductors narrower than about 0.45 μm will meet a 1000 Å planarity requirement after HDP deposition.
[0025] Planarization of the ILD having imbedded conductors wider than the critical width may still require, e.g., a CMP step after HDP deposition. In general, CMP is more effective on an HDP oxide ILD than a PETEOS ILD (possibly because of the smaller, narrower ridges), resulting in the highly planar ILD 32 shown in FIG. 3D. This advantage may not be clear, however, for structures with extremely wide conductors (e.g. 10× minimum width) imbedded therein, which are poorly planarized by the HDP process. Because of this phenomenon, it may be preferable to only partially build an ILD using HDP oxide (e.g. to the level shown in FIG. 3B) and complete the ILD using PETEOS, silane-deposited oxide, or a similar technique which deposits faster than HDP oxide.
[0026] One alternate method for producing a selectively-planarizing insulating layer is as a spin-coated dielectric. For example, hydrogen silsesquioxane available from Dow Corning may be spin-coating onto a wafer containing substrate 20 and conductors 22 and 24 to produce an insulating layer. The deposition profile may be made similar to that of layer 32 in FIG. 3B or FIG. 3C (albeit less angular by nature and not requiring seed layer 30 ), by adjusting viscosity to of the spin-coating before application to the wafer and/or adjusting wafer spin rate (rates of 1000 to 6000 rpm are typical). Insulating layer thicknesses of 0.2 μm to 1 μm (as measured on an unpatterned wafer or open field on a patterned wafer) are easily fabricated by such a method.
[0027] It is preferable to construct only a partial ILD by a spin-on technique (e.g. to the level of layer 32 in FIG. 3B), with the remainder of the ILD formed using PETEOS or silane-deposited CVD oxide, for example.
[0028] It is known that for semiconductors packaged in resin-molded packages, large conductors near the corners of a chip may be formed with slits or rows of small holes to alleviate stress cracking of the top passivation layer during packaging (U.S. Pat. No. 4,625,227, Hara et al., Nov. 25, 1986). As shown in FIG. 4, on a substrate 36 are formed a wire lead 38 connected to a bond pad 39 and a guard ring (e.g. a V CC power bus) 40 surrounding such bond pads. A slit 42 , formed at the corner of guard ring 40 , reduces the width of a typically 100 μm to 200 μm conductor to 40-80 μm segments in the corner regions, thereby preventing the overlying passivation layer from cracking during packaging.
[0029] It has now been discovered that slits or small holes formed in a large conductor, when combined with a planarizing ILD deposition such as HDP oxide or a spin-coated dielectric, may advantageously increase planarization of such an ILD. Slits or small holes such as those disclosed in the '227 patent generally do not provide such a feature: they are meant for top-level metallization, where planarization is generally unimportant and a planarizing deposition has little advantage; only portions of certain conductors contain the slits, leaving many large conductors and partially-slitted conductors, such that only small regions of the overall chip surface might see any improvement at all (with the dimensions discussed in the '227 patent, HDP deposition would not planarize even in the vicinity of the slits); slit 42 creates a section of increased resistivity in conductor 40 , which may cause electromigration if conductor 40 carries significant current.
[0030] Conductors and conducting regions patterned according to the present invention are described as reticulated; that is, a pattern of slits or holes is created in a conductor, breaking the conductor into a set of integrally-formed conducting segments. To achieve maximum planarization benefit, such a pattern is preferably: created using minimum design rules; repeated along an entire large (greater than critical width) conductor; and included on every large conductor on a lower-level metallization (this may not be required, e.g., if part of the lower-level metallization has no conductors overlying it). Also, it is preferred to maintain an appropriate conductor cross-section for the current requirements of a given conductor; i.e. cutting holes in an existing conductor without increasing overall conductor width is not preferred (unless the conductor width was overdesigned to start with).
[0031] In accordance with the present invention, FIG. 5 shows a reticulated conductor 52 and a minimum width conductor 24 formed on a substrate 20 . Reticulated conductor 52 has an interior region 50 where conducting material has been removed. Such a conductor may be designed directly into the mask pattern, such that interior region 50 is created at the same time as the outer walls of the conductor. Conductor 52 can be described as comprising a set of connected conducting segments: right segment 44 , left segment 46 , bottom segment 48 , and top segment 49 . Segments 44 and 46 provide multiple current paths between top and bottom segments 49 and 48 .
[0032] [0032]FIG. 6 contains a cross-sectional elevation of FIG. 5, taken through small conductor 24 and left and right segments 46 and 44 along section line 6 - 6 , A seed layer 30 and HDP oxide layer 32 deposition are shown to illustrate the excellent ILD planarity achievable above the conductor segments 44 and 46 , as well as conductor 24 , where widths of such are all smaller than the critical width.
[0033] [0033]FIG. 7 shows a reticulated conductor 52 containing two cross-conducting segments 56 and three non-conductive interior regions 50 surrounded thereby Such an arrangement has less resistance and more redundant conduction paths than conductor 52 in FIG. 5, and yet planarizes comparably. For conductors requiring a cross-section generally greater than three times minimum, more elaborate segment layouts, such as those shown for reticulated conductors 52 in FIGS. 8 and 9 may be chosen. Note that in these reticulation patterns individual conducting segments are less distinct; however, conducting segment size may be defined by a “minimum horizontal dimension” measured between neighboring regions 50 . FIG. 10 shows a reticulated conductor 52 with a landing pad 55 on an end. Reticulation schemes may produce both interior regions 50 and notch regions 54 , as illustrated in both FIGS. 9 and 10. In an extreme case, such as landing pad 55 connected to minimum-width conductor 24 in FIG. 11, only notch regions 54 may be included in the reticulation pattern.
[0034] [0034]FIG. 12 is a plan view illustrating a portion of two levels of conductors. The first level of conductors contains a reticulated conductor 52 and three non-reticulated conductors 64 , two of which terminate at conductor 52 and one of which terminates at reticulated landing pad 55 . The latter conductor is electrically connected through via 58 to one of the second level conductors 60 (the second level may or may not contain reticulated conductors). In the cross-sectional elevation taken along line 13 - 13 and shown in FIG. 13, HDP ILD 32 and second-level conductor 60 both exhibit the high degree of planarity achievable with a reticulated conductor and an appropriate ILD deposition method.
[0035] Reticulated conductors fabricated in accordance with the present invention may be designed with segments of greater than critical width. Although the region above such conductors may still require planarization after ILD deposition, it has been found that such a reticulated conductor/ILD generally polishes down faster with CMP than an equivalent non-reticulated conductor/ILD. This may be useful, for instance, to reduce CMP polish time where CMP for a conductor/ILD level is unavoidable because of other constraints.
[0036] The invention is not to be construed as limited to the particular examples described herein, as these are to be regarded as illustrative, rather than restrictive. The principles discussed herein may be used to design many other reticulation patterns not shown herein which produce the same effect. Other ILD deposition techniques may be applicable to the present invention under appropriate conditions, including sequential deposition and back-sputter cycling (as opposed to continuous simultaneous deposition and back-sputtering), combined sputter/back-sputter techniques, and methods requiring no seed layer. The seed layer itself may be produced by many known processes, if such a layer is included. A deposition+back-sputter method may, for instance, only be used for one layer of the overall ILD, with the remainder formed from a conformal deposition. Other materials such as silicon nitride and silicon oxynitride may be included in the ILD. A large variety of dielectric materials may be applicable to ILD deposition by spin-on technique, since selective planarization for such a deposition is primarily a function of viscosity and wafer spin rate. The conductors themselves may be formed of virtually any conducting materials compatible with a semiconductor process (or include non-conducting sublayers), since patterned conductors tend to exhibit similar shape irrespective of composition.
|
A semiconductor device and process for making the same are disclosed which use reticulated conductors and a width-selective planarizing interlevel dielectric (ILD) deposition process to improve planarity of an interconnect layer. Reticulated conductor 52 is used in place of a solid conductor where the required solid conductor width would be greater than a process and design dependent critical width (conductors smaller than the critical width may be planarized by an appropriate ILD deposition). The reticulated conductor is preferably formed of integrally-formed conductive segments with widths less than the critical width, such that an ILD 32 formed by a process such as a high density plasma oxide deposition (formed by decomposition of silane in an oxygen-argon atmosphere with a back-sputtering bias) or spin-coating planarizes the larger, reticulated conductor as it would a solid conductor of less than critical width. Using such a technique, subsequent ILD planarization steps by, e.g., chemical mechanic polishing or etchback, may be reduced or avoided entirely.
| 7
|
FIELD OF THE INVENTION
This invention relates to a non-soap shave gel composition. Such a composition is dispensed in the form of a gel containing a volatile component that causes the gel to turn into a foam when spread on the skin in preparation for wet shaving--that is, shaving with a razor blade.
BACKGROUND OF THE INVENTION
Post-foaming or self-foaming shave gels are now well-known and have been described, for example, in U.S. Pat. Nos. 2,995,521 (Bluard), 3,541,581 (Monson), 4,405,489 (Sisbarro), 4,528, 111 (Su), 4,651,503 (Anderson), 5,248,495 (Patterson), 5,308,643 (Osipow), and 5,326,556 (Barnet) and published PCT application WO 91/07943 (Chaudhuri). Such compositions generally take the form of an oil-in-water emulsion in which the self-foaming agent, generally a volatile (i.e. low boiling point) aliphatic hydrocarbon, is solubilized in the oil phase, and the water phase comprises a water-soluble soap component. The product is generally packaged in an aerosol container with a barrier, such as a piston or collapsible bag, to separate the self-foaming gel from the propellant required for expulsion of the product. The product is dispensed as a clear, translucent or opaque gel that is substantially free from foaming until it is spread over the skin, at which time it produces a foam lather generated by the volatilization of the volatile hydrocarbon foaming agent.
While the conventional self-foaming shave gels have gained wide acceptance by consumers, they can be somewhat harsh and drying to the skin due to the soap component. To counteract this effect, the typical shave gel composition is formulated with skin soothing components such as humectants, emollients, silicones, etc. While the addition of such components substantially improve the aesthetics of the product, repeated use can still produce undesirable drying of the skin, particularly among female users. Accordingly, it is highly desirable to develop a self-foaming shave gel composition that is less harsh and drying to the skin than conventional shave gels, without sacrificing any of the performance characteristics thereof.
N-acyl sarcosinates are well-known anionic surfactants represented by the formula ##STR1## where R is a fatty acid hydrocarbon chain. These materials are typically used in the form of water-soluble salts formed by neutralization with sodium, potassium or ammonium hydroxide or triethanolamine and have been suggested for use in a wide variety of products including shampoos, detergents, dentifrices, hand soaps, and shave creams. For example, aerosol shaving creams containing sarcosinates are disclosed in U.S. Pat. Nos. 3,959,160 (Horsler), 4, 113,643 Thompson), and 4,140,648 (Thompson) and in Harry's Cosmeticology (7th ed., 1982), p. 169 (see Croda Cosmetic and Pharmaceutical Formulary Supplement, formula SV11 ). A soap-free non-aerosol shave cream which may optionally contain a sarcosinate is disclosed in U.S. Pat. No. 4,892,729 (Cavazza) and a non-aerosol shave gel which contains both a soap and a sarcosinate is disclosed in U.S. Pat. No. 5,340,571 (Grace).
Soap-free shaving products are also known, but have met with limited acceptance. For example, U.S. Pat. Nos. 4,046,874 (Gabby) and 4,761,279 (Khalil) disclose shaving cream compositions containing respectively a polyglycerol fatty ester (e.g. triglycerol monostearate) and a fatty ester of lactylic acid (e.g. sodium salt of stearyl lactylic acid). A pre-shave gel containing polyethylene oxide polymer and polysulfonic acid polymer is disclosed in U.S. Pat. No. 4,999,183 (Mackles).
SUMMARY OF THE INVENTION
The present invention comprises a soap-free self-foaming shave gel composition which maintains superior performance attributes while avoiding the harshness and drying associated with soap-based shave preparations. The shave gel composition of the present invention comprises water, a water-soluble N-acyl sarcosinate salt, a volatile self-foaming agent, and a non-volatile paraffinic hydrocarbon fluid.
DETAILED DESCRIPTION OF THE INVENTION
The essential components of the shaving composition of the present invention include, in percent by weight, about 65 to 85% water, about 4 to 16% N-acyl sarcosine wherein the acyl group has 10 to 20 carbon atoms, sufficient base to solubilize the N-acyl sarcosine and provide a pH of about 4 to about 8, about 1 to 8% self-foaming agent, and about 1 to 10% non-volatile paraffinic hydrocarbon fluid, said composition being in the form of a self-foaming gel and being substantially free of soap. Preferably the composition will comprise about 70 to 80% water, about 6 to 12% N-acyl sarcosine, sufficient base to provide a pH of about 5 to 7, about 2 to 5% self-foaming agent, and about 1.5 to 7% non-volatile paraffinic hydrocarbon fluid. A more preferred shaving composition will also additionally include a non-ionic surfactant, a fatty alcohol and a gelling aid, and will be subtantially free of other anionic surfactants.
The N-acyl sarcosine may be selected from any of those which are commercially available that have an acyl moiety with 10 to 20, preferably 12 to 18, carbon atoms and that will provide a water-soluble sarcosinate when neutralized with an appropriate base. These typically include stearoyl sarcosine, myristoyl sarcosine, oleoyl sarcosine, lauroyl sarcosine, cocoyl sarcosine and mixtures thereof. Stearoyl sarcosine and myristoyl sarcosine, as well as mixtures thereof, are preferred. It is also possible to utilize a pre-neutralized sarcosinate, such as triethanolamine myristoyl sarcosinate, in which case it will not be necessary to separately add base to the composition except for such amount of acid or base as required to adjust the pH of the final composition. Both the sarcosine component and the base component should be selected so as to provide a clear or translucent gel when combined with the other components of the composition.
The base may be selected from any of the organic amine bases which are typically utilized to neutralize N-acyl sarcosines to form water-soluble salts. These include, for example, isopropanolamine, mono-, di- and triethanolamine, aminomethyl propanol and aminomethyl propanediol. Triethanolamine is preferred. The amount of base which is utilized will depend on the amount of sarcosine which is present in the composition. A sufficient amount should be utilized to solubilize the sarcosine in the aqueous phase of the composition and provide a pH of about 4 to 8, preferably about 5 to 7. To arrive at this pH range the sarcosine must be about 50 to 90% neutralized, preferably about 60 to 80% neutralized. It is, thus, most preferred that there is at least a slight molar excess of sarcosine to base. Typically, the base will comprise about 1 to 6% of the composition.
The self-foaming agent may be any volatile hydrocarbon or halogenated hydrocarbon with a sufficiently low boiling point that it will volatilize and foam the gel upon application to the skin, but not so low that it causes the gel to foam prematurely. The typical boiling point of such an agent generally falls within the range of 20°to 40° C. Preferred self-foaming agents are selected from saturated aliphatic hydrocarbons having 4 to 6 carbon atoms, such as n-pentane, isopentane, neopentane, n-butane, isobutane, and mixtures thereof. Most preferred is a mixture of isopentane and isobutane in a weight ratio of about 1:1 to about 3:1. The self-foaming agent will normally be present in an amount comprising about 1 to 8% of the composition, preferably about 2 to 5%.
The shaving composition additionally contains about 1 to 10%, preferably about 1.5 to 7%, of a non-volatile paraffinic hydrocarbon fluid which aids in gelling the composition. The terms "non-volatile" and "fluid" mean that these materials are liquid at room temperature and have a boiling point above 200° C. Such hydrocarbon fluids include mineral oils and branched-chain aliphatic liquids. These fluids typically have from about 16 to about 48, preferably about 20 to about 40, carbon atoms and a viscosity of about 5 to about 100 cs., preferably about 10 to about 50 cs., at 40° C. The preferred non-volatile paraffinic hydrocarbon fluid is selected from mineral oil with a viscosity of about 10 to about 50 cs. at 40° C., hydrogenated polyisobutene with a molecular weight of about 320 to about 420, and mixtures thereof.
Water is the major component of the composition and is used in sufficient quantities to solubilize the surfactant component and form the continuous phase of the emulsion, while providing a stable gel of suitable viscosity with desirable lathering and rinsing properties. It is added in a sufficient amount (q.s.) to bring the total of all components to 100%. The quantity of water in the composition typically falls within the range of about 65 to 85%, preferably about 70 to 80%.
In addition to the above-described essential components, the shaving composition of the present invention may include a variety of other well-known cosmetic ingredients to improve the aesthetics and performance characteristics of the composition.
It is generally desirable to include up to 8%, preferably about 1 to 6%, of a non-ionic surfactant in the composition to improve foam quality, wettability, gel consistency, and rinsability. Suitable non-ionic surfactants will typically have an HLB of 15 or more and must be compatible with the aqueous sarcosinate component. Preferred non-ionic surfactants include the polyoxyethylene ethers of fatty alcohols, acids and amides, particularly those having 10 to 20, preferably 12 to 18, carbon atoms in the fatty moiety and about 8 to 60, preferably 10 to 30, ethylene oxide units. These include, for example, Oleth-20, Steareth-21, Ceteth-20, and Laureth-23. Other non-ionic surfactants include the polyoxyethylene ethers of alkyl substituted phenols, such as Nonoxynol-20, polyethoxylated sorbitan esters of fatty acids, such as Polysorbate-20, lauryl polyglucoside, sucrose laurate, and polyglycerol 8-oleate.
It may also be desirable to include a water-soluble gelling aid or thickening agent in the shaving composition to improve the consistency and stability of the gel, as well as to adjust its viscosity. These may include, for example, hydroxyalkyl cellulose polymers such as hydroxyethyl cellulose and hydroxypropyl cellulose (sold under the trademarks "Natrosol" and "Klucel" respectively), copolymers of acrylic acid and polyallyl sucrose (sold under the trademark "Carbopol"), carboxymethyl cellulose, and cellulose methyl ether (sold under the trademark "Methocel"). Natural or synthetic gums, resins, and starches may also be used. The preferred thickening agents are hydroxyethyl cellulose, hydroxypropyl cellulose, and mixtures thereof. The gelling aid or thickening agent is typically included in an amount of about 0.01 to 5%, preferably about 0.1 to 2%, by weight of the composition.
The shaving composition will also preferably include up to 8%, preferably about 2 to 6%, by weight of a fatty alcohol such as myristyl, lauryl and stearyl alcohol and octyl dodecanol. The term "fatty" is intended to include 10 to 20, preferably 12 to 18, carbon atoms.
It is particularly desirable to include in the composition a cationic conditioning polymer which is substantive to the skin in order to improve lubricity and post-shave skin feel. Such polymers may include polymeric quaternary ammonium salts of hydroxyethyl cellulose such as polyquaternium-10 and polyquaternium-24. These polymers are typically included in an amount of about 0.05 to 2%, preferably about 0.1 to 1%, by weight.
Other useful additives which may be utilized in the composition include humectants such as glycerin, sorbitol, and propylene glycol, emollients including fatty esters such as isopropyl myristate, decyl oleate, 2-ethylhexyl palmitate, PEG-7 glyceryl cocoate, and glyceryl linoleate, propoxylated fatty ethers such as PPG-10 cetyl ether and PPG-11 stearyl ether, di- and triglycerides such as lecithin and caprylic/capric triglyceride, vegetable oils, and similar materials, skin freshening and soothing agents such as menthol, aloe, allantoin, lanolin, collagen and hyaluronic acid, lubricants such as polyethylene oxide, fluorosurfactants, and silicones ( e.g. dimethicone, dimethiconol, dimethicone copolyol, stearyl dimethicone, cetyl dimethicone copolyol, phenyl dimethicone, cyclomethicone, etc. ), vitamins (including vitamin precursors and derivatives) such as panthenol, tocopherol acetate, and vitamin A palmitate, colorants, fragrances, antioxidants and preservatives.
A preferred shaving composition of the present invention comprises, in percent by weight, about 65 to 85% water, about 4 to 16% N-acyl sarcosine wherein the acyl group has 10 to 20, preferably 12 to 18, carbon atoms, sufficient organic amine base to solubilize the N-acyl sarcosine and provide a pH of about 4 to about 8, about 1 to 8% self-foaming agent, about 1 to 10% non-volatile paraffinic hydrocarbon fluid, about 1 to 8% of a non-ionic surfactant, and about 1 to 8% of a fatty alcohol. Most preferably the composition will comprise about 70 to 80% water, about 6 to 12% N-acyl sarcosine, sufficient base to provide a pH of about 5 to 7, about 2 to 5% self-foaming agent, about 1.5 to 7% non-volatile paraffinic hydrocarbon fluid, about 1 to 6% of a non-ionic surfactant, about 2 to 6% of a fatty alcohol, and about 0.1 to 2% of a thickening agent.
The shaving composition of the present invention may be packaged in any dispenser suitable for dispensing post-foaming shave gels. These include aerosol containers with a barrier, such as a collapsible bag or piston, to separate the gel from the propellant required for expulsion, collapsible tubes, and pump or squeeze containers.
The following examples illustrate representative shave gel compositions of the present invention. All parts and percentages are by weight.
______________________________________Component Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5______________________________________Stearoyl sarcosine 5.192 3.558 7.500Myristoyl sarcosine 1.923 8.000 3.558 7.500Triethanolamine 2.596 2.750 2.596 2.750 2.750(99%)Myristyl alcohol 2.692 4.000 2.692 4.000 3.000Mineral oil 180/190.sup.1 1.923Mineral oil 65/75.sup.1 5.000 1.442 4.500 3.000Hydrog. 1.442Polyisobutene.sup.2Dimethicone/ 0.192 0.288dimethiconol.sup.3Stearyl Dimethicone.sup.4 0.250Oleth-20 4.327 1.000 4.327 1.000 4.500Isopentane 2.887 1.900 1.925 2.887 2.887Isobutane 0.963 1.900 1.925 0.963 0.963Hydroxyethyl 0.240 0.250 0.240 0.400 0.400cellulose.sup.5Hydroxypropyl 0.019 0.019 0.020 0.020cellulose.sup.6Polyquaternium-10.sup.7 0.240 0.144 0.200 0.250PEG-14M.sup.8 0.144 0.144 0.250 0.200PEG-115M.sup.9 0.025Aloe vera gel 0.962 0.962 1.000Frag.,color.,preserv. q.s. q.s. q.s. q.s. q.s.Water 74.854 74.424 73.892 74.484 72.724______________________________________ .sup.1 Protol 180/190 and Carnation 65/75 from Witco Corp. .sup.2 Panalane L14E from Amoco Chemical .sup.3 DC 21420 from Dow Corning .sup.4 DC 2503 from Dow Corning .sup.5 Natrosol 250 HHR from Hercules Inc. .sup.6 Klucel HFF from Aqualon .sup.7 Polymer LK from Amerchol .sup.8 Polyox WSR N3000 (MW about 300,000) from Union Carbide .sup.9 Polyox Coagulant (MW about 5 million) from Union Carbide
Procedure: Dissolve into the water at room temperature with stirring the hydroxyethyl cellulose, polyquaternium-10, and PEG-14M (or 115M). After about 40 minutes of stirring, heat the aqueous solution to about 85° C., add the sarcosine (which has been pre-melted), myristyl alcohol, mineral oil and/or hydrogenated polyisobutene and mix for about 10 minutes. Add the triethanolamine and Oleth-20 and continue mixing at about 85° C. for about 30 minutes. Cool to 70° C., add the preservative and mix for 10 minutes. Cool to 35° C. and add the silicone, fragrance, colorant, aloe gel and hydroxypropyl cellulose, the latter having been first premixed with about 0.5 parts of water at 55° C., then an additional 3.5 pads of water at room temperature. After cooling to room temperature the mixture is blended with the isopentane/isobutane and packaged in a barrier-type aerosol container.
While the invention has been described in detail with particular reference to preferred embodiments thereof, various modifications and substitutions will be apparent to those skilled in the art and should be considered to fall within the spirit and scope of the invention as defined by the following claims.
|
The present invention comprises a soap-free self-foaming shave gel composition which maintains superior performance attributes while avoiding the harshness and drying associated with soap-based shave preparations. The shave gel composition of the present invention comprises water, a water-soluble sarcosinate salt, a volatile self-foaming agent, and a non-volatile paraffinic hydrocarbon fluid.
| 8
|
BACKGROUND OF THE INVENTION 1. Field of the Invention
This invention relates to a pinch valve and, in particular, to a pinch valve of low mass which is capable of developing a very large closing force.
2. Brief Statement of the Prior Art
Pinch valves are frequently used for specialized applications such as for the handling of highly corrosive liquids, suspensions of errosive solids, or for sanitary applications where the process fluid cannot be contacted directly with a valve and its mechanical components.
Typically, pinch valves are provided with flanged ends for attachment in the process line and have flexible conduits which are surrounded by wear boots. An actuator drives a mechanism against the wear boot, pinching the flexible conduit closed and, for this purpose, a massive drive structure is commonly employed. Generally, pneumatic or hydraulic actuators must be used to develop the large closing forces required when the valve is to be used on lines of 2 inches or greater diameters.
BRIEF STATEMENT OF THE INVENTION
This invention comprises a small, lightweight pinch valve which can be installed or relocated on a flexible conduit without cutting or breaking the conduit. The valve uses a sinusoidal actuator that moves in a single rotary direction between open and closed positions, thereby minimizing wear on the conduit and avoiding plugging of the conduit when slurries are handled.
The pinch valve has a housing with end plates having through apertures that provide a passage through the housing. The housing is split into two halves transversely through the apertures of the end plates, thereby forming upper and lower saddle members that can be assembled about the flexible conduit. This permits installation or relocation of the pinch valve without breaking the flexible conduit or interrupting the process flow through the conduit. One of the housing halves carries a stationary bar or anvil and the other half carries the actuator and the movable valve member which pinches the flexible conduit against the stationary anvil. Preferably the latter is fixedly adjustable to permit use of the valve for throttling flow.
The valve member is a cylindrical sleeve mounted with bearings onto circular cams which impart a sinusoidal action to the actuator whereby maximum force and minimum travel is generated at closure of the valve. Shear or scuffing movement on the surface of the flexible conduit is precluded by the free rotational mounting of the circular valve member.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with reference to the figures of which:
FIG. 1 is a perspective view of the pinch valve of the invention;
FIG. 2 is an exploded view illustrating placement of the pinch valve on a flexible line;
FIG. 3 is an elevated sectional view of the pinch valve of the invention;
FIG. 4 is an electrical schematic of the control circuit for the valve;
FIG. 5 illustrates the closing action of the valve member;
FIG. 6 illustrates the motor and its integral braking system;
FIG. 7 is a side elevational view of an alternative embodiment of the valve member of the invention; and
FIG. 8 is a view along lines 8--8 of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the invention is shown as a pinch valve 10 which has a housing 12 defined by end plates 14 and 16 which are secured to a top beam 18, and side plates 20 and 22, thereby defining a housing which contains the valve mechanism. The end plates 14 and 16 have centrally located through apertures 24 and 26 and are split into two halves such as 28 and 30 by slits such as 32 that traverse the apertures, thereby forming an upper saddle block 34 and a lower saddle block 36 from each of the end plates. The two upper saddle blocks 34 and 34' are interconnected by the top beam 18 secured thereto by screw 37, and are detachably secured to their respective lower saddle blocks by fastening means such as machine screws 38.
The beam 18 carries the stationary rod or anvil 40 which is preferably secured to the free end of arm 42 that is hinged to the underside of the beam. The position of the anvil bar 40 is fixedly adjustable vertically by the lead screw 46 which is threadably received in an internally threaded aperture of the beam 18 and which projects beneath its undersurface to provide an abutment stop at its lower end for the anvil bar 40. The position of this lead screw 46 can be fixedly secured by lock nut 50 that is threadably engaged on lead screw 46.
The pinch valve has a movable valve member generally indicated at 52 which is mounted on a circular cam actuator. The actuator is rotatably mounted in the housing by bearings journalled in each side plate 20 and 22 and covered by end cover 54. The drive source for moving the valve member through the actuator mechanism preferably comprises an electrical motor, which is secured to sidewall 22 and housed within cover 70.
The sidewall 20 can be provided with a connector plug such as 62 for attachment of a power supply electrical conductor and the device is preferably provided with a connector jack 64 for attachment of a remote control unit. An electrical fuse receptacle 130 can also be provided on sidewall 20.
Referring now to FIG. 2, the method of installing and/or relocating the pinch valve assembly on a flexible line will be described in greater detail. As shown in FIG. 2, the upper saddle block assembly comprising the two upper saddle blocks 34 and 34' interconnected by the upper beam 18, can be readily removed from the lower half of the valve by loosening the four machine screws 38. Thereafter, the user simply raises the upper saddle block assembly as illustrated in FIG. 2, exposing the through passageway of the valve, and places a flexible conduit 72 (shown in phantom lines) into the open, through passageway, resting on the lower saddle blocks 36 and 36'. The valve should be in the open position in this installation, with the valve member 52 retracted from the flexible conduit. The user need only locate the pinch valve in the desired location along flexible line 72 and replace the upper saddle block assembly by inserting and tightening the four machines screws 38 into their threaded receiving apertures 39 located in each of the lower saddle blocks 36 and 36'. The user can then position the stationary or anvil bar 40 to the appropriate position for either throttling or closing the flow through the pinch valve when the valve actuator is urged to close the valve member. This is accomplished by moving the valve member to its closed position advancing lead screw 46 to move the anvil bar 40 downwardly until the desired throttled flow or closed flow condition exists. Thereupon, the lock nut 50 is tightened to secure the lead screw in its proper position and repeated actuation of the valve moves the valve member into and out of the desired flow controlling position.
Referring now to FIG. 3, the pinch valve 10 is shown in a elevational sectional view. As illustrated, the valve is in a flow throttling position with flexible conduit 72 compressed between the stationary or anvil bar 40 and the valve closure member, circular sleeve 52. The view illustrates the rearward upper saddle block 34' with its aperture 26 for receiving the flexible tubing 72. This view also shows a section through the upper beam 18, the lock nut 50 and the lead screw 46 with its lower end 48 that serves at the abutment stop for the arm 42.
The valve closure member, circular sleeve 52, is mounted with needle bearings 86 to circular cams 76 which are mounted on the actuator drive shaft 78. The circular cams have aligned eccentric bores 80 and 81 that are received over shaft 78, and are keyed to this shaft against angular rotation by roll pins 82 which are received in through bores of shaft 78 and which fit into radial slots 84, on the inside faces of the circular cams 76.
Two sets of needle bearings 86 are press fitted into opposite ends of the circular sleeve 52 and these bearings are received about the edges of the circular cams 76. The bearings 86 are mounted in races 88 which are retained by annular rims 90 about the periphery of each of the circular cams 76. The assembly of circular cams 76 is secured on shaft 78 against axial movement by suitable means such as retaining clips 94.
The actuator shaft 78 is received in roller bearings 96 and 98, respectively supported by sidewalls 20 and 22. The actuator drive shaft 78 is interconnected to the power supply shaft 100 by coupling member 102 which is keyed to these shafts by conventional means, not shown. The power supply shaft depends from a conventional gear train assembly 104 that is connected at the input end to the drive shaft of motor 106.
Motor 106 is preferably an electrical motor and the pinch valve of the invention has an electrical control circuit which includes a pair of microswitches 108 and 110 that are mounted in the assembly in juxtaposition to coupling 102. The latter is provided with two set screws, 112 and 114, which are located on opposite sides of coupling 102 and which project into actuating positions to the switch levers, such as 116, of the microswitches 108 and 110.
The housing 12 is subdivided into a subjacent chamber 58 by the transverse horizontal partition 60 and the electrical components such as transformer 118 and relay 120 are located in the subjacent chamber 58.
Referring now to FIG. 4, the electrical control circuit will be described. The power supply cord 122 is provided with a conventional three-prong male plug 124 for connection to an electrical outlet and is interconnected to the control unit through the connector plug assembly consisting of a female receptacle 126 which interconnects with a male plug 62 carried on the inside sidewall 20 of the valve 10. The electrical circuit includes a safety fuse 128 which preferably is contained within a fuse receptacle 130 (shown in FIG. 1) on the sidewall 20 of the valve 10. The main power supply is connected directly across the primary windings 132 of transformer 118 and to the switch contacts 134 and 136 of the relay 120. The windings of motor 106 are in circuit with the power supply lines 140 and 142 through the switch of relay 120 in the illustrated manner.
The secondary windings 138 of transformer 118 are in circuit with the actuator coil of relay 120 and the pair of normally closed microswitches 108 and 110. The circuit through the secondary windings of transformer 138 and the actuator coil 120 of the relay includes conductor 146 that extends to a remote control unit through the connector jack 64 and its associated female receptacle plug 65, which are connected at the sidewall 20 of the valve 10; see FIG. 1.
The remote control unit of the electrical control circuit comprises a hand-held control box 150 that contains a conventional double-pole, double-throw switch 152. The microswitch 108 is connected to one side of switch 151 of the switch poles through the connector 154 and the other microswitch is connected to the opposite side of the other switch 153 by conductor 156.
The switches 152 and microswitches 108 and 110 together form a make and break control circuit in which the manual movement of switch 152 to either of its positions, completes a circuit through the secondary windings 138 of transformer 118 and its respective microswitch 108 or 110. A circuit can be completed through the manual switch 152, conductor 156, and microswitch 110. This actuates the relay 120, closing the relay contacts 136, and energizing motor 106 which moves the control valve actuator to its closed position. Upon reaching the closed position, (as shown in FIG. 3), the abutment screw 112 engages the switch lever 116' of the microswitch 110. This opens the normally closed microswitch and breaks the circuit through the secondary winding 138 of the transformer, de-energizing the motor and stopping movement of the valve actuator. This movement, however, releases switch lever 116 of microswitch 108 and permits the normally closed microswitch to move to its closed position thereby and motor 106 can be again energized by reversal of the lever of switch 152. In this manner, an intermittent or make and break operation of motor 106 is achieved which is effective in moving the valve actuator between and open and closed, or throttling positions.
The valve drive system incorporates brake means effective to prevent coasting of the valve actuator after the motor is de-energized. Preferably a conventional motor and brake means is provided such as shown in FIG. 6. This motor has a field coil 107 with a conventional motor stack 109 of iron plates with a motor armature 111, on shaft 104 which is rotatably mounted in bearings (not shown) which are journalled in end plates 113, one of which is shown in cut-away view in FIG. 6. The end plates are secured in the assembly by machine screws 115. The brake means includes a pair of brake tangs 117 and 117' which project from the peripheral edge of armature 111 at 180 degree spacing. A brake pawl 119 is distally carried by brake arm 121 which is mounted on bushing 123 that is pivotally mounted to the motor stack 109. An armature arm 125 also extends from bushing 123 in juxtaposition to the side of the motor stack 109 and a bumper 129 is distally carried by the armature arm. The brake arm is resiliently biased by spring 127, counterclockwise as viewed, to engage pawl 119 with the opposing tang 117, braking rotation of motor armature 111 and shaft 104.
When the field coil 107 is energized, armature arm 125 moves to the illustrated position against the bias of tension spring 127, releasing tang 117 and armature 111 for rotation. In this fashion, precise positioning of the motor armature and shaft 104 is achieved.
An important feature of the present invention is the unidirectional movement of the actuator. The actuator is moved through a complete rotation as it travels from open to closed to open positions. It moves in a single rotary direction, e.g., counterclockwise as shown by the arrowhead arc line 161 of FIG. 5. This direction is selected so that its tangential component along the conduit 72 is in the direction of flow through conduit 72.
Another important feature of the invention is the sinusoidal action of the actuator which imposes a closing force on the flexible conduit that is entirely perpendicular to the axis of the flexible conduit, without any scuffing or shear forces applied to the surface of the conduit. This operation is described in greater detail in reference to FIG. 5 where a partial elevational view of the actuator is shown. As illustrated, the stationary anvil bar 40 provides an upper stop for the conduit 72. The valve member 52 is rotatably mounted on the circular cam assembly of the circular cams 76 by a plurality of needle bearings 86. The circular cams are mounted on shaft 78 with eccentrically located apertures 81. The circular valve member 52 is shown in its most recessed position by the phantom lines 52'. Upon initial rotation of the valve closure and actuator assembly from the position shown in the phantom lines at 52', the actuator will move with its greater velocity and minimal force. As the closure member 52 reaches its closing position, shown in the solid lines, it will be vertically displaced along the arrowhead line 160 at minimal velocity and maximum force from the drive motor 106. Since the circular sleeve 52 is freely rotatable on the assembly of circular cams 76, after it engages flexible conduit 72 it ceases to move relative to the conduit. Instead circular cams 76 rotate within the circular sleeve 52. The circular sleeve 52 is thus pressed upwardly against the conduit 72 and does not move relative to the surface of this conduit, avoiding any scuffing or dragging against the outer surface of the conduit.
In some applications, particularly with large diameter lines, it is desirable to concentrate the closing force around a valve member having a minimal surface area of engagement with the flexible conduit. This is particularly desirable for high pressure applications or for applications using relatively large diameter conduits. An embodiment of the invention which is shown in FIGS. 7 and 8 is preferably employed for this application. As there shown, the flexible conduit 72 is engaged between the upper, stationary anvil bar 40 that is carried on the arm 42 which is hinged to the undersurface of beam 18 at axis 44, all in the manner previously described. Similarly, the valve closure member 52 is a cylindrical sleeve and is received on the assembly of circular cams 76, again all as previously described. In the embodiment shown in FIGS. 7 and 8, however, the valve closure member is a cylindrical rod 166 that is mounted between the opposite standards 168 and 170. The opposite ends of each of the standards 168 and 170 are slotted at 172 and 174. Slots 174 in the lower ends of the standards 168 and 170 are received over the actuator shaft 78 and are retained thereon by suitable means such as C-clips 176. With this assembly, the lower bar or actuator 166 bears against the outer surface of cylindrical sleeve 52 and is free to move up and down in response to rotation of the assembly of the circular cams 76 and the cylindrical sleeve 52 mounted thereon. As the rod 166 is moved upwardly, it deflects the sidewall of flexible conduit 72 inwardly until it reaches the closed position shown in FIGS. 7 and 8. Suitable pin means 180 can be provided on the ends of stationary anvil rod 40 to be received in the upper slots 172 of each of the standards 168 and 170, thereby maintaining alignment of the H-bar assembly of the standards 168 and 170 and the closure bar 166.
The pinch valve assembly of the invention provides a number of beneficial results and advantages. The valve is applicable for high force pinching of varied diameter lines from small to large flexible tubings and utilizes a sinusoidal acting valve closure member which provides minimal movement and maximum torque at the throttling or closed position of the valve, permitting the use of small and compact drive units while, nevertheless, producing the necessary high forces for use with large tubing or high pressure applications. The valve housing is provided in two halves whereby the housing can be readily disassembled for removal or relocation on a flexible tubing. The flexible tubing can be received within the valve housing without any need for breaking or cutting of the flexible tubing, thereby permitting installation of the valve on a process line without interruption of the process.
The pinch valve utilizes a freely rotatable circular valve closure member which provides minimal wear on the flexible tubing since no shear or scuffing forces are applied to the external surface of the tubing. This insures maximum life of the tubing. In its preferred embodiment, the pinch valve is provided for remote operation utilizing a simple electrical control circuit. The pinch valve of the invention provides a fixedly adjustable anvil bar whereby the valve can be operated as a full closure or throttling valve.
The valve operator movement is unidirectional with the eccentric actuator always moving in the direction of the flow when opening. This insures that the line pressure assists in opening of the valve. The closing motion of the valve actuator is not abrupt, but, rather, the valve actuator squeezes closed with its velocity of movement progressively decreasing as it moves towards the closed position. This gradual closing avoids any water hammer effects and also insures that particles are not trapped in the pinched area since the gradual closing of the valve with the resultant progressive decrease in flow area through the flexible tubing results in increasing flow velocity which sweeps the particles from the progressively constricting area between the pinch bars.
The valve assembly can be used for single or multiple tubes in the manner illustrated and can be used for a full shut off or throttling control of processed fluids. It is extremely compact and portable and can be readily assembled and disassembled from process lines.
The invention has been described with reference to the illustrated and presently preferred embodiment. It is not intended that this description of the presently preferred and illustrated embodiment be unduly limiting of the invention. Instead, it is intended that the invention be defined by the means, and their obvious equivalents set forth in the following claims.
|
There is disclosed a pinch valve of greatly improved performance. The pinch valve has a housing with end plates having apertures forming a through passageway to receive a flexible conduit. The housing is split through the apertures of the end plates, into two halves, forming upper and lower saddles that are detachably interconnected to permit assembly of the housing about a flexible conduit, thereby eliminating cutting or breaking of the flexible conduit to insert or to relocate the pinch valve. The upper half of the housing carries a stationary bar or anvil and a circular cam actuator moves the valve member through a complete, 360 degree, rotation in a sinusoidal action movement. This action gives the valve a great mechanical advantage at shutoff position, permitting use of a small, lightweight valve structure.
| 5
|
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
CROSS REFERENCE TO RELATED APPLICATIONS
Not applicable.
BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for monitoring the cerebral cellular environment, especially in patients who have sustained brain injury.
BRIEF SUMMARY OF THE INVENTION
In the event of medical incidents, such as severe trauma to the head, it is frequent practice to monitor the intracranial pressure (ICP) in a ventricle of the brain. An increase in ICP is thought to be indicative of secondary injury such as brain swelling, and it is known to be necessary to relieve pressure by draining cerebrospinal fluid (CSF) if a patient's ICP rises above a critical level. While a body of data exists in the management of intracranial hypertension there have been few investigations of the significance of other cerebral physiological parameters.
The present invention is based on this observation that the pH of CSF is an indicator of the condition of a patient's brain after suffering head trauma and thus the likely outcome of medical treatment.
According to one aspect of the present invention there is provided a method of predicting the outcome of head trauma which comprises monitoring the pH of cerebrospinal fluid (CSF) and comparing the measured pH with a base line representing brain death.
In investigations which have been carried out by the present inventors, a pH sensor was inserted into a cerebral ventricle of a patient and the pH monitored by sequential measurements. Both the rate of change of pH and the absolute level of pH were measured on a continuous basis. While a rapid decrease of pH is a strong indicator of a poor survival prognosis, the absolute value of pH can be used directly to provide a guide to the patients' well being. In general, it has been found that stable levels of pH in the region of 7.15 to 7.25 suggest that the patient is likely to improve clinically, while significantly lower pH levels or continuously falling pH levels are a pointer to poor survival chances. In one case, a pH of about 7.05 correlated with brain stem death.
The present invention also includes apparatus for monitoring the pH and optionally other cerebral physiological parameters which comprises a lumen adapted for introduction through an opening in a skull of a living patient into a cerebral ventricle, said lumen having a pH sensor therein and permitting CSF to flow thereinto and over the sensor.
Preferably, the pH sensor contains a pH-sensitive colour change or fluorescent material and the colour change or fluorescence is measured optically by determining the absorption of a standard light beam.
The catheter containing the pH probe may be a single lumen and may also be used for removing samples of CSF fluid from the ventricle. Alternatively, a bitumen catheter may be employed in which the sensor is housed in one lumen and CSF is withdrawn from the other lumen. Removal of CSF may be desirable because of a perceived increase in ICP or may be removed prior to a detected increase in ICP because of a predicted deterioration in the patients well being because of a fall in pH.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The invention is illustrated by reference to the accompanying drawings in which:—
FIG. 1 is a section through a tubular probe containing various sensors;
FIG. 2 is a part section through the probe;
FIG. 3 is a schematic view showing one way in which the apparatus may be connected to a patient;
FIG. 3A is an enlarged view of the Luer lock; and
FIG. 3B is a partial section through the patient's head showing one method of introducing the lumen containing the pH sensor.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings the apparatus comprises a tubular probe ( 1 ) comprising a microporous sheath which permits the transfer of CSF into a gel (A) filling the probe. A number of sensors are housed within the tubular probe. One of these is a pH sensor ( 3 ). Sensor 3 comprises a length of optical fibre having a mirrored distal end 10 to reflect light back towards the proximal end 11 , longitudinally of the optical fibre. Several holes ( 12 ) are laser drilled through the optical fibre in a number of random directions normal to the longitudinal axis of the fibre. These holes are filled with a gel containing a phenol red dye which undergoes a colour change with change in pH. A colour change over the pH range from about 6.8 to 7.8 is desirable. The colour shade of the phenol red indicator is determined by passing a light beam along the optical fibre and measuring the absorption spectrum of the reflected beam. After calibration, the absorption spectrum of the reflected beam gives a measure of the pH of the CSF.
As indicated in FIG. 1 , the tubular probe may also include other sensors such as a CO 2 concentration sensor (pCO 2 ), 4 , a partial oxygen pressure sensor (PO 2 ), 6 , and a thermocouple 5 .
Tubular probe 1 is introduced into a ventriculostomy catheter 21 which has a distal end having a foraminous wall to permit CSF to flow into and around the tip of the probe.
The catheter may be introduced into the patient's skull and retained in place with a tubular skull bolt, e.g. as shown in U.S. Pat. No. 4,903,707 (the contents of which are specifically incorporated herein by reference). Conveniently, the catheter is urged into the opening in the skull as shown schematically in FIG. 3 until expression of CSF indicates that the catheter tip has reached the cerebral ventricle.
Referring to FIG. 3 , the catheter 21 has a distal end into which the tip of the probe is positioned. In the Example illustrated, the catheter comprises a single lumen, e.g. of PVC or polypropylene. The catheter is connected via a Luer lock to an extension tube 13 which may incorporate a side port (not shown) for sampling CSF and monitoring ICP. The extension tube is further connected by optical fibres to a detection, monitoring and display equipment.
Apparatus which is commercially available for intravascular blood monitoring under the registered trade mark ‘Paratrend’ 7 (Diametrics Medical Ltd 5, Manor Court Yard, Hughendon Ave, High Wycombe, HP13 5RE, United Kingdom) may be adapted for monitoring the pH of CSF by providing means for holding the sensor lumen in place in the skull. This may involve a bolt as described in the above cited U.S. Pat. No. 4,903,707 or secured by other fixing means as indicated in FIG. 3B . Referring to this latter Figure it can be seen that the catheter 21 is fixed to the patient's head by securing means 14 , passes under the scalp in contact with the skull 15 and then through an opening in the skull and brain 16 to reach a brain ventricle 17 . The small, size and flexibility of the catheter (about 2–3 mm diameter) facilitates introduction of the catheter. The distal tip of the catheter is provided with holes to permit flow of CSF therethrough and around the tip of the probe which is also located within the cerebral ventricle.
EXAMPLE
16 patients admitted to hospital following brain trauma resulting in severe brain injury (GCS≦8) were included in the study. A ‘Paratrend 7’ sensor measuring pH, pCO 2 and PO 2 was advanced into a ventriculostomy. Sensor data was stored into a computer and transferred to a spreadsheet, pH, pCO 2 , PO 2 , 1CP, CPP, patent manipulation and outcome were monitored.
Six patients were excluded due to technical difficulties in obtaining and recording data early in the study.
Four patients were found to have initial pH in the range 7.15 to 7.22 but had progressive CSF acidemia over the next 24 to 48 hours. All progressed to herniation and brain death. Clinical evidence of brain death occurred as the pH approached 7.05.
Two patients were found to have a relative high initial CSF pH in the range 7.20–7.25. These values remained substantially constant and both patients remained vegetative.
In the remaining four patients initial pH was in the range 7.12 to 7.24 but increased over the following 48 hours. All displayed significant clinical recovery.
It was found that patient care activities and other known stressors were found to cause a rapid decrease in CSF pH which resolved shortly after the activity stopped. All negative changes in brain pH occurred significantly before elevations of ICP or change in CPP could be detected. This suggests that CSF pH is a more effective indicator of a patient's neurological condition since remedial action can be taken earlier. It was also noted that measurement of CSF pH provides a means for monitoring cerebral ischemia following blunt head trauma. Falling pH correlates to ongoing cellular injury and occurs well before increases in intracranial pressures.
|
A method and apparatus for predicting the outcome of head injury trauma by monitoring cerebrospinal fluid (CSF) characteristics, preferably my monitoring the pH of CSF. The apparatus includes a catheter with a wall section adapted to permit CSF to flow therein, and a sensor located within the catheter such that the CSF is permitted to flow adjacent the tip of the sensor.
| 0
|
TECHNICAL FIELD TO WHICH THE INVENTION BELONGS
[0001] The present invention relates to a cement composition which improves drawbacks of Portland cement wherein an environmental countermeasure is taken such that the cement composition is of low pH and free of eluting a hexavalent chromium (hereinafter the cement composition is also referred to as a soil stabilizer in the specification).
PRIOR ART
[0002] It is a present state that Portland cement elutes a great quantity of hexavalent chromium such that it elutes 50 ppm of hexavalent chromium against 1.5 ppm or less of Environment Agency Notification No. 46. Moreover, it elutes a high alkali material of pH 14 over a long period of time so that it is considered to effect an environmental deterioration and scenery disruption. Further, since scarcity of concrete aggregates has recently advanced, a concrete mold which does not use gravel and sand has been required. On the other hand, since a countermeasure against sludge which deposits on beds of river, pond and lake has not been progressed in an easy way, a water environment affected by sludge deposition has become a large social problem.
[0003] To cope with these problems, environmental countermeasures such as cement in which a countermeasure against hexavalent chromium is taken, neutral cement, a neutral soil stabilizer, a high polymeric coagulant, an ultra water-absorbing resin and the like are used have been taken; however, it is a present situation that a satisfactory result has not been obtained. As the neutral cement, magnesia phosphoric acid cement has conventionally been put on market; however, this is high in cost and is limited to a partial application so that it has been used as an adhesive rather than as cement. The reason is based on that the chemical composition thereof is that of bobierrite and has a ratio of phosphoric acid to magnesium oxide is from 1:1 to 2:3 (mol) whereupon adjustment of setting time is difficult so that there are many products which show an exceedingly rapid setting compared with a pot life of Portland cement.
[0004] In soil cement, high-sulfate based stabilizer, and lime based soil stabilizer, a solidified product using any of them exhibits extremely inferior strength generation in some cases in accordance with qualities of soil whereupon they can not comply with peat, andosols, acidic volcanic ashes in some cases; particularly, in high organic sludge treatment, an agent with advantageous solidification which can reuse the sludge has been requested. Further, aggregates for use in concrete has been scarce for long and a novel cement which can well solidify clay, silt, decomposed granitic soil, volcanic ashes and the like for utilizing them as an aggregate in cement.
[0005] It is preferable that heavy metals and cyan specified by Environment Agency Notification No. 46, organic chlorides and the like are not eluted in a pH range of 5.5 to 8.5 as environmental standards, whereas, as in Portland cement, in a case of high pH or in an acidic side, if any one of lead and cadmium is stabilized, the other one tends to be eluted, where a neutral stabilization is required; however, there exists no suitable solidifying material/stabilizer capable to correspond to this kind of requirement, while, if in a ph range of 3.5 to 10.0, an effect of a chelating agent can be expected so that the stabilizer which works in a alkalescent range can attain an object. Further, various tests verify that, if a stabilizer which can decrease a moisture content of sludge from about 500% to 60% can be utilized, sludge in beds of lakes can be treated in an easy manner; however, a pH range is required in which sedimentation sludge in the beds of lakes is solidified without separating water therefrom and the resultant solidified product made of sludge can be utilized as a fertilizer. Concrete using Portland cement does not attract animate thing in water thereon for a long period of time so that it is required to construct blocks for use in revetment of rivers, tetrapod-like concrete blocks, artificial fishing banks and the like using other materials than conventional concrete and, for this purpose, there are some case in which a folding trap for fish and the like has been used to replace them. Further, since banks of canals or rivers are protected from destruction by cutting weed twice or more a year, it is required to decrease a number of weed cutting by suppressing growth of the weed. Still furthermore, in agricultural engineering, in order to protect ridges between rice fields, farm roads and waterways from weed and water leakage, they have been treated with soil cement and the like; however, due to pH problem and inferior capability of soil solidification, a number of treatment of this kind has recently been decreased. As an engineering method for stabilizing soil, a soil solidification for bases for engineering and building has been performed by soil stabilization by means of deep layer mixing or surface layer solidification; however, it is pointed out that, in a case of soil stabilizer, there exist problems related with pH and hexavalent chromium and, in a case of lime-based stabilizer, there exist problems related with pH and risks of underground water pollution. Even if the above-described problems are intended to be solved, there exist many problems which using conventional soil stabilizers or lime-based stabilizers can not solve. In order to solve the above-described problems, provision of a novel cement which, being alkalescent, is capable of solidifying/stabilizing a wide range of soil and applicable to biological environment has been required.
DISCLOSURE OF THE INVENTION
[0006] The prevent inventors found light burned magnesia, among magnesium oxides, reacts well with various types of phosphates, in particular, phosphate fertilizer within a specified ratio therebetween while having a moderate setting time in a presence of gypsum, an oxycarboxylic acid or a ketocarboxylic acid for a purpose of a reaction control and the resultant product shows a strength comparable to that of Portland cement and, further, a solid solution having a same chemical composition also reacts with a phosphate in a similar manner whereupon the present invention has been accomplished. That is, in a method of using a light burned magnesia and a phosphate in a non-chemical equivalent manner instead of using phosphate magnesia cement in a conventional chemical equivalent manner, it is one of characteristics that a weight ratio of a light burned magnesia and a phosphate is in a range of 100:3 to 3.5. This is the same with a case where a main component of a solid solution is magnesium silicate and has a completely different chemical composition from a conventional phosphate magnesia cement composition where a weight ratio of Mg 3 (PO 4 ) 2 .8H 2 O (bobierrite) and a phosphate is 100:120. Moreover, as a method of controlling a solidifying reaction, addition of gypsum, an oxycarboxylic acid or a ketocarboxylic acid can enhance the strength. Examples of oxycarboxylic acids and ketocarboxylic acids capable of being applied in the present invention include citric acid, gluconic acid, ketogluconic acid and the like; in particular, citric acid is most preferable. Taking citric acid as a representative example, an explanation is made below. On this occasion, these chemicals can be mixed as anhydride forms or various types of salts thereof.
[0007] Further, as a method to enhance an initial strength, calcium aluminate and alumina, aluminum silicate, ferrous sulfate, ferrous chloride and the like were added while inorganic coagulant and a high polymeric coagulant were concurrently used in high-water-content sludge or organic sludge whereupon solidifying capability of sludge was able to be highly improved compared with a conventional method.
[0008] That is, the present invention is a cement composition in which 100 parts by weight of magnesium oxide containing 5 to 25% by weight of any one of silicic acid, alumina and iron oxide, 3 to 35 parts by weight of phosphate, 2 to 30 parts by weight of gypsum and 0.005 to 7 parts by weight of an oxycarboxylic acid or a ketocarboxylic acid are compounded.
DETAILED DESCRIPTION OF THE INVENTION
[0009] It has ordinarily been a prohibited matter to mix hydrated lime, caustic lime, burned dolomite, light burned magnesia or the like with a phosphate fertilizer or to concurrently apply them as fertilizers. The reason is that the calcium phosphate or magnesium phosphate was generated thereby causing solidification of soil. Moreover, there has been no method to utilize this as cement; however, the present inventors have made an extensive study based on this theory and found a phosphate that can maintain a safe pH region by having the pH thereof lower than that of Mg(OH) 2 and with a help of a PH buffer action of phosphoric acid and, further, become a solidifying agent for light burned magnesia. Though self-hardening capability of light burned magnesia has already been known, it has not been suitable for applications requiring high strength; it is sure that there has been a method to use it for oxychloride cement or phosphoric acid magnesia cement, but it has a problem in water resistance, setting time and the like and, further, is high in cost so that it can enjoy only a limited market compared with Portland cement; however, physical properties and cost which are not much different from those of Portland cement have been attained by a method which utilizes phosphate fertilizer or phosphate as a phosphoric acid source thereby reducing an addition rate.
[0010] Light burned magnesium oxide, a phosphate fertilizer and a phosphate described in the present invention is soluble to citric acid and, since 0.005 parts by weight to 7.0 parts by weight of citric acid are contained in the composition, a phenomenon can be seen such that water solubility of light burned magnesium oxide, phosphate fertilizer and phosphate were increased, they are activated, the reactivity thereof are enhanced and the flow values thereof are increased; hence, setting time can be adjusted. For this reason, regardless of water-soluble phosphoric acid and water-insoluble phosphoric acid, a solidified reaction product can be obtained in which, since coexisting light burned magnesium oxide is soluble to citric acid, citric acid is critical in the present reaction as an essential ingredient. Further, gypsum as a component acts to adjust hydration of light burned magnesium oxide in the same way as in Portland cement whereupon anhydrous gypsum, hemihydrate gypsum, dihydrate gypsum and magnesium sulfate are individually used according to their respective applications.
[0011] In a cement composition shown in claim 1 of the present invention, light burned magnesium oxide is suitable as magnesium oxide to be used and it is preferable that a particle size of the light burned magnesium oxide is from 60 mesh to 360 mesh, a content of MgO in the composition is from 40% to 85% and a material purity of MgO is from 65% to 98% while the composition may contain an amount of from 5% to 25% of SiO 2 , Al 2 O 3 and/or Fe 2 O 3 as an impurity.
[0012] As a means for further decreasing pH, further decreasing productivity and cost and improving strength, there is a method in which a solid solution containing magnesium ferro aluminium solid solution by substituting Ca used in a production method of Portland cement by Mg thereby producing magnesium silicate (mixed melting product of enstatite, forsterite and cordierite) or substituting Ca in a production method of alumina cement by Mg thereby producing magnesium alminate (periclase, spinel) and further adding iron for a purpose of decreasing a melting point of the solid solution is produced and powders of the thus produced solid solution are acted by a phosphate.
[0013] In a method to effectively utilize phosphates, a water-soluble phosphate fertilizer is used from among magnesium triple superphosphate, calcium triple superphosphate and calcium superphosphate in this order of easiness of application, urea magnesium phosphate, magnesium ammonium phosphate, acidic magnesium phosphate and/or acidic calcium magnesium phosphate can be used in a quick-setting compound composition and, when quick setting is avoided, any of these components can be absorbed in an inorganic porous material such as diatomaceous earth and the like to allow it to be in a sustained release state or subjected to heating treatment at a temperature of 200° C. or over to allow it to be meta phosphoric acid. Examples of components which are soluble to citric acid include magnesium metaphosphate, calcium metaphosphate, fused phosphate, Thomas phosphate fertilizer and the like in this order of easiness of solubility. An addition rate of phosphate in a composition is from 3 parts by weight to 35 parts by weight and is substantially determined by a content of P 2 O 5 whereupon the addition rate is determined depending on solubility thereof in water or citric acid and, when fineness of the phosphate exceeds a range of 200 mesh to 500 mesh, reactivity thereof is not deteriorated even if an addition rate of citric acid is held at a required minimum and, therefore, the addition rate of citric acid can be from 0.005 part by weight to 7 parts by weight. The above-described phosphates can be used individually or in combination of two or more of them and also in various types of compositions according to applications.
[0014] Next, as gypsum to be used in the present invention, anhydrous gypsum, hemihydrate gypsum, dihydrate gypsum and magnesium sulfate are selectively used in accordance with applications whereupon anhydrous gypsum is used for sludge treatment, hemihydrate gypsum for applications which require quick setting and dihydrate gypsum for applications which put stress on retardant setting.
[0015] A method can be performed in which a clinker of a solid solution is first produced by 3 MgO.SiO 2 , 3 MgO.Al 2 O 3 and MgO.Al 2 O 3 or NaO.2MgO.SiO 2 .3MgO.Al 2 O 3 .Fe 2 O 3 which can form a solid solution as chemical ingredients in the cement composition according to the present invention and then a crushed product thereof is added with the above-described phosphate, gypsum and citric acid. Magnesite and brucite, magnesium oxide, magnesium dross or magnesium chloride as main materials of MgO sources, MgO.SiO 2 .Al 2 O 3 as an auxiliary material, magnesio vermiculite, forsterite, enstatite, chlorite, pyrope, talc, serpentinite, sepiolite, anthophyllite, spinel and the like as mineral ores, felspar, clay and, further, iron oxide, iron chloride, ferrous sulfate, slag, iron ore and the like as iron sources containing no chromium and, furthermore, Ca or Mn of 5% or less may be included. Components are compounded so that respective coefficients inclusive of ratios of cement hydraulic properties show as follows in terms of that CaO in a Portland cement type is substituted by mgO: hydraulic ratio is from 1.26 to 2.0; magnesium ratio is 2.5; chemical index is 1.0 or less; silicic acid ratio is from 2.0 to 3.0; activity coefficient is from 3.0 to 4.0; ratio of iron oxide to alumina is from 1.5 to 2.0; magnesium index is 1.09; cement index is 5.0; acidity coefficient is 7.5; each of saturation degree of magnesium, Hess number and spintel number is 100. A simplest fused composition is made such that 130 parts by weight of magnesite, 30 parts by weight of clay and silica stone and 8 parts by weight of slag are mixed, melted at 1500, then cooled and crushed to be 300-mesh or more powders; the resultant powders are mixed with 4 to 5 parts by weight of gypsum, 3 to 35 parts by weight of the above-described phosphate and 0.005 to 7 parts by weight of citric acid thereby producing cement. In the thus produced clinker composition, an appropriate quantity of magnesite is replaced by serpentinite, SiO 2 contained in clay and silica stone is supplemented by serpentinite, clay and bauxite is used as Al 2 O 3 sources and slag is used after subjected to iron containing no chromium or phosphoric acid treatment. In the thus obtained solid solution chemical composition, a ratio of MgO is required to be large in order to generate a large quantity of 3MgO.SiO 2 , 3MgO.Al 2 O 3 and 2MgO.Fe 2 O 3 and it is preferable that quantity of Na is increased to about 1% in order to enhance the hydraulic property.
[0016] In a magnesium aluminate type, 3MgO.Al 2 O 3 is contained as a main ingredient and 2MgO.Al 2 O 3 (periclase) and 3MgO.Al 2 O 3 .Fe 2 O 3 may be contained; however, an eutectic material of 3MgO.Al 2 O 3 and 12MgO.7Al 2 O 3 is preferable and it decreases a melting point thereby facilitating a production as in the aluminate cement to contain silic acid or iron oxide by from 3% to 10%. Since fire retardancy is not taken into consideration for the application of the present invention, it is preferable that mole ratio of MgO in a mole ratio relation of MgO>Al 2 O 3 is an excessive one in order to enhance hydraulic capability; however, when low temperature fusion capability is taken into consideration, if an iron content is increased while containing MgO.Al 2 O 3 as a main ingredient, then it facilitates production. In ores as starting materials, magnesium oxide, magnesium dross, magnesium chloride and magnesium hydroxide are used as main magnesium sources, bauxite, aluminum dross and aluminum hydroxide are used as aluminum sources and, on this occasion, serpentinite can be utilized for the purpose of cost reduction. A production method comprises the steps of crushing starting materials into powders in 80 mesh or less; making them into a briquet by adding 40% or less of water and subjecting the thus obtained briquet to heating fusion treatment at a temperature between 1200° C. and 1700° C. for 6 hours to obtain a clinker. The thus obtained clinker is used after crushed into powders in 500 mesh or less. Optionally, the clinker can also be used by mixing the composition as set forth in at least any one of claims 1 , 2 and 3 . Phosphate which is reactive solidifying agent has a low reactivity different from light burned magnesia so that because of low alkalinity thereof it is difficult to use in form of pyrophosphoric acid but acid phosphate or phosphoric acid adsorbed in an inorganic porous material can be used. 3 to 35 parts, favorably 5 to 15 parts by weight of the above-described phosphate is added to 100 parts by weight of MgO.Al 2 O 3 and then 3 parts by weight of gypsum and from 0.05 to 5 parts by weight of citric acid are added to produce a cement composition.
[0017] Soil stabilizer according to the present invention can shorten a setting time thereof by adding 0.5 to 20 parts by weight of calcium aluminate as a setting accelerator and can be used in a condition that pH is not largely increased. Calcium aluminate as a component thereof may be a solid solution comprising C 12 A 7 , C 4 A 7 , C 3 A, CA and gypsum. By adding these materials, the soil stabilizer can set extremely quicker than that in which nothing is added to achieve early setting and early strength as close as those of Portland cement of ultra high-early strength type.
[0018] The soil stabilizer according to the present invention can not only shorten the setting time but also enhance water-absorbing property of high water-content sludge by adding alumina, in particular activated alumina, burned bauxite, aluminum hydroxide and the like containing alumina. An addition rate is 3 to 30 parts by weight and favorably 5 to 10 parts by weight.
[0019] The cement composition according to the present invention can enhance solidifying property thereof by adding kaolin, acid clay, clay, allophane, hydrated halloysite or montmorillonite as a aluminum silicate compound thereby increasing viscosity thereof; hence it can have plasticity and texture which can not be achieved by Portland cement When a porcelain-like texture can be obtained by adding 10 to 30 parts by weight of these materials, 10 to 30 parts by weight thereof is used and, when underwater non-separable property is required, 3 to 10 parts by weight thereof is a preferable range.
[0020] In a method in which the soil stabilizer according to the present invention is used together with an inorganic or high polymeric coagulant, an ordinary lime or cement type inorganic material can not obtain a favorable flock and serves mainly as a pH adjusting agent, whereas the soil stabilizer according to the present invention is different from a calcium-based one and forms a favorable flock in a low alkaline region due to the pH buffer action by the contained phosphoric acid and the thus formed flock undergoes an underwater shift reaction to exhibit a phenomenon that it dries in the air by discharging water thereby easily obtaining a dehydrated cake of an organic sludge which can not conventionally be obtained. When this reaction is utilized, it is possible that the dehydrated cake of the organic sludge having a water content of about 80% is changed into that having a water content of about 60% which can easily be treated. This phenomenon utilizes a phenomenon in which the soil stabilizer having crystallization water of 22 to 32 hydrated salts according to the present invention is changed into that of 8 hydrated salts and there is a convenient condition such that the phenomenon occurs in an acidic region or a side of weak alkaline of about pH 8 and does not occur in a range of high content thereof in a high strength region by virtue of low range of addition rate of the soil stabilizer according to the present invention. As an inorganic coagulant, ferrous sulfate, ferrous chloride, poly aluminum chloride or the like is exemplified. An addition rate thereof is 0.5 to 5.0% to the total weight of sludge. As a high polymeric coagulant, polyacrylamide, a copolymer of polymethacrylic acid and polyacrylamide, a copolymer of maleic acid and polybutadience or the like is exemplified. These materials are used at an addition rate of 0.001 to 0.5%.
[0021] The cement composition according to the present invention can also be used as mortar as in a case of Portland cement whereupon it has characteristics that, since it does not exhibit whitening, when a pigment is added, it can be brightly colored and when an aggregate is added in a high compounding ratio, it can exhibit a good glossy color thereof and, moreover, since it is white tint of color, it has a tone of color which can not be obtained by a conventional white cement. Tests conducted under conditions set forth in JIS R-5201 show that initial set is 2.5 hours at 20° C. when citric acid is added by 0.3%; final set is 3.3 hours; a flow value is as small as 11.5, but it does not increase linearly like that in Portland cement; bending and compression strength after 28 days are 3.2 N/mm 2 and 24.6 N/mm 2 , respectively. Cement of this soil stabilizer is capable of producing various types of compounds having a pH of 10 or less by mixing with various kinds of aggregates or fillers whereupon it can prepare plastering materials, spray coating materials and various types of molds and, further, due to the low pH thereof, prepare GRC molds and mortar having glass-based aggregates using E glass filter.
[0022] Concrete comprising the soil stabilizer according to the present invention is capable of producing concrete in which a conventional concrete composition is held except for cement replacement and the thus produced concrete elutes substantially no hexavalent chromium and can find an animate object attached thereon in about 3 months due to its pH of 9.8 or less. Slump thereof in accordance with Concrete Standard Specification is low as being similar to that of mortar when water reducing agent is not added, but same flowability is obtained when about 0.3 of super water reducing agent is added; bending strength and compression strength of that in a case of 300 kg/m 3 with a water content showing 0 slump are 3.4 N/mm 2 and 2 6.8 N/mm 2 , respectively. Contraction, creep and the like thereof are approximate to those of Portland cement and, characteristically, a surface thereof does not get whitened and hardly undergoes carbonation. But it is liable to permit iron formwork or iron bar to get rusted thereby necessitating anti-rust treatment on them.
[0023] Soil cement of the soil stabilizer according to the present invention has an advantage such that it can obtain a same strength with soil of loamy layer, for example, loamy soil of the Kanto district and the like as that of an ordinary high sulfate type soil stabilizer or slag soil cement by one third of an addition rate of the latter two thereby obtaining 3.5 N/mm 2 in a case of 10 kg/m 3 . It also can advantageously solidify peat, andosols, quasi-gley soil, decomposed granitic soil, volcanic ashes, volcanic glassy sand and the like. It can with the same strength solidify white clay, argil, kaoline and the like which exist in soil of deep layers by one half the addition rate in the case of loamy soil, for example, of the Kanto district and the like. The soil cement of the soil stabilizer according to the present invention from which air content therein has extremely been reduced by a vacuum soil kneader or a press mold can attain a density of 2.2, a pencil hardness of 6 H or more and high strength such as bending strength of 23.4 N/mm 2 and compression strength of 121.4 N/mm 2 and, further, since a tone of color of soil can be held as it is, it can produce a mold which will not spoil scenery. For this reason, secondary products such as unburned brick, artificial stone, building materials, boards, soil concrete mold and the like can be obtained and, further, soil sand concrete compounded with sand irrespective of incorporation or non-incorporation of aggregates or coarse aggregates and the like can be produced and, still furthermore, in the field of agriculture engineering, permanent footpaths between rice fields, weed preventive footpaths, canal retaining walls, revetment blocks and the like can be produced from on-site soil. In the field of soil stabilizing construction method, deep mixing can be performed with the soil stabilizer according to the present invention either in form of powders or slurry whereupon a press-in method of an earth pillar and a continuous wall both incorporated with on-site soil can be utilized and constructed, respectively.
[0024] Further, in a surface soil improvement, surface soil is mixed with the soil stabilizer according to the present invention by a stabilizer, a backhoe and other appropriate tools and machineries and imparted with plasticity by means of a planar pressing method using a vibration roller or a table compactor while adjusting the water content thereof thereby performing soil solidification in an easy manner. The soil stabilizer according to the present invention added with a plasticizer can be utilized in a backfilling grout for a shield, various types of soil grouting agents while using on-site soil and, since it is inherently provided with a property capable of being used in a multiplicity of applications when incorporated in a flash setting or retardant setting composition comprising any one of or a mixture of a phosphate, a setting accelerator, setting retarder and the like and also it can be shaped in granules, it allows to construct on site a drainage conduit, water-permeable pavement and a backfilling material. These resultant products cause an environmental pollution to an extremely low extent and, moreover, when pulverized, can be returned to soil whereupon it becomes a recyclable material which does not aggravate an environment.
[0025] The soil stabilizer according to the present invention can solidify various types of construction sludge, sewage sludge, sedimentation sludge in beds of rivers and lakes by a relatively small amount thereof at a pH value of 9.5 or less. Conventional soil stabilizers tend to increase the usage thereof in order to suppress a pH value so that there are many cases in which solidification can not be performed with decrease of the addition rate thereof whereupon there is a limitation to sea water and organic sludge; however, the soil stabilizer according to the present invention can solidify the construction sludge and the sedimentation sludge in beds of rivers and lakes by addition of as small as 3 to 10% and can treat the sewage sludge, even highly hydrated sludge thereof having a water content of 700 to 200% when used together with an inorganic or high polymeric coagulant. These kinds of sludge have ordinarily been pretreated with hydrated lime before they are treated with the inorganic or organic coagulant whereupon ammonia dissolved in water tends to be salted out; however, in order to solve this problem, the sludge is neutralized using light burned magnesium oxide or magnesium hydroxide, added with the coagulant to produce a flock and the resultant flock is mixed with the soil stabilizer according to the present invention by 5% to 30% and stirred to be solidified and then water which has been captured in the thus solidified flock as crystallization water can be discharged by underwater shift reaction under a mild alkali to mild acidic condition. This reaction can be viewed in bobierrite as in a chemical reaction, Mg 3 (PO 4 ) 2 .22H 2 O→Mg 3 (PO 4 ) 2 .8H 2 O; however a non-chemical equivalent reaction, 10(Mg 3 (PO 4 ) 2 ).22H 2 O.32H 2 O→10(Mg 2 (PO 4 ) 2 ).8H 2 O, is executed by a more remarkable shift reaction. This dehydration reaction enables a dehydration ratio to reach 60% to 69% while an ordinary physical dehydration is limited to be 80% to 120% whereupon it is characteristic in that, even if the thus solidified sludge is returned to water, it will not restore an original sludge form.
[0026] The soil stabilizer according to the present invention can produce various types of products by changing components in compounds or additives in accordance with applications and usages whereupon the principal material, MgO, can be changed into magnesite or an Mg-containing ore; therefore, it has a mass-production capability and cost close to those of Portland cement. It has a far lower pH compared with a conventional low alkali cement, does not interfere with durability of E glass and does not pollute the environment so that it finds a multiplicity of industrial applications.
EXAMPLE
[0027] The present invention is specifically explained in detail with reference to embodiments illustrated below.
Example 1
[0028] 85 parts by weight of sea water light burned magnesium oxide (available from Kyowa Chemical Industry Co., Ltd.), 10 parts by weight of triple super phosphate powders, 5 parts by weight of natural anhydrous gypsum Type-II, 0.5 part by weight of citric anhydride were well mixed to obtain a soil stabilizer. In accordance with a cement testing method stipulated in JIS R5201, 520 g of the thus obtained soil stabilizer, 1560 g of standard sand and 312 g of water were mixed by a Hobert mixer for 10 minutes and then a flow test was conducted on the resultant mixture to obtain a flow value of 10.5 to 11.5. In the same way, a setting test was conducted on the resultant mixture to obtain an initial set of 3 hours and 23 minutes and a final set of 4 hours and 18 minutes. Further, 10 g of the mixture was diluted with 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 9.86. The above-described resultant mixture, namely, mortar, was flowed into a formwork of 40 mm×40 mm×160 mm to allow it to be molded. The thus molded material showed compression strength of 5.6 N/mm 2 , 13.7 N/mm 2 and 23.9 N/mm 2 at material ages of 3 days, 7 days and 28 days, respectively. Stability tests showed no cracking observed in the molded materials.
Example 2
[0029] 365 parts by weight of basic magnesium carbonate of reagent first grade, 25 parts by weight of kaoline, 7.5 parts by weight of silica sand, 8.0 part by weight of iron oxide and 80 parts by weight of water were mixed to prepare a cake. The thus prepared cake was then heated at 1600° C. for 6 hours in an electric oven to obtain a clinker. A block of this clinker was cooled and crushed by a ball-mill to collect powders of 300 mesh or less by a filtering operation. 100 parts by weight of the thus collected powders, 4 parts by weight of dihydrate gypsum, 12 parts by weight of dried heavy calcined phosphate powders of 200 mesh or less and 0.6 part by weight of sodium gluconate ware mixed by a Hobert mixer for 10 minutes to obtain a soil stabilizer. In accordance with a cement testing method stipulated in JXS R5201, 520 g of the thus obtained soil stabilizer, 1560 g of standard sand and 312 g of water were mixed by a Hobert mixer for 10 minutes and then a flow test was conducted on the resultant mixture to obtain a flow value of 14.5 to 15.5. In the same way, a setting test was conducted on the resultant mixture to obtain an initial set of 4 hours and 36 minutes and a final set of 5 hours and 32 minutes. Further, 10 g of the mixture was diluted with 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 8.5. The above-described resultant mixture, namely, mortar, was flowed into a formwork of 40 mm×40 mm×160 mm to allow it to be molded. The thus molded material showed compression strength of 6.4 N/mm 2 , 15.3 N/mm 2 and 26.4 N/mm 2 at material ages of 3 days, 7 days and 28 days, respectively. Stability tests showed no cracking observed in the molded materials.
Example 3
[0030] 182 parts by weight of basic magnesium carbonate of reagent first grade, 80 parts by weight of powdered serpentinite, 25 parts by weight of kaoline, 8.0 part by weight of iron oxide and 60 parts by weight of water were mixed to prepare a cake. The thus prepared cake was then heated at 1600° C. for 6 hours in an electric oven to obtain a clinker. A block of this clinker was cooled and crushed by a ball-mill to collect powders of 300 mesh or less by a filtering operation. 100 parts by weight of the thus collected powders, 4 parts by weight of dihydrate gypsum, 12 parts by weight of dried heavy calcined phosphate powders of 200 mesh or less and 0.3 part by weight of sodium 2-ketoglutarate ware mixed by a Hobert mixer for 10 minutes to obtain a soil stabilizer. In accordance with a cement testing method stipulated in JIS R5201, 520 g of the thus obtained soil stabilizer, 1560 g of standard sand and 312 g of water were mixed by a Hobert mixer for 10 minutes and then a flow test was conducted on the resultant mixture to obtain a flow value of 14.5 to 15.5. In the same way, a setting test was conducted on the resultant mixture to obtain an initial set of 4 hours and 56 minutes and a final set of 5 hours and 42 minutes. Further, 10 g of the mixture was diluted with 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 8.4. The above-described resultant mixture, namely, mortar, was flowed into a formwork of 40 mm×40 mm×160 mm to allow it to be molded. The thus molded material showed compression strength of 5.4 N/mm 2 , 13.6 N/mm 2 and 23.8 N/mm 2 at material ages of 3 days, 7 days and 28 days, respectively. Stability tests showed no cracking observed in the molded materials.
Example 4
[0031] 400 parts by weight of sea water light burned magnesium oxide (available from Kyowa Chemical Industry Co., Ltd.), 1000 parts by weight of alumina of reagent first grade, 17 parts by weight of ferric oxide, 35 part by weight of water were kneaded to obtain a block having 10 φ which is then placed in a platinum skull crucible furnace and calcined at 1400° C. for 6 hours. The thus calcined block was cooled and crushed by a ball-mill to powders of 200 mesh or less. 100 parts by weight of the thus prepared powders, 15 parts by weight of super phosphate, 3 parts by weight of dihydrate gypsum, 0.5 part by weight of citric anhydride were mixed to obtain a soil stabilizer. In accordance with a cement testing method stipulated in JIS R5201, 520 g of the thus obtained soil stabilizer, 1560 g of standard sand and 312 g of water were mixed by a Hobert mixer for 10 minutes and then a flow test was conducted on the resultant mixture to obtain a flow value of 18.5 to 19.5. In the same way, a setting test was conducted on the resultant mixture to obtain an initial set of 2 hours and 56 minutes and a final set of 3 hours and 32 minutes. Further, 10 g of the mixture was diluted with 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 9.4. The above-described resultant mixture, namely, mortar, was flowed into a formwork of 40 mm×40 mm×160 mm to allow it to be molded. The thus molded material showed compression strength of 15.3 N/mm 2 , 23.7 N/mm 2 and 34.2 N/mm 2 at material ages of 3 days, 7 days and 28 days, respectively. Stability tests showed no cracking observed in the molded materials.
Example 5
[0032] 100 parts. by weight of aluminum dross (metallic aluminum; 47%, alumina; 43%, other components such as aluminum nitride, zinc and the like; 9%), 140 parts by weight of magnesium dross (metallic magnesium; 51%, MgO; 45%, other components such as Mn, cupper, zinc and the like; 4%), 10 parts by weight of powdered serpentinite, and 10 parts by weight of water were mixed to react. After 24 hours, the thus reacted mixture was molded into a briquet. The briquet was fused at 1750° C. in an electric oven, quenched and crushed by a ball-mill to powders of 400 mesh to obtain magnesium aluminate powders having a periclase composition. 100 parts by weight of the thus obtained powders, 5 parts by weight of magnesium metaphosphate powders, 3 parts by weight of citric acid and 65 parts by weight of water were mixed by a Hobert mixer for 10 minutes and then a flow test was conducted on the resultant mixture to obtain a flow value of 19.0 to 20.5. In the same way, a setting test was conducted on the resultant mixture to obtain an initial set of 4 hours and 20 minutes and a final set of 4 hours and 38 minutes. Further, 10 g of the mixture was diluted with 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 8.5. The above-described resultant mixture, namely, mortar, was flowed into a formwork of 40 mm×40 mm×160 mm to allow it to be molded. The thus molded material showed compression strength of 14.2 N/mm 2 , 24.2 N/mm 2 and 28.9 N/mm 2 at material ages of 3 days, 7 days and 28 days, respectively. Stability tests showed no cracking observed in the molded materials.
Example 6
[0033] 85 parts by weight of light burned magnesium oxide (produced in Liaoning Province, P.R.C.) (200 mesh or less), 10 parts by weight of heavy calcined phosphate powders, 5 parts by weight of hemihydrate gypsum, 0.5 part by weight of citric anhydride were well mixed to obtain a soil stabilizer. In accordance with a cement testing method stipulated in JIS R5201. 520 g of the thus obtained soil stabilizer, 1560 g of standard sand and 312 g of water were mixed by a Hobert mixer for 10 minutes and then a flow test was conducted on the resultant mixture to obtain a flow value of 11.0 to 11.5. In the same way, a setting test was conducted on the resultant mixture to obtain an initial set of 3 hours and 28 minutes and a final set of 4 hours and 30 minutes. Further, 10 g of the mixture was diluted with 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 9.98. The above-described resultant mixture, namely, mortar, was flowed into a formwork of 40 mm×40 mm×160 mm to allow it to be molded. The thus molded material showed compression strength of 4.3 N/mm 2 , 14.2 N/mm 2 and 20.2 N/mm 2 at material ages of 3 days, 7 days and 28 days, respectively. Stability tests showed no cracking observed in the molded materials.
Example 7
[0034] 85 parts by weight of light burned magnesium oxide (produced in Liaoning Province, P.R.C.) (200 mesh or less), 25 parts by weight of fused phosphate powders, 5 parts by weight of hemihydrate gypsum, 5 parts by weight of citric anhydride were well mixed to obtain a soil stabilizer. In accordance with a cement testing method stipulated in JIS R5201, 520 g of the thus obtained soil stabilizer, 1560 g of standard sand and 312 g of water were mixed by a Hobert mixer for 10 minutes and then a flow test was conducted on the resultant mixture to obtain a flow value of 12.0 to 12.3. In the same way, a setting test was conducted on the resultant mixture to obtain an initial set of 23 hours and 30 minutes and a final set of 32 hours and 56 minutes. Further, 10 g of the mixture was diluted with 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 10.96. The above-described resultant mixture, namely, mortar, was flowed into a formwork of 40 mm×40 mm×160 mm to allow it to be molded. The thus molded material showed compression strength of 1.2 N/mm 2 , 4.6 N/mm 3 , 10.2 N/mm 2 and 21.5 N/mm 2 at material ages of 3 days, 7 days, 28 days and 35 days, respectively. Stability tests showed no cracking observed in the molded materials.
Example 8
[0035] 85 parts by weight of light burned magnesium oxide (produced in Liaoning Province, P.R.C.) (200 mesh or less), 20parts by weight of fused phosphate powders, 5 parts by weight of hemihydrate gypsum, 7 parts by weight of citric anhydride were well mixed to obtain a soil stabilizer. In accordance with a cement testing method stipulated in JIS R5201, 520 g of the thus obtained soil stabilizer, 1560 g of standard sand and 312 g of water were mixed by a Hobert mixer for 10 minutes and then a flow test was conducted on the resultant mixture to obtain a flow value of 12.0 to 13.7. In the same way, a setting test was conducted on the resultant mixture to obtain an initial set of 96 hours and 30 minutes and a final set of 131 hours and 15 minutes. Further, 10 g of the mixture was diluted with 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 10.98. The above-described resultant mixture, namely, mortar, was flowed into a formwork of 40 mm×40 mm×160 mm to allow it to be molded. The thus molded material showed compression strength of 0, 0.6 N/mm 2 , 80.8 N/mm 2 and 20.5 N/mm 2 at material ages of 3 days, 7 days, 28 days and 35 days, respectively. Stability tests showed no cracking observed in the molded materials.
Example 9
[0036] 85 parts by weight of light burned magnesium oxide (produced in Liaoning Province, P.R.C.) (200 mesh or less), 5 parts by weight of magnesium metaphosphate powders, 5 parts by weight of anhydrous gypsum, 0.01 part by weight of citric anhydride were well mixed to obtain a soil stabilizer. In accordance with a cement testing method stipulated in JIS R5201, 520 g of the thus obtained soil stabilizer, 1560 g of standard sand and 312 g of water were mixed by a Hobert mixer for 10 minutes and then a flow test was conducted on the resultant mixture to obtain a flow value of 14.0 to 15.7. In the same way, a setting test was conducted on the resultant mixture to obtain an initial set of 4 hours and 25 minutes and a final set of 4 hours and 57 minutes. Further, 10 g of the mixture was diluted with 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 9.8. The above-described resultant mixture, namely, mortar, was flowed into a formwork of 40 mm×40 mm×160 mm to allow it to be molded. The thus molded material showed compression strength of 7.6 N/mm 2 , 14.3 N/mm 2 and 26.4 N/mm 2 at material ages of 3 days, 7 days and 28 days, respectively. Stability tests showed no cracking observed in the molded materials.
Example 10
[0037] 300 kg/m 3 of the soil stabilizer according to Example 1,900 kg/m 3 of river sand, 1450 kg/m 3 of gravel, 210 kg/m 3 of water and 6 kg/m 3 of Mighty 21 were mixed and kneaded by a concrete mixer to obtain concrete having Slump of 58 and air volume of 5%. This concrete was flowed into a formwork of 100 φ×200 mm and cured at 60% RH and 20° C. Unconfined compressive strength of the resultant product showed 9.8 N/mm 2 and 24.3 N/mm 2 at material ages of 7 days and 28 days, respectively. Concrete having the above-described composition was added with 50 kg/mm 3 of calcined kaoline and was, further, allowed to have 220 kg/mm 3 of water and 7 kg/mm 3 of Mighty 21 thereby obtaining concrete having slump of 52 and air volume of 4.6%. Unconfined compressive strength of the thus obtained concrete showed 13.4 N/mm 2 and 26.7 N/mm 2 at material ages of 7 days and 28 days, respectively. This concrete exhibited a favorable abrasive resistant and smooth surface.
Example 11
[0038] 300 kg/m 3 of the soil stabilizer according to Example 2, 900 kg/m 3 of river sand, 1450 kg/m 3 of gravel, 210 kg/m 3 of water and 9 kg/m 3 of Mighty 150 were mixed and kneaded by a concrete mixer to obtain concrete having slump of 53 and air volume of 5%. This concrete was flowed into a formwork of 100 φ×200 mm and cured at 60% RH and 20° C. Unconfined compressive strength of the resultant product showed 19.8 N/mm 2 and 27.5 N/mm 2 at material ages of 7 days and 28 days, respectively.
Example 12
[0039] 85 parts by weight of light burned magnesium oxide (produced in Liaoning Province, P.R.C.) (200 mesh or less), 12 parts by weight of heavy calcined phosphate powders, 5 parts by weight of hemihydrate gypsum, 1 part by weight of citric anhydride were well mixed to obtain a soil stabilizer. 30 parts by weight of the thus obtained soil stabilizer, 30 parts by weight of silica sand No. 5 and 70 parts by weight of loamy soil of the Kanto district, 65 parts by weight of water were mixed by a Hobert mixer for 20 minutes and then pushed into a formwork of 50 φ×100 mm using a rammer to produce a mold. The mold showed an initial set of 2 hours and 30 minutes and a final set of 3 hours and 15 minutes. Further, 10 g of the resultant mixture was taken out of the formwork, diluted with 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 9.8. The mold showed compression strength of 0.22 N/mm 2 , 0.46 N/mm 2 , 17.2 N/mm 2 and 21.7 N/mm 2 at material ages of 3 days, 7 days, 28 days and 35 days, respectively. It has a specific gravity of 2.1.
[0040] While, a mold made of 30 parts by weight of soil stabilizer having this composition, 30 parts by weight of silica sand No. 5, 70 parts by weight of loamy soil of the Kanto district, 3 parts by weight of Denka ES and 65 parts by weight of water showed an initial set of 34 minutes and a final set of 48 minutes. Further, 10 g of the resultant mixture was taken out of the formwork, was diluted with 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 10.2. The mold showed compression strength of 0.32 N/mm 2 , 0.66 N/mm 2 , 23.2 N/mm 2 and 26.5 N/mm 2 at material ages of 3 days, 7 days, 28 days and 35 days, respectively. It has a specific gravity of 2.1.
Example 13
[0041] 85 parts by weight of light burned magnesium oxide (produced in Liaoning Province, P.R.C.) (200 mesh or less), 10 parts by weight of heavy calcined phosphate powders, 5 parts by weight of hemihydrate gypsum, 1 part by weight of citric anhydride were well mixed to obtain a soil stabilizer. 30 parts by weight of the thus obtained soil stabilizer, 30 parts by weight of silica sand No. 5 and 70 parts by weight of loamy soil of the Kanto district, 60 parts by weight of water were mixed by a Hobert mixer for 20 minutes, pushed into a formwork of 50 φ×100 mm using a rammer and, further, applied with a pressure of 10 kg/cm 2 to produce a mold. The mold showed an initial set of 2 hours and 121 minutes and a final set of 2 hours and 38 minutes. Further, 10 g of the resultant mixture was taken out of the formwork, diluted with 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 9.6. The mold showed compression strength of 3.2 N/mm 2 , 5.68 N/mm 2 and 27.2 N/mm 2 at material ages of 3 days, 7 days and 28 days, respectively. It has a specific gravity of 2.3 and a pencil hardness of 6.
Example 14
[0042] 80 parts by weight of light burned magnesium oxide (produced in Liaoning Province, P.R.C.) (200 mesh or less), 10 parts by weight of heavy calcined phosphate powders, 5 parts by weight of hemihydrate gypsum, 0.5 part by weight of citric anhydride were well mixed to obtain a soil stabilizer. 10 parts by weight of the thus obtained soil stabilizer, 90 parts by weight of acid clay and 65 parts by weight of water were mixed by a Hobert mixer for 20 minutes, pushed into a formwork of 50 φ×100 mm using a rammer and, further, applied with a pressure of 10 kg/cm 2 to produce a mold. The mold showed an initial set of 3 hours and 20 minutes and a final set of 3 hours and 45 minutes. Further, 10 g of the resultant mixture was taken out of the formwork, diluted with 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 9.8. The mold showed compression strength of 0.28 N/mm 2 , 0.48 N/mm 2 and 12.2 N/mm 2 at material ages of 3 days, 7 days and 28 days, respectively. It has a specific gravity of 2.0 and a pencil hardness of 4.
Example 15
[0043] 10 parts by weight of the soil stabilizer according to Example 2, 90 parts by weight of loamy soil of the Kanto district, 60 parts by weight of water were mixed by a Hobert mixer for 20 minutes, pushed into a formwork of 50 φ×100 mm using a rammer and, further, applied with a pressure of 10 kg/mm 2 to obtain a mold. The mold showed an initial set of 4 hours and 26 minutes and a final set of 5 hours and 12 minutes. Further, 10 g of the resultant mixture was taken out of the formwork, was diluted in 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 8.4. The mold showed compression strength of 0.14 N/mm 2 , 0.26 N/mm 2 and 0.40 N/mm 2 at material ages of 3 days, 7 days and 28 days, respectively. It has a specific gravity of 1.74 and a pencil hardness of 2.
Example 16
[0044] 10 parts by weight of the soil stabilizer according to Example 1 and 90 parts by weight of loamy soil of the Kanto district having a moisture content of 170% (specific gravity being 1.31) were mixed by a Hobert mixer for 10 minutes and pushed into a formwork of 50 φ×100 mm using a rammer to obtain a mold. 10 g of the resultant mixture was taken out of the formwork, diluted in 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 9.8. The mold showed compression strength of 0.25 N/mm 2 and 0.61 N/mm 2 at material ages of 7 days and 28 days, respectively.
Example 17
[0045] 10 parts by weight of the soil stabilizer according to Example 1 and 90, parts by weight of loamy soil of the Kanto district having a moisture content of 105% (specific gravity being 1.41) were mixed by a Hobert mixer for 10 minutes and pushed into a formwork of 50 φ×100 mm using a rammer to obtain a mold. 10 g of the resultant mixture was taken out of the formwork, diluted in 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 9.8. The mold showed compression strength of 1.65 N/mm 2 and 2.08 N/mm 2 at material ages of 7 days and 28 days, respectively.
Example 18
[0046] 10 parts by weight of the soil stabilizer according to Example 1 and 90 parts by weight of silt having a moisture content of 60% (specific gravity being 1.64) were mixed by a Hobert mixer for 10 minutes and pushed into a formwork of 50 φ×100 mm using a rammer to obtain a mold. 10 g of the resultant mixture was taken out of the formwork, diluted in 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 9.9. The mold showed compression strength of 0.26 N/mm 2 and 0.50 N/mm 2 at material ages of 7 days and 28 days, respectively.
Example 19
[0047] 10 parts by weight of the soil stabilizer according to Example 1 and 90 parts by weight of decomposed granitic soil (moisture content being 180%, specific gravity being 1.34) were mixed by a Hobert mixer for 10 minutes and pushed into a formwork of 50 φ×100 m using a rammer to obtain a mold. 10 g of the resultant mixture was taken out of the formwork, diluted in 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 8.9. The mold showed compression strength of 0.11 N/mm 2 and 0.340 N/mm 2 at material ages of 7 days and 28 days, respectively.
Example 20
[0048] 15 parts by weight of the soil stabilizer according to Example 4 and 85 parts by weight of organic sludge having a moisture content of 400% (specific gravity being 1.12) were mixed by a Hobert mixer for 10 minutes and pushed into a formwork of 50 φ×100 mm using a rammer to obtain a mold. 10 g of the resultant mixture was taken out of the formwork, diluted in 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 8.4. The mold showed compression strength of 0.03 N/mm 2 and 0.08 N/mm 2 at material ages of 7 days and 28 days, respectively.
Example 21
[0049] 30 parts by weight of the soil stabilizer according to Example 5, 70 parts by weight of loamy soil of the Knato district, 50 parts by weight of charcoal powders and 60 parts by weight of water were mixed by a Hobert mixer for 25 minutes to obtain soil having charcoal therein in form of granules. 10 g of the thus obtained soil having charcoal granules was immersed in 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 9.3. The soil was filled in a formwork of 50 φ×100 mm and then subjected to a compression test which showed compression strength of 0.16 N/mm 2 and 0.36 N/mm 2 at material ages of 7 days and 28 days, respectively. It has a void volume ratio of 37%.
Example 22
[0050] 30 parts by weight of the soil stabilizer according to Example 2, 70 parts by weight of volcanic ashes of Miyake Island and 50 parts by weight of water were mixed by a Hobert mixer for 10 minutes and pushed into a mortar bar formwork of 40 mm×40 mm×160 mm using a rammer to obtain a mold. 10 g of the resultant mixture was taken out of the formwork, diluted in 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 8.5. The mold showed compression strength of 1.61 N/mm 2 and 25.6 N/mm 2 at material ages of 7 days and 28 days, respectively.
Example 23
[0051] Elution tests were conducted on the soil stabilizers according to Examples 1 to 6 to measure an elution quantity of hexavalent chromium. Results of the tests are shown in Table 1.
[0052] Total chromium quantity by:
DC method=diphenylcarbazide absorptiometry; and IPC (T-Cr)=IPC,
[0055] in accordance with environmental standards according to soil pollution stipulated in Environment Agency Notification No. 46.
TABLE 1 Cr +6 elution quantities Soil stabilizers DC method IPC (T—Cr) Example 1 <0.02 <0.02 Example 2 <0.02 <0.02 Example 3 <0.02 <0.02 Example 4 <0.02 <0.02 Example 5 <0.02 <0.02 Example 6 <0.02 <0.02
Example 24
[0056] Elution tests were conducted on molds made of loamy soil of the Kanto district (moisture content being 60%) using 10 parts by weight of respective soil stabilizers according to Examples 1 to 6 in accordance with environmental standards according to soil pollution stipulated in Environment Agency Notification No. 46.
TABLE 2 Cr −6 elution quantities Material ages 14 days 28 days Soil addition DC IPC DC IPC stabilizers rates method (T-Cr) method (T-Cr) Example 1 10 <0.02 <0.02 <0.02 <0.02 Example 2 10 <0.02 <0.02 <0.02 <0.02 Example 3 10 <0.02 <0.02 <0.02 <0.02 Example 4 10 <0.02 <0.02 <0.02 <0.02 Example 5 10 <0.02 <0.02 <0.02 <0.02 Example 6 10 <0.02 <0.02 <0.02 <0.02
[0057] These figures are detection limits of Cr −6 ; the elution quantities and contents thereof are within the environmental standards.
Example 25
[0058] 30 parts by weight of the soil stabilizer according to Example 3, 70 parts by weight of volcanic ashes of Miyake Island, 5 parts by weight of burned bauxite and 53 parts by weight of water were mixed by a Hobert mixer for 10 minutes and pushed into a mortar bar formwork of 40 mm×40 mm×160 mm using a rammer to obtain a mold. 10 g of the resultant mixture was taken out of the formwork, diluted in 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 8.5. The mold without addition of the burned bauxite showed an initial set of 3 hours and 45 minutes, while that added with the burned bauxite showed an initial set of 2 hours and 54 minutes. The mold showed compression strength of 1.84 N/mm 2 and 26.2 N/mm 2 at material ages of 7 days and 28 days, respectively.
Example 26
[0059] 0.001 g of Accofloc B-1 (copolymer of polyacrylic acid and polyacrylamide) was dissolved in water and then added into 1000 ml of organic sludge having a moisture content of 400% (specific gravity being 1.12). The thus prepared sludge having Accofloc was mixed with 150 parts by weight of the soil stabilizer by a Hobert mixer for ten minutes according to Example 4 and flowed into a formwork of 50 φ×100 mm to obtain a mold. 10 g of the resultant mixture was taken out of the form work, diluted with 100 cc of deionized water and subjected to a pH measurement to obtain a pH value of 8.2. The mold showed compression strength of 0.02 N/mm 2 and 0.11 N/mm 2 at material ages of 7 days and 28 days, respectively. When a solidified product of this mold was held in the air, it underwent dehydration whereupon the weight thereof was decreased from 286 g to 57.2 g in 14 days while, when it was immersed in water, it was in sandy form and did not return to sludge.
Example 27
[0060] 1000 ml of sewage activated sludge having a moisture content of 600% (specific gravity being 1.04) was neutralized by 8 g of MgO , added with an aqueous solution comprising 0.005 g of Accofloc A-3 (copolymer of polyacrylic acid and polyacrylamide), added with 50 parts by weight of the soil stabilizer according to Example 4 and well mixed. The resultant mixture was stood still for 4 hours to form a flock. After a supernatant liquid of the mixture was removed therefrom, the mixture was subjected to a filtering operation by a filter press to obtain a dehydrated cake having a moisture content of 64%. If neutralization was performed by lime, ammonium gas was generated; however, when performed by MgO, no ammonium gas was generated whereupon the resultant dehydrated cake was scarcely smelled.
Example 28
[0061] 1000 cc of sewage activated sludge having a moisture content 600% (specific gravity being 1.04) was neutralized by 8 g of MgO, added with an aqueous solution comprising 4.5 g of aluminum sulfate, added with 150 parts by weight of the soil stabilizer according to Example 4 and well mixed. The resultant mixture was stood still for 4 hours to form a flock. After a supernatant liquid of the mixture was removed therefrom, the mixture was subjected to a filtering operation by a filter press to obtain a dehydrated cake having a moisture content of 52%. Though ammonium content in sewage was enough to generate gas, there was no generation of ammonium gas during neutralization by MgO whereupon the resultant dehydrated cake was scarcely smelled.
|
To provide a novel cement which is alkalescent, capable of solidifying a wide range of soil and applicable to biological environment. That is, a cement composition comprising 100 parts by weight of magnesium oxide comprising 5 to 25% by weight of at least any one of silicic acid, alumina and iron oxide, 3 to 35 parts by weight of a phosphate, 2 to 30 parts by weight of gypsum and 0.005 to 7 parts by weight of an oxycarboxylic acid or a ketocarboxylic acid.
| 2
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of U.S. Provisional Application for Patent Serial No. 60/404,069, filed Aug. 16, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to the slicing of ready to eat meat logs or chubs.
BACKGROUND
[0003] Ready-to-eat (“RTE”) meat logs, or chubs, are rolls of processed meat which can be, for example, of a diameter from about 3 to about 6 inches, and up to about 72 inches in length. After the meat logs are processed, i.e., prepared, they must be sliced for market. In order to slice the meat logs in a cost effective manner, especially in consideration of the amount of material that must be sliced, it is necessary to cool and preferably freeze the surface layer of the meat log for proper and effective slicing. The cylindrical shape of the meat log makes them difficult to freeze in standard chilling tunnels and, in those situations where the crust is frozen unevenly, the slicing process is less effective and the cutting device becomes clogged with the meat material.
[0004] The market for ready-to-eat (“RTE”) products offered in supermarkets is increasing, as is the need for cost-effective slicing processes.
[0005] An unfrozen meat log impacted by a slicing blade is cut less effectively and less accurately than would be the case when using a surface frozen meat log. Conventional meat log cutting apparatus, upon retraction of the blade for a subsequent cut, cause portions of the product to adhere to the blade, which portions are flung about the processing area, while some of the material is retained on the blade surface during the subsequent cut. This causes increased maintenance and repair of the blade and support for the machinery, and is a less effective processing of the meat log. In machines conducting 1000 slices a minute, this could translate into a 5-15 percent loss of product.
[0006] Typical meat log processing apparatus include the following:
[0007] 1. Conveyer belts upon which the food product is conveyed to a chilling region, which chills only one side of the meat log.
[0008] 2. A plurality of meat logs are loaded in bulk into a large cryogen freezer, and the cooling medium is circulated about the meat logs in order to cool them to where the meat logs are ready for slicing.
[0009] However, these known processes take from 15 minutes to 4 hours, depending upon the equipment installed and the consistency of the composition of the meat logs. These known apparatus and methods are not cost effective, are time consuming, and consume large amounts of floor space.
[0010] Other apparatus and methods of crust-freezing meat products in preparation for cutting or slicing operations are disclosed in U.S. Pat. No. 4,943,442, which is directed to a method and apparatus for forming a frozen crust on a preformed meat body by direct immersion of a pumped, meat stream in liquid nitrogen in a freezer, followed by downstream severing and patty formation; and in U.S. Pat. No. 5,352,472, which is directed to a method and apparatus for freezing the surface of loaf-shaped meat products by compressing the loaf against a refrigerated contact surface prior to slicing. These apparatus and methods involve direct contact with either a liquid or solid heat exchange medium.
[0011] It would therefore be desirable to have a high gas-flow cruster apparatus and method, which uniformly freezes the exterior surface crust of the meat log and also is adapted to conform to the shape of the meat log for effective and accurate processing thereof.
SUMMARY
[0012] An apparatus is provided for surface crust freezing of a food product comprising: a shell enclosing a freezing chamber, the freezing chamber having a cavity shaped to substantially accommodate a shape of the exterior surface of the food product; the cavity in communication with the shell; a transport substrate to carry the food product within the freezing chamber; a cryogen supply; and a gas circulation device in the shell in communication with the cryogen supply to introduce a cooling flow of gas containing cryogen into the cavity to contact the food product along its exterior surface.
[0013] In one embodiment in which the food product is cylindrical in shape, the freezing chamber comprises an impingement cylinder having openings substantially across its length for communicating the cooling flow from the gas circulation device into cooling impingement jets of cryogen directed perpendicular to the surface of the food product.
[0014] In another embodiment in which the food product is cylindrical in shape, the freezing chamber comprises a cylinder having an opening for communicating the cooling flow from the gas circulation device along the interior of the cavity parallel to the exterior and longitudinal axis of the food product.
[0015] In another embodiment, the freezing chamber includes at least one open mesh basket adapted to accommodate the shape of the food product, the basket is carried on a drive wheel through a substantially ovaloid (that is, circular or oval) impingement chamber within the shell, the impingement chamber having impingement holes about its circumference communicating with the shell exteriorly and the freezing chamber interiorly, the basket being adapted to rotate in relation to the drive wheel such that the entire exterior of the food product is exposed to the cooling flow from the gas circulation device into the cooling impingement jets of cryogen directed through the impingement holes from the exterior of the impingement chamber substantially perpendicular to the surface of the food product. The interior of the impingement chamber is in communication with the gas circulation device to recirculate gas and cryogen to the gas circulation device.
[0016] In yet another embodiment, the freezing chamber includes at least one open mesh basket adapted to accommodate the shape of the food product, the basket is carried on a drive wheel through an elongated, substantially ovaloid (that is, circular or oval) elongated shell within the shell, the elongated shell communicating with the shell exteriorly and the freezing chamber interiorly, the basket being adapted to rotate in relation to the drive wheel such that the entire exterior of the food product is exposed to the cooling flow from the gas circulation device along the interior of the elongated shell parallel to the exterior and longitudinal axis of the food product.
[0017] A method of surface crust freezing of a food product is provided comprising: transporting the food product into a freezing chamber having a cavity shaped to substantially accommodate the shape of the exterior surface of the food product; and, introducing a cooling flow of gas containing cryogen into the cavity so as to contact the food product along its exterior surface.
[0018] In one embodiment, the method includes communicating the cooling flow into cooling impingement jets of cryogen directed perpendicular to the surface of the food product.
[0019] In another embodiment, the method includes communicating the cooling flow along the interior of the cavity parallel to the exterior and longitudinal axis of the food product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The accompanying drawings are included 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, but are not intended to limit the invention as encompassed the claims of the application.
[0021] [0021]FIG. 1 is a perspective view of an RTE meat log inside a cylinder where impingement flow is employed.
[0022] [0022]FIG. 2 is a perspective view of an RTE meat log inside a cylinder where cross flow is employed.
[0023] [0023]FIG. 3 is a cross-sectional view of one embodiment of the cruster apparatus.
[0024] [0024]FIG. 4 is a cross-sectional view along the longitudinal length of the embodiment of FIG. 3 of the cruster apparatus.
[0025] [0025]FIG. 5 is a cross-sectional view of another embodiment of the cruster apparatus.
[0026] [0026]FIG. 6 is a cross-sectional view of a further embodiment of the cruster apparatus.
[0027] [0027]FIG. 7 is a perspective view of the embodiment of FIG. 6 of the cruster apparatus.
[0028] [0028]FIG. 8 is a cross-sectional view of another embodiment of the cruster apparatus.
[0029] [0029]FIG. 9 is a cross-sectional view along the longitudinal length of the embodiment of FIG. 8 of the cruster apparatus.
[0030] [0030]FIG. 10 is a cross-sectional view of yet another embodiment of the cruster apparatus.
[0031] [0031]FIG. 11 is a cross-sectional view along the longitudinal length of the embodiment of FIG. 10 of the cruster apparatus.
DETAILED DESCRIPTION
[0032] The present apparatus and method provides for a uniform freezing (“crusting”) of the meat log to a selected depth from the meat log surface, preferably {fraction (1/4)} inch, which crusting is uniform throughout the surface of the meat log, in order to overcome the disadvantages of known apparatus and methods. Freezing or crusting time for apparatus and process disclosed herein is about 1½ minutes to about 2 minutes.
[0033] The apparatus provides a cylindrically shaped freezing section that crusts a meat log product uniformly and much more efficiently than known chilling tunnels. In one embodiment, an impinging-type gas flow is employed which is directed uniformly along an exterior surface of the meat log, disposed within a cylindrically shaped chamber, so that the high velocity and perpendicular impingement heat transfer is effected along the entire surface of the meat log. In an alternative embodiment, a cross-flow gas flow is used, wherein the gas moves at high velocities parallel to a surface or longitudinal axis of the meat log. This embodiment produces comparable surface heat transfer coefficients to that of the impingement heat transfer embodiment.
[0034] Each of the embodiments described provides for a very cold surface crust (approximately ¼ inch deep) to be rapidly achieved by the meat log. Upon removal from the apparatus, the meat log can be sped to a high-speed slicer, wherein the crusting process permits a uniform, neat, and cost effective slicing operation.
[0035] As an example, one embodiment of the apparatus and process utilizes impingement type gas flow of cryogen, such as carbon dioxide or nitrogen gas, in a straight pass-through configuration. The meat log is loaded into one end of the apparatus, and is removed with a full frozen crust at the opposite end. A plurality of screw-type conveyors may be used to convey the product through the freezing apparatus and process. This method is effective for freezing round, cylindrical shaped meat logs. As a result of the conveying process, the meat log is rotated while it is frozen, eliminating the need for a moving impingement cylinder. Since meat logs are produced in a number of various cross-sectional shapes, other embodiments of the apparatus and process accommodate these shapes. The “cryogen” discussed in this Specification may include solid or liquid carbon dioxide or nitrogen, provided by a cryogen supply and mixed with the respective cryogenic gas to form a cooling gas flow.
[0036] In certain embodiments, the meat log is conveyed for crusting along a passage formed between a pair of dual hemispheres or impingement plates through which a cooling flow of a cryogen, such as carbon dioxide or nitrogen gas, is circulated to crust the meat log. In an alternative embodiment, the arrangement of the dual hemisphere impingement plates may be set off to the side, as opposed to being beneath the blower which circulates the cryogen. The conveyer in these embodiments may be a screw-type system, where the meat log has a circular cross-section. However, if the cross-section of the meat log is other than round, the conveyer may comprise belts. In yet another embodiment, the apparatus is inverted to facilitate cleaning beneath the apparatus, and between the apparatus and the underlying surface.
[0037] In alternative embodiments, the blower may be opposite the slot so that gas is drawn through the cylinder. That is, the blower may be positioned at an exit of the impingement cylinder and the slot at an entrance to the impingement cylinder.
[0038] In certain embodiments, a “rotary type” meat log crusting apparatus may be employed, again utilizing impingement type gas flow. The meat logs may be loaded and discharged at one port, for example by being placed in a stainless steel mesh basket, and being conveyed between two cylinders. One complete rotation will result in all surfaces of the product being frozen. Centrifugal fans mounted to the sidewall of the freezer provide the high-pressure cryogen gas to the impingement cylinders.
[0039] Another “rotary type” apparatus embodiment utilizes cross-flow type gas movement. The meat log is conveyed along a similar path as described above. However, without using impingement cylinders, the total space required for freezing is significantly reduced. As in the above embodiment, the meat logs are conveyed in mesh baskets and centrifugal fans provide the necessary gas flows. The cryogen gas is forced along the surface of the meat log and is circulated back into the fans, as the process continues.
[0040] Food freezing apparatus and methods are disclosed in U.S. Pat. Nos. 4,803,851; 6,263,680; and 6,434,950; and in U.S. Published Patent Application No. 2001/0025495, all assigned to The BOC Group. These patents and application are incorporated by reference herein, as if fully written below.
[0041] For a more complete understanding of the apparatus and process, reference may be had to FIGS. 1 to 11 shown in connection with the description of various the embodiments.
[0042] The flow patterns of the various embodiments of the cruster apparatus are generally described in FIGS. 1 and 2. The cylinders 12 and 16 are used for exemplary purposes to illustrate the flow patterns used to freeze the surface layers of the RTE meat logs in the various embodiments of the apparatus and process. In FIG. 1 the surface layer of an RTE meat log 13 is frozen to a specified depth with impingement flow of a cooling flow. For example, the cylinder 12 is provided with holes 14 up and down its length, and the holes 14 provide for communication between the interior cavity 37 and exterior of the cylinder 12 . Therefore, when the cooling flow is directed toward the cylinder 12 , it is focused by the holes 14 into various cooling jets 15 . Inside the cylinder 12 , the cooling jets 15 are perpendicular to the exterior of the RTE meat log 13 . As the cooling jets 15 impinge the exterior of the RTE meat log 13 , the cooling jets 15 absorb heat, and subsequently freeze the surface layer of the RTE meat log 13 . The impingement flow as described hereinabove is used in the first, second, third, and fourth embodiments described hereinafter, to freeze the surface layer of the RTE meat logs.
[0043] In FIG. 2, the surface layer of an RTE meat log 17 is frozen to a specified depth with cross flow of a cooling flow 18 . For example, the cylinder 16 is provided with a slot 19 , and the slot 19 allows for communication between the interior cavity 37 and exterior of the cylinder 16 . Therefore, when the cooling flow 18 is directed toward the cylinder 16 , it enters the slot 19 , and moves at a high velocity parallel to the exterior of and along the longitudinal axis of the RTE meat logs 17 . As the cooling flow 18 is applied to the exterior of the RTE meat log 17 , the cooling flow 18 absorbs heat, and subsequently freezes the surface layer of the RTE meat log 17 . The cross flow as described hereinabove is used in the fifth embodiment of the apparatus and process to freeze the surface layer of the RTE meat logs.
[0044] As shown in FIGS. 3 and 4, the first embodiment of the cruster using impingement flow is generally indicated by the numeral 20 . The impingement cruster 20 includes a refrigeration shell 21 having a ceiling 22 , a floor 23 , and side walls 24 and 25 . The refrigeration shell 21 has an entrance 26 and exit 27 , and functions as a tunnel freezer for freezing the surface layer of the RTE meat log 30 .
[0045] Extending through the ceiling 22 is a motor shaft 31 attached to a motor 32 . The motor 32 is located on the exterior surface of the ceiling 22 , and is provided with an electrical supply (not shown). The motor 32 drives a blower assembly 33 , and the blower assembly 33 includes an impeller 34 and a volute 35 . The blower assembly 33 is attached to an impingement shell 40 using a shroud 36 , and is used to circulate and re-circulate gas around the impingement shell 40 .
[0046] The impingement shell 40 is formed from hemispherical impingement plates 41 and 42 , and is supported in the interior of the refrigeration shell 21 using support legs 38 and 39 . As shown in FIG. 3, the impingement shell 40 is cylindrically shaped to accommodate the cylindrical shape of the RTE meat log 30 . That is, the hemispherical impingement plates 41 and 42 effectively envelop the cylindrical shape of the RTE meat log 30 . However, the impingement shell 40 can be adapted to accommodate RTE meat logs having different shapes.
[0047] As shown in FIG. 4, the impingement shell 40 extends through the longitudinal length of the refrigeration shell 21 . Furthermore, as shown in FIG. 3, a conveyer system 44 consisting of two rotating screws 45 and 46 is provided on the interior cavity 37 of the impingement shell 40 . The rotating screws 45 and 46 support the RTE meat log 30 inside the impingement shell 40 , and are used to convey the RTE meat log 30 along the longitudinal lengths of the refrigeration shell 21 and impingement shell 40 . Furthermore, as the rotating screws 45 and 46 move the RTE meat log 30 through the impingement shell 40 , the rotating screws 45 and 46 simultaneously rotate the RTE meat log 30 .
[0048] The rotation of the RTE meat log 30 allows a cooling flow 47 supplied by the blower assembly 33 to be applied uniformly to the exterior of the RTE meat log 30 . For example, the impingement shell 40 is provided with holes (or apertures) 48 , and these holes 48 allow the cooling flow 47 to enter, and be spread throughout the interior cavity 37 of impingement shell 40 .
[0049] The cooling jet pattern 50 created by cooling flow 47 inside the impingement shell 40 is shown in FIG. 3. Various cooling jets are formed as the cooling flow 47 passes through the holes 48 . The cooling flow 47 may comprise a cryogenic gas (CO or N 2 ), and the heat of the RTE meat log 30 is absorbed when the cooling flow 47 impinges the exterior of the RTE meat log 30 . As such, the uniform application of the cooling jet pattern 50 to the exterior of the RTE meat log 30 uniformly freezes the surface layer of the RTE meat log 30 to a selected depth. In practice, the RTE meat log 30 is loaded onto the conveyer system 44 and into the impingement shell 40 at the entrance 26 of the refrigeration shell 21 , and is subsequently removed from the exit 27 with a frozen surface layer.
[0050] After the cooling jet pattern 50 is applied to the exterior of the RTE meat log 30 , the reflected gas flow 51 is drawn by the impeller 34 into the blower assembly 33 , and is subsequently re-circulated. For example, the impeller draws the reflected gas flow 51 into the shroud 36 . The shroud 36 communicates with the interior cavity 37 of the impingement shell 40 , and encloses an opening therein. After entering the shroud 36 , the impeller 34 draws the reflected gas flow 51 through the volute 35 . The volute 35 acts as the entrance to the impeller 34 . After entering the impeller 34 , the reflected gas flow 51 is mixed with the above-discussed cryogen, and subsequently re-circulated as the cooling flow 47 .
[0051] Attached to the exterior of the impingement shell 40 are vibrators 56 and 57 . The vibrators 56 and 57 can be pneumatically or mechanically actuated, and are used to prevent snow and ice from building up inside the holes provided in the impingement shell 40 . The frequency and time intervals of the vibrations provided by the vibrators 56 and 57 are dependent on the process conditions, including the moisture content of the RTE meat log 30 , the humidity of the ambient air in and outside the refrigeration shell 21 , and the temperature on the interior of the refrigeration shell 21 .
[0052] As shown in FIG. 5, the second embodiment of the cruster apparatus using impingement flow is generally indicated by the numeral 60 . The impingement cruster 60 includes a refrigeration shell 61 having a ceiling 62 , a floor 63 , and side walls 64 and 65 . Like refrigeration shell 21 , the refrigeration shell 61 functions as a tunnel freezer for freezing the surface layer of an RTE meat log 30 is frozen. However, unlike the refrigeration shell 21 , the motor shaft 31 extends through the floor 63 . The motor shaft 31 is attached to a motor 32 , and the motor 32 is located on the exterior surface of the floor 63 . As such, the legs 66 and 67 support the refrigeration shell 61 , and provided clearance for the motor 32 .
[0053] Like the impingement cruster 20 , the motor 32 in the impingement cruster 60 drives the blower assembly 33 , and the blower assembly 33 is used to circulate and re-circulate gas around the impingement shell 40 . However, in the impingement cruster 60 and refrigeration shell 61 , the blower assembly 33 is inverted. For example, a support plate 68 is provided inside the refrigeration shell 61 . The support plate 68 extends between the side walls 64 and 65 , and carries the support legs (not shown) supporting the impingement shell 40 . Consequently, the volute 35 is provided below the support plate 68 , the shroud 36 is provided above the support plate 68 , and a opening (not shown) in the support plate allows the volute 35 and shroud 36 to communicate.
[0054] Other than the different configuration, the impingement cruster 60 operates like the impingement cruster 20 . That is, as the RTE meat log 30 is conveyed and rotated by the conveyer system, the cooling flow supplied by the blower assembly 33 enters the impingement shell 40 , and a cooling jet pattern is applied uniformly to the exterior of the RTE meat log 30 . The uniform application of the cooling jet pattern to the exterior of the RTE meat log 30 uniformly freezes the surface layer of the RTE meat log 30 to a selected depth. After the cooling jet pattern impinges the exterior of the RTE meat log 30 , the reflected gas flow is drawn by the impeller 34 through the shroud 36 into the volute 25 , and is subsequently re-circulated by the blower assembly 33 .
[0055] As shown in FIGS. 6 and 7, the third embodiment of the cruster apparatus using impingement flow is generally indicated by the numeral 70 . The impingement cruster 70 includes a refrigeration shell 71 having a ceiling 72 , a floor 73 , and side walls 74 and 75 . Like refrigeration shells 21 and 61 , the refrigeration shell 71 functions as a tunnel freezer for freezing the surface layer of an RTE meat log 30 . Furthermore, like the refrigeration shell 21 , but unlike the refrigeration shell 61 , the motor shaft 31 extends through the ceiling 72 . The motor shaft 31 is attached to a motor 32 , and the motor 32 is located on the exterior surface of the ceiling 72 .
[0056] Like the impingement crusters 20 and 60 , the motor 32 in the impingement cruster 70 drives the blower assembly 33 , and the blower assembly 33 is used to circulate and re-circulate gas around the impingement shell 40 . However, in the impingement cruster 70 and refrigeration shell 71 , a low pressure plenum 76 and shroud 77 are used. For example, the impingement shell 40 is attached to the low pressure plenum 76 using brackets 78 . The shroud 77 provides for communication between the interior cavity 37 of the impingement shell 40 and the low pressure plenum 76 .
[0057] When operating, the cooling flow supplied by the blower assembly 33 enters the impingement shell 40 through holes 48 to create cooling jet pattern 50 . The uniform application of the cooling jet pattern 50 the exterior of the RTE meat log 30 uniformly freezes the surface layer of the RTE meat log 30 to a selected depth. Furthermore, after the cooling jet pattern 50 is applied to the exterior of the RTE meat log 30 , the reflected gas flow is drawn by the impeller 34 into the lower pressure plenum 76 through the shroud 77 , and is subsequently re-circulated by the blower assembly 33 .
[0058] As shown in FIGS. 8 and 9, the fourth embodiment of the cruster apparatus using impingement flow is generally indicated by the numeral 100 . The impingement cruster 100 includes a cube-shaped refrigeration shell 101 having a ceiling 102 , a floor 103 and side walls 104 , 105 , 106 and 107 . The impingement cruster 100 is supported by pedestals 108 and 109 attached to the exterior surface of the floor 103 .
[0059] Extending through the side wall 107 are motor shafts 112 and 113 attached to motors 114 and 115 . The motors 114 and 115 are located on the exterior surface of the side wall 107 , and are provided with an electrical supply (not shown). The motors 114 and 115 are used to rotate blowers 116 and 117 attached to the motor shafts 112 and 113 . As will be discussed hereinbelow, the blowers 116 and 117 are used to circulate and re-circulate gas around the interior of the refrigeration shell 101 .
[0060] Supported on the interior of the refrigeration shell 101 is a cup-shaped impinger 118 . The cup-shaped impinger 118 is partially formed from concentric impingement cylinders 120 and 121 . As shown in FIG. 9, the impingement cylinder 120 has a larger diameter than impingement cylinder 121 . Furthermore, the impingement cylinder 120 also has a longer length than the impingement cylinder 121 .
[0061] To form the cup shape of the cup-shaped impinger 118 , the space between the impingement cylinders 120 and 121 is enclosed using a ring-shaped plate 124 , and circular-shaped plates 125 and 126 . For example, the ring-shaped plate 124 is joined to the diameters of the impingement cylinders 120 and 121 , and encloses one end of the cup-shaped impinger 118 . Furthermore, to enclose the other end of the cup-impinger 118 , the circular-shaped plate 125 is joined around the circumference of the impingement cylinder 120 and the circular-shaped plate 126 is joined around the circumference of the impingement cylinder 121 . As such, the impingement cylinders 120 and 121 , along with the ring-shaped plate 124 and the circular plates 125 and 126 form the cup-shaped impinger 118 . Like the above-referenced impingement shell 40 , the cup-shaped impinger 118 is provided with holes 128 . The holes 128 extend through the impingement cylinders 120 and 121 , and allow for communication between the interior of the refrigeration shell 101 and the interior of the impinger 118 .
[0062] Supported on the interior of the cup-shaped impinger 118 is a drive wheel 131 . The drive wheel 131 supports a plurality of conveying baskets 132 at various positions around the circumference of the cup-shaped impinger 118 . The conveying baskets 132 are hinged to the drive wheel 131 , and, like the baskets of a ferris wheel, the orientation of the conveying baskets 132 adjusts with respect to the drive wheel 131 as the drive wheel 131 rotates. The conveying baskets 132 are composed of wire mesh, and, as shown in FIG. 9, extend through the interior of the cup-shaped impinger 118 .
[0063] Carried by each of the conveying baskets 132 are RTE meat logs 133 . The individual conveying baskets 132 are adapted to accommodate the shape of the RTE meat logs 133 . Consequently, as the drive wheel 131 rotates, the conveying baskets 132 and RTE meat logs 133 are rotated within the interior of the cup-shaped impinger 131 . As will be discussed hereinbelow, the rotation of the drive wheel allows the surface layer of the RTE meat logs 133 to be frozen.
[0064] As the drive wheel rotates inside the cup-shaped impinger 118 , cooling flows 134 and 135 are provided by the blowers 116 and 117 . The cooling flows 134 and 135 circulate around the interior of the refrigeration shell 101 and the exterior of the cup-shaped impinger 118 , and ultimately enter the interior of the cup-shaped impinger 118 through holes 128 . As the cooling flows 134 and 135 enter the holes 128 various cooling jets (not shown) are formed. The cooling jets ultimately impinge the exterior of the RTE meat log 133 . The cooling flows 134 and 135 consist of a cryogenic gas (CO or N 2 ), and the heat from the RTE meat logs 133 is absorbed when cooling jets formed from the cooling flows 134 and 135 are applied to the exterior of the RTE meat logs 133 .
[0065] An inlet 136 and an outlet (not shown) are provided near the bottom of the refrigeration shell 101 , and a conveyer system 138 extends therethrough. The inlet 136 allows RTE meat logs 133 to be loaded and the outlet allows RTE meat logs 133 to be unloaded via the conveyer system 138 into the conveying baskets 132 . As such, the conveying system effectively allows the individual RTE meat logs 133 to be loaded and subsequently unloaded from the conveying baskets 132 as the drive wheel 131 rotates between various positions.
[0066] In practice, each of the RTE meat logs 133 is loaded into the conveyor baskets 132 via the conveyor system 138 at the inlet 136 . The rotation of the drive wheel 131 , enables each of the RTE meat logs 133 to complete at least one rotation around the interior of the cup-shaped impinger 118 . During the rotation of the RTE logs 133 around the interior of the cup-shaped impinger 118 , the uniform application of the cooling flows 134 and 135 to the exterior of the RTE meat logs 133 uniformly freezes the surface layer of the RTE meat logs 133 to a selected depth. After at least one rotation around the interior of the cup-shaped impinger 118 , each of the RTE meat logs 133 is unloaded from the conveying baskets 132 at the outlet.
[0067] As described hereinabove, the cooling jets formed from the cooling flows 134 and 135 freeze the surface layer of the RTE meat logs 133 . However, after the cooling jets impinge the exterior of the RTE meat logs 133 , the reflected gas flows 140 and 141 are drawn from the interior of the cup-shaped impinger 118 through the holes 142 and 143 and into the blowers 116 and 117 . The holes 142 and 143 are provided in the circular-shaped plate 125 , and allow the reflected gas flows 140 and 141 to enter the blowers 116 and 117 to be re-circulated as cooling flows 134 and 135 .
[0068] As shown in FIGS. 10 and 11, the fifth embodiment of the cruster apparatus using cross flow is generally indicated by the numeral 200 . The cruster 200 includes a box-shaped refrigeration shell 201 having a ceiling 202 , a floor 203 and side walls 204 , 205 , 206 and 207 . The cruster 200 is supported by pedestals 208 and 209 attached to exterior surface of the floor 203 .
[0069] Extending through the side wall 207 are motor shafts 212 , 213 , and 214 attached to motors 216 , 217 , and 218 . The motors 216 , 217 , and 218 are located on the exterior surface of the side wall 207 , and are provided with an electrical supply (not shown). The motors 216 , 217 , and 218 are used to rotate blowers 220 , 221 , and 222 attached to the motor shafts 212 , 213 , and 214 . As will be discussed hereinbelow, the blowers 220 , 221 , and 222 are used to circulate and re-circulate gas around the interior of the refrigeration shell 101 .
[0070] Supported on the interior of the refrigeration shell 201 is an oval-shaped plate 225 with holes 226 , 227 , and 228 . Extending from the perimeter of the oval-shaped plate 225 is an elongated shell 230 having an oval cross-section. Furthermore, provided adjacent the blowers 220 , 221 , and 222 is an oval-shaped baffle 231 .
[0071] Supported on the interior of the refrigeration shell 201 is a drive wheel 241 . The drive wheel 241 supports a plurality of conveying baskets 242 at various positions. The conveying baskets 242 are hinged to the drive wheel 241 , and, like the baskets of a ferris wheel, the orientation of the conveying baskets 242 adjusts with respect to the drive wheel 241 as the drive wheel 241 rotates. The conveying baskets 242 are composed of wire mesh, and, as shown in FIGS. 10 and 11, are encapsulated inside the elongated shell 230 along with the drive wheel 241 .
[0072] Carried by each of the conveying baskets 242 are RTE meat logs 243 . The individual conveying baskets 242 are adapted to accommodate the shape of the RTE meat logs 243 . Like the conveying baskets 132 , the conveying baskets 242 are composed of wire mesh. As will be discussed hereinbelow, as the drive wheel 241 rotates, the conveying baskets 132 and RTE meat logs 243 are rotated within the interior of the elongated shell 230 , and the rotation of the drive wheel 241 allows the surface layer of the RTE meat logs 243 to be frozen.
[0073] As the drive wheel rotates inside the elongated shell 230 , a cooling flow 244 is provided by the blowers 220 , 221 , and 222 . The cooling flow 244 circulates around the inside of the elongated shell 230 . For example, the oval-shaped baffle 231 causes the cooling flow 244 to be directed outwardly from the blowers 220 , 221 , and 222 toward the conveying baskets 242 and RTE meat logs 243 . However, the elongated shell 230 captures the cooling flow 244 , and ensures that the cooling flow is adequately applied to the RTE meat logs 243 . The cooling flow 244 is a cross flow which moves at a high velocity parallel to the exterior along the longitudinal axis of the RTE meat logs 243 . As shown in FIG. 10, parts of the cooling flow 244 are disposed adjacent the conveying baskets 242 and RTE meat logs 243 . The cooling flow 244 consists of a cryogenic gas (CO or N 2 ), and the heat from the RTE meat logs 243 is absorbed when the cooling flow 244 is applied to the exterior of the RTE meat logs 243 . Overall, the heat transfer coefficients of the cooling flow 244 is comparable to the heat transfer coefficients of the cooling jets formed from the cooling flows 134 and 135 when using impingement flow.
[0074] An inlet 246 and an outlet (not shown) are provided near the bottom of the refrigeration shell 201 , and a conveyer system 248 extends therethrough. The inlet 246 allows RTE meat logs 243 to be loaded and the outlet allows RTE meat logs 243 to be unloaded via the conveyer system 248 into the conveying baskets 242 . As such, the conveying system effectively allows the individual RTE meat logs 243 to be loaded and subsequently unloaded from the conveying baskets 242 as the drive wheel rotates between various positions.
[0075] In practice, each of the RTE meat logs 243 are loaded into the conveyor baskets 242 via the conveyor system 248 at the inlet 246 . The rotation of the drive wheel 241 , enables each of the RTE meat logs 243 complete at least one rotation around the inside of the elongated shell 230 . During the rotation of the RTE logs 243 around the inside of the elongated shell 230 , the uniform application of the cooling flow 244 to the exterior of the RTE meat logs 243 uniformly freezes the surface layer of the RTE meat logs 243 to a selected depth. After at least one rotation around the inside of the elongated shell 230 , each of the RTE meat logs 243 are unloaded from the conveying baskets 242 at the outlet.
[0076] As described hereinabove, the cooling flow 244 freezes the surface layer of the RTE meat logs 243 . However, after the cooling flow 244 is applied to the exterior of the RTE meat logs 243 , the remaining gas flows 250 and 251 flow around the outside of the elongated shell 230 and into the blowers 220 , 221 , and 222 . The holes 226 , 227 , and 228 allow the remaining gas flows 250 and 251 to pass into the blowers 220 , 221 , and 222 , and be re-circulated as cooling flow 244 .
[0077] Each of the embodiments of the cruster apparatus act to rapidly freeze the surface layer of the RTE meat logs to approximately 0.25 inch deep. Upon removal from the various embodiments, the RTE meat logs can be transferred to a cutting blade to be sliced. The frozen surface layer of the RTE meat logs allows for a uniform, neat, and cost-effective slicing operation as described hereinabove.
[0078] All dimensions and parameters discussed with respect to all the embodiments are by way of example and not limitation. It will be appreciated that other sizes and shapes of the apparatus and its component parts may be employed. Although the invention has been described in detail through the above detailed description and the preceding examples, these examples are for the purpose of illustration only and it is understood that variations and modifications can be made by one skilled in the art without departing from the spirit and the scope of the invention. It should be understood that the embodiments described above are not only in the alternative, but can be combined.
|
An apparatus and method for surface crust freezing of a food product utilizes a refrigeration shell enclosing a freezing chamber, the freezing chamber having a cavity shaped to substantially accommodate the shape of the exterior surface of the food product; the cavity communicating with the refrigeration shell; a transport substrate to carry the food product into the freezing chamber; a cryogen supply; and a gas circulation device in the refrigeration shell in communication with the cryogen supply to introduce a cooling flow of gas containing cryogen into the cavity so as to contact the food product along its exterior surface.
| 5
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to fuel additives for improving thermal efficiency of petroleum fuel such as gasoline or gas oil and reducing the production of pollutive gases upon combustion.
2. Prior Art
In general, as to ignition engine such as automobile engine, the higher the compression ratio is, the higher the thermal efficiency and performance are, and the lower the fuel cost is. When regular gasoline is used, the high compression tends to cause abnormal combustion or knocking, and the thermal efficiency is decreases as a result.
In order to prevent this, gasoline with a high octane number which has an anti-knocking effect is used to raise the compression ratio and improve the thermal efficiency. However, gasolines with high octane number which are produced by mixing various gasoline components in an appropriate ratio are expensive.
Oxidation of gasoline reduces the octane number and resultant high-molecular weight gum increases fuel consumption. Therefore an anti-oxidizing agent ought to be added to commercial gasoline.
On the other hand, as to oil used for gas engines (compression--ignition engines), stability, fluidity and ignitability are the critical properties. Therefore, gas oil with a high octane number is necessary, although it is expensive compared to the ordinary gas oil.
Another drawback is that oxidation of gas oil produces a high-molecular weight gum. If the amount of the high-molecular weight gum produced is high, it blocks the injection nozzle and hence impedes the supply of the fuel.
In order to prevent this, hydrogenation purification has been required.
The present inventor of the invention was inspired by the abundance of elements contained in seawater and the reaction of an alkaline agent in the combustion process, and developed a combustion aid by dissolving a specific alkaline agent into seawater (Jap. Pat. Laid-open Publ. No. 63-225695), and achieved a marvelous success. This combustion aid (liquid) proved to be especially effective when sprayed into the engine and led to the development of a system for adding this combustion aid to the engine (Jap. Pat. Laid-open Publ. No. 63-147938, Jap. Pat. Appl. No. 62-319327)
However, this combustion aid requires modification of the engine and can not be applied to all types of engines. Above all, the above-mentioned system is designed for an engine utilizing the low pressure produced by the piston motion to send mixture of gases to the combustion chamber. When used with a turbo engine, the combustion aid must be supplied with pressure and hence requires a sophisticated system which involves technical difficulties.
SUMMARY OF THE INVENTION
The above-mentioned drawbacks in the prior art have been successfully eliminated by the present invention.
It is, therefore, the object of the present invention is to provide fuel additives for improving thermal efficiency of any kind of liquid fuel such as gasoline or gas oil by adding directly to the fuel.
Another object of the present invention is to provide fuel additives which are applicable to any kind of combustion system, and at the same time, satisfy both the need for cleaning exhaust gas and the need for improving combustion efficiency.
The fuel additives of the present invention are composed of (1) a powder obtained by removing water from an aqueous solution of the reaction product of a hydrocarbon oil and a strong alkali in seawater and (2) a solvent wherein the powder is dissolved which is soluble in the fuel which to the fuel additive is added. The fuel additives can prevent formation of acidic pollutants such as CO, NOx and the like in the combustion system, and at the same time, can achieve complete combustion of the fuel, when admixed with fuel.
These and other objects of the present invention will become apparent from the following description of preferred embodiments.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention will be described with reference to the examples to follow below but the invention is not deemed to be limited to such examples, the scope of the invention being indicated by the appended claims.
The fuel additive of the present invention is a solution which is soluble in fuel, wherein powder obtained by removing water from the combustion aid developed by the applicant is dissolved. The combustion aid from which water is to be removed is an aqueous solution of the reaction product of a hydrocarbon oil and a strong alkali in seawater.
The reaction product of a hydrocarbon oil and a strong alkali will be described hereinafter.
Petroleum fractions equivalent to or heavier than the fuel, or the like are employed as the hydrocarbon oil and they are not necessarily commercially available petroleum fractions but may alternatively be halogen-containing oils. Further, distillates obtained by fractionation (dry distillation) of vinyl resins such as plastics which are industrial wastes, foamed polystyrene, used tires or the like can be effectively utilized and such a source is preferred from the viewpoint of effective utilization of industrial waste.
As the strong alkali used here preferred are alkali materials containing calcium oxide as a major component. However, again from a practical viewpoint, there can be used alkaline products obtained by sintering shell, bone, limestone or the like at high temperatures of approximately 1000° to 1500° C. The sintered products of shell or the like at high temperatures are strongly alkaline and contain calcium oxide as a major component. When dissolved in water, such sintered materials give a strongly alkaline aqueous solution having a pH of 13. The reaction product (a) is a powdery or clay-like reaction mixture obtained by mixing the hydrocarbon oil with the strong alkali in a ratio of approximately 1:1, adding a small amount of an aqueous solution of the strongly alkaline agent thereto and stirring the mixture. The blending ratio of the hydrocarbon oil and the strong alkali, while normally approximately 1:1, is not limited thereto since the ratio will vary slightly depending upon the type of oil used. The small amount of strong alkali aqueous solution is added to accelerate the reaction of the oil with the dry strong alkali and the alkali used to form that aqueous solution may be the same strong alkali added to the hydrocarbon to form the reaction product (a). Where the dry fractionation oils used in the reaction mixture (a) contain water, it is unnecessary to add water in the preparation of (a).
An aqueous solution is obtained by dissolving the reaction product (a) in seawater. Seawater is used because, firstly, seawater is a infinite resource. Secondly, seawater contains trace amounts of various metal ions and it is believed that such metals catalytically aid combustion. Thirdly, the composition of seawater is relatively constant and can be utilized as is. It is preferred that the pH of seawater be adjusted to strongly acidic or strongly alkaline prior to mixing with the product (a), depending upon the intended use. Before dissolving the reaction product in seawater, the pH of seawater is adjusted to low or high.
In order to make seawater acidic, diluted sulfuric acid (pH 0.1 or less) or a particularly adjusted acid (hereinafter referred to as "P-S acid") as described below is added to seawater. The terminology "P-S acid" as used herein has reference to an aqueous solution obtained by adding about 5% of concentrated sulfuric acid to a strong electrolyte solution containing calcium phosphate and removing precipitates, resulting in a solution having a pH of 0.1 or less. The seawater in which the pH is lowered by addition of the P-S acid provides a good miscibility with the product (a), i.e. the reaction mixture of the hydrocarbon oil and alkali.
P-S acid or diluted sulfuric acid is added to seawater in an amount of about 5% to adjust its pH to 2 or less. The pH-adjusted seawater may be used for dissolving the reaction product. Further, the pH-adjusted seawater wherein the pH has been so lowered may be adjusted to high pH by adding a strongly alkaline agent thereto.
In order to make seawater strongly alkaline, one may use sodium hydroxide, calcium oxide or the same strong alkali as used to form the reaction product (a). By removing insoluble matters or precipitates, an aqueous solution having a pH of 13 or more can be obtained.
The reaction mixture (a) of hydrocarbon oils and a strong alkali is dissolved in the pH adjusted-seawater up to saturation. By removing insoluble matter, an aqueous solution (b) is obtained.
The solid component of the fuel additives of the present invention, powder (1) is obtained by removing water from the aqueous solution (b) by heating and evaporating. This procedure is preferably carried out under low pressure. The result of the elementary analysis of the powder (1) is shown in Table 1.
TABLE 1______________________________________ Fuel (wt %)Powder (1) (wt %) additives Seawater (mg/l)______________________________________Na 43.2 0.20 10.5K 0.72 0.009 0.380Ca 0.11 -- 0.401Sr 0.009 -- 0.008B 0.005 -- 0.0048Si -- 0.002 0.003Fe 0.005 -- --Br 0.15 0.002 --Cl 25 0.007 18.98S 2.4 0.023 0.90______________________________________
The amount of chloride in the powder (1) is considerably less than that in seawater according to the analysis, and the powder (1) is strongly alkaline.
Then the fuel additive of the present invention is obtained by dissolving the powder (1) in a solvent which is compatible with the intended fuel. The solvent satisfying this condition is preferably the mixture of alcohol and an organic solvent. Kerosene is practical as an organic solvent. The alcohol may be methanol, butanol, mixture of those alcohols or the like.
The ratio of kerosene and alcohol or the like is selected according to fuel with which the addition is to be used. When gasoline or light gas is used for fuel, it is preferable that the solvent of the fuel additive contains at least 10% of butanol therein.
The concentration of the powder (1) in the solvent is about 1%. It is preferred to prepare a stock solution in which several % of the powder (1) is dissolved and then to adjust the concentration and composition of solvent by adding a proper solvent to match with fuel used. The result of the elemental analysis of the stock solution is shown in Table 1.
As described hitherto, the fuel additives of the present invention are applied directly to the fuel, such as gasoline, light gas or heavy oil. The amounts of the fuel additives to be added differ according to the kind of the fuel. Generally, 0.1-0.3% is added in gasoline, 0.3-0.5% in light gas and approximately 1% in heavy oil.
By adding the fuel additives of the present invention to these fuels, the condition of combustion is improved considerably, the fuel cost decreases and the toxic gases such as CO, NOx are suppressed.
EXAMPLE
1. Preparation of P-S acid
50 g of a powder consisting mainly of calcium phosphate obtained by sintering animal bones was dissolved in 1 liter of pure water. Then 5% of conc. sulfuric acid was added to the aqueous solution to give a strongly acidic aqueous solution having a pH of 0.2 (P-S acid).
2. Adjustment of pH of seawater
To 500 liters of seawater was added 10 liters of the P-S acid described above. After allowing to stand for 3 hours, impurities were filtered off. As a result, the seawater had a pH of 1.6. Then, 3% of sodium hydroxide was added thereto. After allowing to stand overnight, precipitates were removed to give seawater having a pH of 13.7.
3. Preparation of a reaction product
500 g of the strong alkali obtained by sintering limestones at high temperatures of approximately 1000° to 1500° C. was added to 500 cc of fractionated oil of used tires and, 100 cc of an aqueous solution of strong alkali was further added to the mixture. After stirring, the mixture was allowed to stand for 30 minutes under about 2 atms. to give a powdery reaction mixture (a).
After stirring 1000 cc of the alkaline seawater and 30 g of the reaction mixture (a) in a reactor under 1.5 atms. at room temperature for about an hour, the mixture was allowed to stand almost overnight. Insoluble matters were removed to give an aqueous solution in the form of a homogeneous liquid.
60 kg of powder (1) was obtained by evaporating one ton of this solution.
On the other hand, the mixed solvents of kerosene and alcohol were made up according to the following prescription, and 1 kg of aforesaid powder (1) was added to each 30 l of mixed solvent and stirred, so that stock solution of the fuel additives were obtained.
______________________________________Prescription AMethanol 6 lButanol 10 lKerosene 14 lPrescription BMethanol 8 lButanol 12 lKerosene 20 lThinner 4 lPrescription CButanol 0.5 lThinner 4 lPrescription DMethanol 5 lButanol 12.5 l______________________________________
10 liters of these stock solutions of prescription A and D were diluted with a solvent consisting of 20 liters of kerosene and 1.5 liters of butanol to give fuel additives A and D. Fuel additive C was obtained by diluting 2.5 liters of the stock solution of prescription C by a solvent consisting of 15 liters of kerosene and 6.5 liters of butanol.
EXAMPLE 1 AND 2
The fuels were made by adding 120 cc of fuel additives A or D to 60 liters of gasoline and running test of a gasoline car of 2000 cc exhaust were conducted by using these fuels. After running for 15000 km, the amounts of HC and CO in the exhaust gas were analyzed. The results and the fuel efficiency are shown in Table 2, as compared to Comparative example 1 of an automobile for the same type using no additives.
TABLE 2______________________________________ Example 1 Example 2 Comparative 1______________________________________CO (%) 0.1 0.01 0.3HC (ppm) 0.2 20 180Fuel (km/l) 8.35 8.80 7.35______________________________________
EXAMPLE 3
The fuel was made by adding 180 cc of the fuel additive A to 60 liters of gas oil and running tests of a diesel car were conducted using this fuel. After running for 15000 km, the fuel efficiency was tested and black smoke in the exhaust gas was analyzed. The results are shown in table 3, as compared to Comparative Example 2 for an automobile of the same brand using no additives.
TABLE 3______________________________________ Example 2 Comparative 2______________________________________Fuel (km/l) 11.4 9.2Black smoke 16% 22%______________________________________
EXAMPLE 4 and 5
The fuel additive C or the stock solution of B was added in an amount 1% to fuels of an oil stove and the stock solution of B in an amount 1% to an oil boiler. The combustion condition was improved as compared with the previous condition using no fuel additives in each case. At the same time, odor and black smoke decreased and less fuel was spent.
Thus, there is provided in accordance with the invention fuel additives which can improve of fuel efficiency and reduction of HC, CO etc. in the waste gas and can be applied to not only internal combustion engines but also to other types of combustion systems such as boiler, stove, etc. The embodiments described above are intended to be merely exemplary and those skilled in the art will be able to make variations and modifications without departing from the spirit and scope of the invention. All such modifications and variations are contemplated as falling within the scope of the claims.
|
The novel fuel additives contain elements available in seawater and the reaction product of a hydrocarbon oil and a strong alkali, dissolved in an organic solvent solution. The fuel additives are added to fuels directly and are effective for reducing fuel costs and cleaning the exhaust gas of every type of combustion system.
| 2
|
The present invention concerns a flat cleaning system for a card equipped with a set of revolving flats, the individual flats of which are not in mutual contact, each flat consisting of a T-shaped profile. The legs of the flat are arranged on both sides and support a point clothing on their working surface. The web of the point clothing extends towards the inside of the flat room formed by the set of flats, and in this sytem the part of the revolving flat set located at the main drum is guided along the surface of the main drum.
On the cards equipped with the above mentioned set of flats the problem arises, that fine and finest fibre and dirt particles penetrate via the gaps between neighbouring flats. This occurs mainly in the part of the set of revolving flats located at the main drum into the inside room formed by the set of flats, where they can accumulate and form undesirable and dangerous fibre and waste accumulations. At the deflection points of the set of flats this accumulation can particularly take the form of fibre rolls.
According to a prior art solution to this problem (German DE-AS 11 18 662), penetration of fly waste and of dirt particles via the gaps between two stationary flats is prevented by providing seals which seal these gaps air-tight. A solution of this type, however, involves considerable disadvantages in practical use, because it is difficult to manufacture, as well as maintain, long, straight seals.
In another known flat cleaning system, German DE-PS12 92 551 an air stream is blown into the flat-inside room from one side and is sucked off on the opposite side via suction openings together with the fly waste and the dirt particles taken up by the air stream. However, this sytem has substantial disadvantages. Initially, it involves a high energy consumption since the effectiveness of the blown air stream is insured only if it extends over the full width of the flat-room which acts as an open room. Furthermore, such strong blown air streams generate an above atmospheric pressure, which, even if slight, is noticeable, in the flat-room. This is undesirable because air charged with fly waste and dirt particles is blown out of the flat room which, for design reasons, canot be hermetically sealed against the surrounding room. The air contamination caused by this air escape cannot comply with the dust content standards presently required in carding rooms. Furthermore, such strong concentrated air streams generate local air vortex formations and dead zones, in which fly waste and contaminations still can accumulate.
SUMMARY AND OBJECTS OF THE INVENTION
It is an object of the flat cleaning system according to the present invention to eliminate the above-mentioned disadvantages of the known devices of this type and to create a flat cleaning system, which effectively cleans the flat-room with low energy consumption, and avoids any air vortex formation and dead zones.
It is another object of the present invention to maintain in the flat-room a slight vacuum at all times and thus excludes any escape of fly waste and dust particles to the surrounding room.
These objects and others are achieved by a flat cleaning system of the type mentioned initially, in which the space between the webs of two neighbouring flats is temporarily sealed substantially air tight. The sealing element extends over the full length of the flats, forming a duct as the flats revolve. Also means for generating an air stream are coordinated to the duct.
By temporarily forming a duct enclosed by the legs and webs of two neighbouring flats and by the sealing element, optimum conditions for eliminating fly waste and dirt particles present in the duct room are established. Insofar as generation of the air stream is limited to the duct room and the duct dimensions are small in comparison to the whole flat-room, a relatively low energy consumption can be insured. As the duct formed is sealed substantially air tight against the flat room, the air stream acting in the duct does not influence the air present in the rest of the flat-room, and, in particular, does not create a pressure above atmospheric pressure in the flat room. Thus, a slight vacuum can also be established in the flat-room using conventional means, and the desired environmental requirements can be achieved.
Furthermore, the sealing element can extend, according to an alternative embodiment of the present invention over a plurality of neighbouring flats. According to a particularly favourable embodiment the sealing element extends substantially over all flats located at the main drum.
The sealing element can consist of a fixed, substantialy rigid plate which hugs the curvature of the flat path in the direction of the flat movement. The free end of the flat web moves along this plate forming a sealing point, or can consist, according to a further embodiment of a fixedly arranged, flexible apron supported on the upper part of the webs of the flats.
The means for generating an air stream in the duct comprise, according to an embodiment of the present invention, a suction duct merging into the duct at the face side.
With these and other objects, advantages and features of the invention that may become hereinafter apparent, the nature of the invention may be more clearly understood by reference to the following detailed description of the invention, the appended claims and to the several drawings attached herein.
FIG. 1 is a schematic cross-section of the main working elements of a card, with a flat cleaning system according to the present invention;
FIG. 2 is a section of the card according to FIG. 1, along the line II--II of FIG. 1;
FIG. 3 is an enlarged detail of FIG. 1;
FIG. 4 is an alternative embodiment of the inventive flat cleaning system in a view corresponding to the one shown in FIG. 1; FIG. 5 is another embodiment of the inventive system, in which only the set of flats and a part of the main drum of the card are shown in a schematic view; and
FIG. 6 is a further alternative embodiment of the present invention shown in a schematic view, only a part of the set of flats being shown.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, in a so-called revolving flat card, the main drum is designated 1, the taker-in or licker-in 2, the doffer cylinder 3, and the feed roll 4. These four rolls or cylinders are rotatably supported at both sides in bearings (not shown) fixedly arranged with respect to the room in a frame (merely indicated) 5, or 5a respectively, of the card. The rolls are driven at predetermined mutual rotational speed ratios and directions of rotation by known means, of which only the drive belt pulley 6 of the main drum 1 is shown in FIG. 2. The fibre material in the form of a layer of flocks is supplied to the feed roll 4, which rotates in the direction of the arrow E, on a trough-shaped feeder plate 7, is caught by the teeth of the point clothing 8 of the licker-in or taker-in 2 and is carried on in the direction of the arrow F. The main drum 1 is also provided with a point clothing 9, which is particularly shown in FIG. 3 which shows an enlarged detail of the main drum periphery, among other items. The points of the point clothing 9 of the main drum 1 take over the fibres, or the fibre flocks respectively, from the clothing 8 of the licker-in 2 and bring them, according to the rotation of the main drum 1 in the direction of the arrow G, to the fibre transfer point, i.e. to the point of contact between the clothing 9 of the main drum 1 and the point clothing 10 of the doffer cylinder 3, which rotates in the direction of the arrow H. At this point, the fibres or the fibre flocks, respectively, are transferred to the doffer cylinder and to the take-off device (not shown) of the card. Within the zone of the main drum 1, between the transfer points from the licker-in 2 to the main drum 1 and from the main drum 1 to the doffer cylinder 3 the actual carding of the fibre material is effected. In this process, the fibres placed on the surface of the main drum clothing 9 (FIG. 3) are pulled through between the main drum clothing 9 and the point clothing 11 (FIGS. 2 and 3) of the slowly revolving card flats 12 (and 12a, 12b, etc., respectively). The card flats 12, 12a, etc. are interconnected by chains or connecting elements 14, and 14a (FIG. 2) into a slowly revolving set of flats, in such a manner that they form a closed arrangement. The inside room of this arrangement is designated in this context as a flat room 15 formed by the set of flats 13.
The flats 12, 12a, 12b, etc. each consist of a T-shaped profile, the legs 16 and 16a (FIG. 3) of which, arranged on both sides, are provided with the point clothing 11 on their working surface 17. The web 18 of the flats 12, 12a, 12b, etc. extends towards the inside of the flat room 15. The T-shaped flat profiles extend, as shown in FIG. 2, over the full width of the main drum 1 and are guided on both sides using gliding shoes 19, 19a on arched guide rails 20, 20a formed by the side walls of the card frame 5 substantially parallel to the main drum. That is, the flat profiles are guided along the surface of the main drum 1.
The flat set 13 consists substantially of two groups, namely the group of the flats 21 along the main drum 1, and the group of the flats 22 returning, and of two flat turning points 23 and 24. The structure of the two turning points is known in the art and a further description is thus not included herein. Along the run 21 of the flats in the working position, the flats 12, 12a, etc., as shown in FIG. 3, are lined up adjacent in a row. The legs 16, 16a of neighbouring flats 12, 12a are arranged in close vicinity, but no mutual, air-tight seal is provided between them, i.e. the flats 12, 12a are not in mutual contact. Between the flats thus a long, narrow gap 25 is formed, via which individual fibres or small fibre aggregates from the main drum surface can penetrate into the flat room 15, where they are deposited mainly in the room formed between two neighbouring flat webs 18 and 18a on the inner side of the flats.
FIG. 2 shows the manner in which the flats 12, 12a, 12b, etc. are guided along the path of the return run 22 of the flats by arched guide members 26, 26a. Almost concentrically with respect to the main drum 1, the gliding shoes 19 and 19a are used in this embodiment. The guide members 26, and 26a respectively, are formed by two support members 27, and 27a respectively, and are mounted onto the card frame 5, and 5a respectively.
All of the room of the flat set 13 is separated also from the surrounding room by a hood 28, which is provided with seals (not shown) in such manner that a vacuum can be maintained in its inside room 29. This is accomplished by connecting it to an external vacuum source, the vacuum required being of the order of a few mm water column. A vacuum of this type is sufficient to prevent fibres from escaping from the hood 28 to the surrounding room, but is, however, not sufficient to effectively preclude the deposition of fibres and fibre aggregates, which penetrates via the gap 25, 25a, etc. (FIG. 3), into the flat room 15, onto the flats 12, 12a, 12b, etc. For this purpose the inventive flat cleaning system is applied, in which in the embodiment according to FIGS. 1 through 3 a fixed sealing element 30 is provided over the flat webs 18, 18a, 18b, etc. along which the free end of the web 18, 18a, 18b, etc., moves (see FIG. 3) forming a sealing point. The sealing element 30 (FIG. 3) in this arrangement is formed by a plate 31 hugging the curved path of the flats, the stiffness of which plate 31 is increased, if required, by ribs not shown, in such manner that its surface 32 facing the webs 18, 18a, 18b, etc. is held in place practically contact-free and substantially air-tight over the whole width of the flats 12 opposite the webs 18, 18a, etc. The plate 31 is provided with ear-type extensions 33, 33a which are laterally mounted on the support members 27, 27a by means not shown in detail.
Since the sealing element 30 extends, as shown in FIG. 3, over three neighbouring flats 12, 12a and 12b, two longitudinal ducts 34 and 35 are formed between the webs 18a and 18, and 18 and 18b respectively, of two neighbouring flats 12a and 12 and 12b respectively, through which an air stream flows.
This air stream is generated e.g. by providing a suction duct 36 (FIG. 2.) merging at the face side of the duct 34, and 35 respectively, i.e. at the face side of the flats 12, 12a, 12b, etc. in the zone of the sealing element 30. In FIGS. 1 through 3 the orifice of the suction duct 36 merging at the face side is designated 37. The suction duct 36 is connected to suction means not shown, in such manner that a suction air stream in the ducts 34 and 35 (FIG. 3) according to arrow f (FIG. 2) is generated. This eliminates fibres, fibre aggregates and contaminations accumulated in the ducts 34 and 35 respectively. As shown in FIG. 3, the width of the orifice 37 of the suction duct 36 is chosen large enough so that it extends over two adjacent ducts 34 and 35 and thus generates an air stream simultaneously in both ducts 34 and 35. The width of the orifice 37 can also be smaller, so that an air stream is generated in only one duct between two flat webs. As the set of flats revolves slowly, as mentioned before, the direction of the revolving movement in this arrangement being of no importance, each flat 12, 12a, 12b, etc. from time to time is placed below the sealing element 30 in such manner that each flat, together with its neighbouring flat, temporarily forms a duct in which the cleaning air stream becomes effective. The cleaning element 30 does not necessarily extend, as shown in FIGS. 1 and 3, over a plurality of flats 12 and 12a, 12b. It is sufficient if it extends over e.g. the two webs 18, 18a of two neighbouring flats 18, 18a, in such manner that the air tight duct 34 is temporarily formed. For design stability reasons, however, use of a sealing element 30 extending over a plurality of flats is recommended.
As each flat revolves, is placed under the sealing element 30, or the plate 31 respectively, and the suction air stream effects an air flow through the duct and produces the desired cleaning effect. It should also be mentioned that, owing to the total cleaning air stream, it is possible to also subject the whole inside room 29 under the hood 28 to slight vacuum in such an advantageous manner that the above mentioned conditions for the air in the surrounding room are achieved. The hood 28 can also be connected to a separate suction duct (not shown). What is important, however, is the fact that due to the formation of tightly enclosed ducts 34, 35 between the flat webs 18, 18a, 18b, etc., the action of a relatively feeble suction air stream is entirely sufficient for insuring cleaning of the whole flat-room 15, without requiring application (as in the known cleaning systems according to the state of the art) of a blow air stream (causing above atmospheric pressure and vortex formation in the flat-room 15).
In FIG. 4, in which elements identical to those shown in FIGS. 1 through 3 are designated with the same reference numbers, the sealing element 30 extends substantially over all flats 12, 12a, etc., of the run of the flat set 21 located at the main drum 1. It consists of a fixed, flexible apron 38, which is supported on the webs 18, 18a, etc. of the flats 12, 12a, etc., and which is anchored at the flat turning points 23, 24 by means not shown. Even if the flexible apron 38 which is preferably made from synthetic plastic material, converts all spaces between the webs of the flats 12, 12a, etc. of the run 21 of the set of flats into closed ducts, the inventive air stream can become effective in the one, or several ducts located in the zone of the orifice 37 of the suction duct (not shown) merging at the face side. This occurs in such a manner that the efficiency of the suction is insured notwithstanding the small suction air quantities utilized (and thus the small energy consumption). The arrangement shown here is an advantage over the solution shown in FIGS. 1 through 3. It permits separation of the flat room 15 into two separated spaces, namely the space above and below the apron 38, in such a manner that any effect from the gaps 25, 25a, etc. between the flats 12, 12a, etc., which in the solution according to FIG. 1 through 3 can eventually still cause small, detrimental air currents, is entirely avoided. Furthermore, the solution according to FIG. 4 yields sealing action advantages, as the sealing on the webs 18, 18a, etc., by the flexible apron 38 is self-regulating so to speak, under the influence of the action of the vacuum in the ducts between the flats 12, 12a, etc., in such manner that expensive machining operations on the webs 18, 18a, etc., and/or on the sealing element 30 is not necessary. Furthermore, application of two support rolls 39 and 40 for the return run 22 of the set of flats 13 are shown in FIG. 4, instead of the guide elements 26 and 26a shown in FIGS. 1 through 3, which can result in possible reduced manufacturing costs for this design.
The flexible apron 38 of preferentially synthetic plastic material is chosen as a thin apron, the surface of which facing the free end of the flat webs 18, 18a, etc. (see FIG. 3) is a low friction surface with low electrostatic chargeability. Thus, the sliding friction of the drive of the flat set 13 can be reduced. Also, electrostatically caused clinging of fibres on the sliding surface of the apron 38 can be precluded. As an apron 38, e.g. a polyester apron of the type Transilon E2/2-U0/V2 with PVC coat, as manufactured by Siegling AG, P. Box 5346, D-3000 Hannover 1, can be used.
In FIG. 5 a further alternative embodiment of the present inventive flat cleaning system is shown, which differs from the embodiments according to FIGS. 1 through 4 described above, because the sealing element 30 in this arrangement is not stationary, but is a body rolling on the webs 18, 18a, etc. In FIG. 5, as a sealing element 30 e.g. a revolving apron 41 was applied, tensioned between two rotatably supported rolls 42 and 43, the lower run 44 of which is supported on the free ends of the webs 18, 18a, etc. of the flats 12, 12a, etc.
The apron 41 can thus follow the movement of the set of flats 13 e.g. in the direction of the arrows I (the roll of the turning point 23 in this case rotating counter clockwise, as indicated by the arrow L) preferably at the same speed, i.e. the apron revolves about the rolls 42 and 43 also counter clockwise (arrow M at the roll 42). In this arrangement, the apron 41 can be equipped with its own drive mechanism (not shown) or can be carried by friction on the webs 18, 18a, etc., of the flats 12, 12a, etc. The apron 41 of course extends over the full width of the flats 12, 12a and is guided and sealed laterally by means not shown.
Also in this embodiment a lateral suction opening 37 is provided, which, as described with reference to the above mentioned embodiments, is connected with a suction source (not shown) for generating a suction air stream in one or a plurality of ducts between the flats 12, 12a, etc. (in the embodiment shown the apron 41 forms four ducts).
The embodiment according to FIG. 5 shows the advantage that the air tight sealing of the room between the webs 18, 18a etc., of two neighbouring flats is effected without causing friction.
In FIG. 6 a further alternative embodiment of the present inventive flat cleaning system is shown, in which the sealing element 30, like the one according to the embodiment described with reference to FIG. 5 is designed as a body rolling on the webs 18, 18a, etc., thus yielding advantages similar to those mentioned above. The sealing element 30 shown in FIG. 6 is designed as a roll 46, which is movably radially guided with respect to the surface of the main drum 1 in two lateral bearings 46 (one only being shown), and which is temporarily supported on two webs 18, 18a of two neighbouring flats 12, 12a with its cylindrical surface. It thus seals the inventive longitudinal duct 47 between the webs 18, 18a.
The revolving movement of the flat set 13, e.g. in the direction of arrow I, causes the roll 45 to rotate counter clockwise (arrow N), the roll 45 in this arrangement also effecting a vertical movement and eventually being temporarily supported on a single web 18a. To obtain a prolonged sealing time of the duct 47, various means can be applied, if required, e.g. the roll 45 can be provided with a soft cover coat (not shown), or a certain movability in the direction of the movement of the flats, i.e. in the direction of arrow I, can be provided.
|
Flat cleaning system for a card equipped with a set of revolving flats, in which the flats (12) consist of a T-shaped profile, and in which, by temporary sealing, of the room between the webs 18, 18a of two neighboring flats (12,12a) using a sealing element 30, a longitudinal duct is formed, in which duct an air stream is generated. By this air stream, any fly waste accumulated on the back side of, and between the flats 12, 12a is eliminated. The air stream in the duct, generated by lateral suction, cleans any fly waste and dust particles accumulated in the duct out of the duct, only low energy suction being required.
| 3
|
BACKGROUND OF THE INVENTION
The present invention is generally directed to a system, method, and apparatus for packaging electronic circuit components. More particularly, the present invention is directed to a system for electronic component packaging which permits easy insertion and removal of fully populated circuit boards without having to remove printed circuit cards which have already been inserted into the boards. Even more particularly, the present invention is directed to systems, methods, and devices which enhance the ability to package electronic components in a dense manner while still being able to provide not only air cooling but which also provides an effective system for electromagnetic interference (EMI) shielding.
It should be appreciated that not all of the features of the present invention need to be incorporated into a single device or system. Many of the features found in the present invention may be employed independently from one another. In general, the present invention seeks to solve a number of problems with respect to electronic circuit packaging. In particular, it is desirable to employ printed circuit cards which can be easily inserted and removed from printed circuit boards without the removal of the board and without removal of any cabinet or enclosure surrounding the electronics package. In desired embodiments of the present invention, therefore, it is found that printed circuit cards are capable of being “hot plugged” into a printed circuit board.
Additionally, it is noted that, in preferred embodiments of the present invention, circuit components operate at relatively high frequencies. At higher frequencies, problems associated with the propagation of electromagnetic interference become more significant. Accordingly, for those situations in which higher frequency components are desired, there is a correspondingly higher desire to employ electromagnetic shielding systems. Thus, there should be provided a mechanism for providing EMI shielding that is commensurate with the notions of hot pluggability. In other words, the EMI shielding system should be compatible with the notion that printed circuit cards are removed and inserted from printed circuit boards which are themselves not pluggable.
Hot pluggable systems are shown in U.S. Pat. No. 6,062,894 issued May 16, 2000, and assigned to the same assignee as the present invention. However, in the system described therein, there is a dependence on the existence of an external cabinet to effect the vertical motion of the printed circuit card into a corresponding mating socket on a printed circuit board. The presence of physical contact between the mechanism for insertion and removal and an enclosure which surrounds a printed circuit board precludes the use of such devices in mechanisms for which the entire printed circuit board itself is removable.
It is also noted that the present discussion refers to printed circuit boards and printed circuit cards. As contemplated herein, the printed circuit board is the larger component into which at least one printed circuit card is inserted for purposes of electrical connection. The present invention places no specific limits on either the size of a printed circuit board or the size of a printed circuit card. In the most general situation, a circuit board is populated with a plurality of printed circuit cards. That is, the printed board has a number of printed circuit cards inserted therein. Accordingly, as used herein, the terms “printed circuit board” and “printed circuit card” are considered to be relative terms. However, it is also noted that one of the motivating factors in the design of the present invention is the fact that printed circuit boards are, when fully populated, relatively heavy and possess one or more connectors at the edges thereof. These board edge connectors typically possess a large number of electrical connections to accommodate the correspondingly larger number of electrical connections that must be accommodated for a board which is populated with a number of printed circuit cards. The present inventors have also contemplated a mechanism for insertion of the entire board in a tight space without the necessity of removing any of the printed circuit cards. Accordingly, some of the specific situations contemplated by the present inventors have also resulted in the inclusion of mechanisms for insertion and removal of fully populated printed circuit boards.
Normally the circuit board, the mother board if you will, is considered fixed and does not usually constitute a movable structure. Moreover, even in those circumstances where one might contemplate inserting or removing a circuit board, one would normally not consider such an operation without first removing the printed circuit cards from the board. Because a typical printed circuit board is often populated with a relatively large number of printed circuit cards, the size and weight of the circuit board is typically relatively large. Thus, one is normally presented with the problem of moving (in forward and reverse directions) a large, flat, relatively thin substrate. Particularly during insertion operations, such a physical structure is likely to experience bending and flexing motions typically referred to as “oil canning.” Accordingly, solutions to problems in the present art address this issue as well.
Accordingly, the present inventors are presented with the following sometimes competing packaging problems: oil canning, dense and close packaging, air cooling, electromagnetic interference shielding, hot pluggability, the desire to provide an easy to load cartridge for carrying printed circuit cards, mechanisms requiring a mechanical advantage for insertion and removal of entire circuit boards, the removal of fully populated boards and the insertion thereof, and means to provide a cooperative EMI shielding arrangement in a system which provides circuit board guide mechanisms which do not require physical contact with a surrounding enclosure or cabinet.
SUMMARY OF THE INVENTION
In accordance with a preferred embodiment of the present invention, a number of features are provided which together solve all of the competing problems indicated above. In particular, a significant aspect of the present invention is provision of a docking cartridge which serves as a printed circuit card carrier and which is capable, in and of itself, of inserting and removing electronic printed circuit cards. While the present invention is particularly suitable for the incorporation of printed circuit cards meeting the so-called PCI (Personal Computer Interface) Standard, the principles of the present invention are generally applicable to any printed circuit card having an edge connector which is insertable into a corresponding mating connector on a printed circuit board. The docking cartridge of the present invention includes an actuating mechanism for card insertion which is completely self contained and which does not rely upon any physical contact with an enclosure or cabinet. Rather, the docking cartridge of the present invention interacts with a single-sided cartridge guide mechanism which is provided at the printed circuit board level. Moreover, the docking cartridge of the present invention is provided with an easy load mechanism for the printed circuit card. In particular, the docking cartridge is provided with a front bezel which also constitutes part of an EMI shield mechanism and which is also pivotable with respect to a top cartridge wall structure. The top cartridge member is slidably disposed with respect to a circuit card carrier which contains corner clips and slidable adjustable mechanisms as shown in the aforementioned U.S. Pat. No. 6,062,894. The top member is thus slidably attached to a moveable carrier which moves the printed circuit board up and down so as to provide insertion and removal of the circuit board with respect to mating electrical connectors on the printed circuit board.
A front bezel of the docking cartridge is also provided with a mechanism for ensuring EMI shielding during the entire insertion and removal process. In particular, desirable circuit boards for use in connection with the present invention include a front EMI shield plate which has electrical contact with the front docking cartridge bezel. In particular, such desirable printed circuit cards having this plate also include, on the bottom of this shield plate, a tab portion which engages a flexible EMI shield strip which is disposed on an electrically conductive stiffener which provides protection against the aforementioned oil-canning effect and which furthermore provides its own degree of EMI shielding for board level circuits and components. The EMI shield strip used in the present invention possesses a geometric structure which renders it readily capable of being fabricated in stamping and forming operations. This EMI strip is disposed so that it includes slotted opening portions which engage edges of apertures found in parallel rows in the stiffener. The strip engages these apertures in one row and includes a flexible portion which extends into the opening in a parallel row of stiffener apertures. Thus, in accordance with the present invention, as the printed circuit is inserted into the printed circuit boards so as to make electrical contact with circuits on the board, there is also provided a continuous EMI shield as the tab on the printed circuit card engages a flexible tab portion on the EMI strip which is in electrical contact with the conductive stiffener.
One of the other significant problems addressed by the present invention is the fact that a fully populated circuit board is relatively heavy and typically possesses a large number of electrical circuit contacts thus increasing the force needed to provide proper electrical connection. The mechanism for providing this force should not be significantly large nor should it consume significant amounts of space. That is to say, the mechanism for inserting and removing the circuit board should be compact and consistent with the compact and dense packaging notions of the present invention. Furthermore, this mechanism should be compatible with the other structures provided herein, notably, the stiffener and the EMI shielding system.
The present invention incorporates two principle aspects. A first structural component utilizes an independent, self-contained cartridge for containing printed circuit cards intended for insertion into and removal from tight spaces. A second aspect of the present invention includes the structure of a printed circuit board which is usable in conjunction with the aforementioned cartridges. Furthermore, the cartridge and board system of the present invention cooperatively interact to provide EMI shielding mechanisms not only compatible with the easy insertion and removal of circuit cards, but which also provide a cooperative mechanism for the insertion and removal of an entire circuit board in its fully populated state, that is, with all printed circuit cards inserted and connected.
With respect to the first aspect of the present invention which relates to the cartridge for protecting, transporting, inserting, and the removal of printed circuit cards, it is noted that this cartridge includes three main components: a front bezel, a top cartridge wall member, and a movable carrier which is upwardly and downwardly movable with respect to the bezel and the top cartridge wall. The cartridge also includes a lever actuated mechanism attached to the top of the bezel which provides sufficient force for card insertion. The lever actuated mechanism of the cartridge is disposed in such a way as to provide both upward and downward forces to the movable carrier at a point along the carrier which is appropriate for both short and long printed circuit cards. The cartridge of the present invention also includes a side cover. In preferred embodiments of the present invention, the bezel is metal and is in continuous electrical contact with an EMI shield plate found on certain printed circuit cards which are desirably useful in conjunction with preferred embodiments of the present invention particularly when they operate at relatively high frequencies. These shield plates preferably include a lower tab portion which extends through an opening in the bottom of the front bezel and which engages an EMI shield spring which thus allows it to be electrically connected with a conductive stiffener affixed to the printed circuit board.
With respect to the second aspect of the present invention which relates to the printed circuit board itself, the board is provided with an electrically conductive shield and stiffener as mentioned above with respect to the incorporation of the tab and spring structures. Furthermore, printed circuit boards of the present invention include a nonconductive base member which is disposed on a side of the printed circuit board opposite the stiffener. This base support structure provides additional resistance to “oil canning” effects that can occur particularly in larger printed circuit board structures. The printed circuit board also includes special guides disposed at the printed circuit board level. These guides engage ridges disposed on side wall covers for the printed circuit card cartridges, as described above. A particular feature of the cartridges also includes a mechanism for interlocking adjacent cartridges. Accordingly, a desirable aspect of the present invention is the fact that the special guides employed herein do not require slot and ridge structures to be present on both sides of the inserted cartridge. This is significant in the present invention since this feature permits cards to be made thinner and accordingly increases the overall packaging density which, as described above, is a highly desirable aspect of the present invention.
The stiffener employed in conjunction with the printed circuit board includes a front row of parallel slots which are spaced to receive an EMI spring shield structure which cooperates with the cartridge structure to provide a continuous EMI shield. Additionally, the present invention also includes a force-producing mechanism which is capable of providing a significant mechanical advantage for insertion and removal of the printed circuit board itself, even when requiring all of the board edge connectors to be mated with corresponding off-board connectors. In preferred embodiments of the present invention, the insertion and removal mechanism for the printed circuit board includes a toothed arm which engages a wrench-activated pinion gear which is affixed to the above-mentioned stiffener at the front or leading edge of the printed circuit board. The toothed arm is pivotally connected to force-producing arms which include pins which ride in slots in the base structure which supports the printed circuit board from below. As the pinion gear is rotated, the combination of the toothed arm and the force-providing levers changes to and from a “T” and “Y” shape. Thus, as the pinion gear is rotated, the lever arms move in what is best described as a “backstroke” motion. These levers push against cabinet or enclosure pins and, in doing so, cause the insertion or removal of the circuit board, in its entirety, into or out of a mating electrical connector.
The cartridge of the present invention is also constructed in such a manner so as to employ components which are pivotally connected so as to enable easy insertion of printed circuit cards having various dimensions. In effect, the maximum size of a card employed in the present invention is thus determined by the height of the bezel and the length of the cartridge top.
Accordingly, it is an object of the present invention to provide a system for packaging electronic circuit components in tight spaces.
It is also an object of the present invention to provide an apparatus for inserting and removing printed circuit cards in tight quarters.
It is a still further object of the present invention to provide a cartridge which is capable of transporting, protecting, inserting, and removing printed circuit cards in a self-contained manner.
It is also an object of the present invention to provide mechanisms which support hot pluggability of electronic circuit cards and boards.
It is a still further object of the present invention to provide a mechanism which permits insertion and removal of fully populated electronic circuit boards.
It is also an object of the present invention to provide a cartridge, for containing printed circuit cards, which is easily loadable.
It is furthermore an object of the present invention to provide a system in which continuous EMI shielding is provided between an easily removable printed circuit cartridge and a printed circuit board.
It is yet another object of the present invention to provide a cartridge for printed circuit cards which is readily adapted to hold cards of varying sizes.
It is yet another object of the present invention to provide a system of interlocked printed circuit card cartridges and a supporting printed circuit board.
It is yet another object of the present invention to provide a mechanism by which an entire fully populated printed circuit board is readily inserted into and removed from the system in which it is electrically connected.
It is also an object of the present invention to provide a printed circuit cartridge card carrying mechanism which is compatible with air cooling of the components contained on the card.
It is a still further object of the present invention to provide a printed circuit board which is still nonetheless compatible with the incorporation of ancillary circuit components such as capacitors, resistors, heat sinks, and the like which extend upward from the printed circuit board.
It is a yet another object of the present invention to provide an EMI shield spring structure which is operative as a mechanism for providing electrical connections and EMI shielding continuity between a printed circuit card and an EMI shield structure disposed on a printed circuit board to which the card is also separately electrically connected.
It is a further object of the present invention to provide a guide mechanism on a printed circuit board for cartridge insertion so as to consume only a small space in the side-to-side direction, between loaded cartridges.
Lastly, but not limited hereto, it is an object of the present invention to provide an integrated printed circuit card cartridge and printed circuit board mechanism which provide compactness, air-cooling capabilities, EMI shielding, hot pluggability, and mechanical force advantages both for the insertion and removal of printed circuit cards and the insertion and removal of fully populated printed circuit boards.
The recitation herein of a list of desirable objects which are met by various embodiments of the present invention is not meant to imply or suggest that any or all of these objects are present as essential features, either individually or collectively, in the most general embodiment of the present invention or in any of its more specific embodiments.
DESCRIPTION OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of practice, together with the 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. 1A is an isometric view illustrating a cartridge in accordance with the present invention;
FIG. 1B is a side elevation view of the cartridge shown in FIG. 1A;
FIG. 2 is a side elevation view of the cartridge shown in FIG. 1B except with the cover removed so as to provide a view of some of the interior components;
FIG. 3A is a side elevation view illustrating a preferred lever mechanism for card insertion and removal and more particularly illustrating lever arm positions when a card is fully inserted;
FIG. 3B is a view similar to that shown in FIG. 3A except that the lever positions shown are indicated when a card is a in the fully removed position;
FIG. 4 is an isometric view illustrating the combination of a top cartridge wall member together with a movable card-carrying mechanism;
FIGS. 5A through 5I illustrate a sequence of operations for the loading of a printed circuit card into the cartridge of the present invention;
FIG. 6 is an isometric view illustrating a cartridge of the present invention inserted into a single slot on a printed circuit board which also conforms to the requirements of the present invention;
FIG. 7 is an isometric view similar to FIG. 6 but more particularly illustrating the entire printed circuit board with a single cartridge installed;
FIG. 8 is an isometric view illustrating a detailed portion of a printed circuit board in accordance with the present invention and particularly illustrating a guide system as preferably employed herein;
FIG. 9 is an isometric view illustrating the bottom of a printed circuit board in accordance with the present invention and more particularly illustrating a preferable mechanism for circuit board insertion and removal;
FIG. 10 is an isometric view illustrating (in a detailed close up) a portion of the preferable board insertion and removal mechanism as shown in FIG. 9;
FIG. 11 is an isometric view illustrating the actuation mechanism for the drive arm shown in FIG. 9;
FIG. 12A is a side elevation, cross-sectional view illustrating the EMI shield system of the present invention particularly with respect to the cooperation between printed circuit board shield plates, cartridge bezels, EMI shield springs, and conductive stiffener structures;
FIG. 12B is a simplified view of the system shown in FIG. 12A provided to more particularly indicate movement of the components;
FIG. 13A is a top view of the EMI shield spring employed in conjunction with the EMI system of the present invention; and
FIG. 13B is a side elevation view of the spring shown in FIG. 13 A.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1A illustrates an isometric view of a preferred embodiment of the present invention. In particular, FIG. 1A illustrates cartridge 100 which contains printed circuit card 200 (visible in FIG. 2 ). Cartridge 100 includes front wall or bezel 130 which preferably comprises metal. Bezel 130 is pivotally attached to top wall member 120 of cartridge 100 . Side cover 110 is attached to bezel 130 at points 137 and 138 . Notably, side wall cover 110 includes ridge portion 111 extending along a bottom portion of wall 110 . Additionally, as an additional major component, cartridge 100 includes actuating lever arm 141 which is used to insert and remove printed circuit card 200 from printed circuit boards into which cartridge 100 is inserted. Additional appreciation of the operation of cartridge 100 is discernible from the side elevation view shown in FIG. 1B which particularly illustrates pivot point 144 for actuating lever arm 141 . By operation of lever arm 141 , an internal mechanism (not visible in FIG. 1A or 1 B) urges printed circuit card 200 having edge connector 201 into corresponding mating connectors ( 311 in FIGS. 6, 7 , and 8 ) on circuit board 300 whose construction is more particularly described below and which cooperatively interacts with cartridge 100 in several ways.
Top wall member 120 preferably comprises a polymeric material which exhibits sufficient stiffness to support the operation of the lever arm mechanism which is included in preferred embodiments of the present invention. Top wall member 120 also preferably includes apertures 121 near the front of the cartridge and aperture 122 near the read of cartridge 100 for the passage of cooling air for those situations where air cooling is desirable. Top wall member 120 is preferably formed to exhibit a generally U-shaped cross-section as a major portion of its structure.
Side wall 110 also preferably comprises a polymeric material which is substantially flat and is attachable to top wall 120 along the top edge of wall 110 using any convenient attachment means such as screws 176 , 177 , and 178 as shown in FIG. 5H which is more particularly considered below. Significantly for the present invention, side wall 110 includes a raised portion or ridge 111 which extends along a bottom portion of side wall 110 . Ridge 111 may possess any convenient cross-section, however, a smooth-rounded cross-section is shown. The main feature of ridge 111 is that it possesses a cross-section which matches the cross-section of slots 351 provided in guides 350 (see FIG. 10) affixed to printed circuit board 300 .
Front wall portion (or bezel) 130 is pivotally attached to top wall member 120 at pivot point 137 . Front wall 130 also preferably includes mounting bracket 149 to which is attached actuating pivot arm 141 which is used as an external drive mechanism for insertion and removal of a printed circuit card 200 into a printed circuit board connector 311 . Front wall 130 preferably comprises a conductive material whenever it is desired to provide electromagnetic interference shielding. However, in those circumstances in which EMI shielding is not essential or desired, front wall 130 may comprise a polymeric material or other nonconductive material. Front wall 130 also preferably includes an opening in the front thereof through which printed circuit board shield plate 202 is visible. In other applications of the present invention, front wall 130 is provided with an opening in the front thereof so that access may be provided to various pluggable connectors that may be found on the front edge of a printed circuit card. Such printed circuit board connectors are disposed through the opening in front wall 130 and may include telephone line RJ-11 type connectors and the like. Front wall 130 also preferably includes one or more openings for the inclusion of light guides 132 which are optionally provided so that light indicators, such as LEDs found on the leading edge of printed circuit board 300 , may be viewed from external positions.
It is noted that the present invention incorporates a number of features that have been provided for specific purposes. For example, in those applications in which relatively high power levels are generated by an enclosed printed circuit card, it is desirable to provide top wall 120 with apertures ( 121 and 122 ) such as those shown in FIG. 1 A. However, if power dissipation is not a concern, such apertures do not have to be present. Likewise for those situations in which connector access to printed circuit card components is not necessary, front wall 130 does not have to be provided with an opening. In a similar fashion, in those situation in which electromagnetic interference is not an issue, front wall 130 may comprise materials which are not electrically conductive. In general, the nonconductive portions of cartridges manufactured in accordance with the present invention are preferably formed in polymeric molding operations.
The cartridge of the present invention is particularly useful in those situations in which it is desirable to have a relatively high component packaging density. Accordingly, it is desirable that cartridge 100 be shaped in as a thin a package as possible so that as many cartridges as possible may be disposed in adjacent positions. Accordingly, in preferred embodiments of the present invention, only cover 110 on one side is provided. In such embodiments, there is only one ridge 111 which engages mating guides 350 on printed circuit board 300 . The lack of necessity for providing a ridge and cover on the opposite side of cartridge 100 is eliminated. By eliminating this structure, cartridge 100 may thus be made thinner. In yet another variation of the present invention, in those circumstances in which a plurality of cartridges are inserted in adjacent positions, as is preferred in the present invention, cartridge 100 is provided with interlocking mating members 112 and 113 (see FIG. 6) which serve to slidably interlock adjacent cartridges. This further contributes to the strength and rigidity of the entire structure. This interlocking mechanism also contributes to the lack of a need for cover such as 110 to be provided on both sides of cartridge 100 .
FIG. 2 is a side elevation view similar to that shown in FIG. 1B except that cover 110 is removed so as to more particularly show and illustrate the internal components and the inclusion of cartridge 100 . In particular, FIG. 2 shows printed circuit card 200 with its edge connector 201 affixed in position with respect to carrier 150 . Carrier 150 is a movable portion of the present invention, and it is the part of the mechanism shown in FIG. 4 as described below which provides a description of a preferred mechanism for carrier 150 . FIG. 2 also illustrates that in those embodiments of the present invention in which air circulation is a desired factor, front wall 130 also preferably includes a plurality of apertures 131 which also facilitate the passage of cooling air. FIG. 2 also illustrates the fact that front wall 130 also preferably includes aperture 133 on the bottom thereof (see also FIGS. 12A and 12B) which provides an exiting path for tab portion 203 of EMI shield plate 202 (see FIG. 12A) which serves as part of an interconnnected EMI shield system. The remaining portion of FIG. 2 serves to particularly indicate the preferred system of linked lever arms which are employed to effect the desired motion of carrier 150 and printed circuit card 200 . The action and operation of this lever mechanism is more particularly illustrated in FIGS. 3A and 3B.
A preferred system of pivoting arms for moving carrier 150 is seen in FIGS. 3A and 3B. In particular, it is noted that pivot points 144 and 147 are fixed. In particular, pivot point 144 is preferably fixed in bracket 149 which is affixed to a point on front wall 130 at the top thereof as shown. Likewise, pivot point 147 is affixed on top wall 120 . In preferred embodiments of the present invention, top wall 120 comprises a polymeric material having a substantially U-shaped cross-section. As such, this provides a mechanism for extending a pin-like pivoting mechanism across the U-shaped channel. Thus, most significantly for the present invention, it is seen that the preferred leverage mechanism includes pivot points 144 and 147 which are fixed to front wall 130 and top wall 120 , respectively. The preferred levering mechanism includes external actuating arm 141 , as shown. Second arm 143 extends from fixed pivot point 147 . Connecting arm 142 linking external arm 141 with second arm 143 is also shown. Arm 141 and arm 142 are linked at pivot point 146 . Arm 142 and arm 143 are linked at pivot point 145 . Also notably for the present invention, at pivot point 145 there is provided a pin which preferably rides in a horizontal slot provided in carrier 150 . The motion of the pin in the slot is the mechanism preferably employed for imparting upward and downward motion to carrier 150 .
It is noted that FIG. 3A illustrates the position of the various arms employed in preferred embodiments of the present invention when printed circuit card 200 is fully inserted into board connector 311 . Likewise, FIG. 3B illustrates the position of a desired leveraging mechanism when card 200 is fully removed from board 300 . It is also noted that since front wall 130 is pivotally connected to top wall 120 at pivot point 137 , the mechanism shown in FIGS. 3A and 3B is particularly useful in that it permits the pivoting operation to occur by providing a longer distance between pivot point 147 and pivot point 146 , thus permitting extension of the configuration of the arms used for insertion and removal during bezel pivoting.
FIG. 4 illustrates the fact that carrier 150 preferably comprises two principal components: tail stock component 150 a which possesses a certain degree of flexibility (as is discussed more particularly below in reference to FIG. 5B) together with flat wall member portion 150 b . Carrier wall portion 150 b (also referred to herein using reference numeral 152 ) includes guide portions 153 . Guide structures 153 preferably include tongue and groove-like structures which serve to guide carrier 150 in a more uniform vertical motion with respect to top wall 120 . FIG. 4 also illustrates adjusting bracket 151 which includes a top portion (not visible) which rides in a toothed slot along tail stock 150 a and includes a ratchetting pawl together with a release mechanism such as that shown in the above-referenced patent issued in the name of one of the inventors herein. Adjusting bracket 151 therefore provides a mechanism for holding various sizes of printed circuit cards in carrier mechanism 150 .
Attention is now directed to the sequence shown in FIGS. 5A-5I. This sequence illustrates the easy loading aspects of the present invention with respect to the placement of printed circuit cards therein. A parts list for a cartridge in accordance with the present invention includes: (1) bezel and linkage subassembly (front wall 130 , top wall 120 , linkage mechanism 141 - 149 , and carrier 150 ); (2) cover 110 , clip 154 ; (3) short card arm 155 ′; (4) long card arm 155 ″; and (5) eight screws ( 171 - 178 ).
In preferred embodiments of the present invention, printed circuit card 200 to be inserted is a standard PCI (Personal Computer Interface) card. However, the present invention is not limited to the utilization of these specific printed circuit cards.
The process for inserting card 200 into cartridge 100 of the present invention begins with a consideration of FIG. 5 A. Printed circuit card 200 is oriented as shown by loading the upper front corner of card 200 into clip 154 and rotating card 200 so that it engages its heel portion with slot 156 . This operation is done for both short and for long printed circuit cards. To accommodate cards which are short in height, clip 154 is slid down until the card is held securely at clip 154 and at heel 156 together. For a detailed description of appropriate sliding mechanisms for carrying out this operation, attention is directed to the above-mentioned patent. The operation shown in FIG. 5A is performed with front wall or bezel portion 130 rotated out of the way, as shown.
Next, as illustrated in FIG. 5B, tail stock portion 150 a of carrier 150 is bent down ( 150 a ′) to allow for either short card arm 155 ′ or long card arm 155 ″ to be attached to carrier 150 . In particular, carrier 150 with tail stock portion 150 a is shown as 150 a ′ as being bent down in FIG. 5 B. Arms 155 ′ and 155 ″ (not both present at the same time) are provided for slideable adjustment along tail stock 150 a of carrier 150 . In particular, in preferred embodiments of the present invention, these arms slide in a ratchetting toothed strip and are provided with releasable pawl mechanisms for snugging up against inserted printed circuit card 200 . Again, attention is directed to the above-referenced patent which is incorporated herein by reference. To position arm 155 ′ and 155 ″ onto a card edge, the arm is slid horizontally. When the arm is squared to the card edge, the arms are pressed against the edge so as to engage clip or heel portions found on the bottoms of short or long card arms 155 ′ or 155 ″.
FIG. 5C illustrates the fact that front wall or bezel 130 may also be temporarily removed from top wall 120 to accommodate passing tab 203 on shield plate 202 of printed circuit card 200 through aperture 133 provided for that purpose in the front of bezel 130 . FIG. 5C also illustrates the relative positions of adjusting arms 155 ′ and 155 ″ (short card and long card positions, respectively).
FIG. 5D illustrates several additional features of the present invention and further aspects of assembly. In particular, FIG. 5D illustrates the presence of brace 136 which extends from a bottom portion of front wall 130 in a substantially diagonal direction so as to be affixable to top wall 120 at point somewhat distal from the top portion of front wall 130 . Bracket 136 preferably comprises metal. It is attached to front wall member 130 by any convenient means particularly including spot welding. Bracket 136 provides additional rigidity which is found to be at least somewhat desirable when polymeric components are employed.
Additionally, FIG. 5D illustrates the presence of notch 139 in the side of front wall member 130 . Notch 139 is provided to permit easy passage of clip or heel 156 as front wall 130 is reattached to the assembly during loading operations for printed circuit cards. A more detailed view of this notch is provided in FIG. 5 E.
Next is considered the illustration shown in FIG. 5 F. FIG. 5F illustrates yet another aspect of the present invention. In particular, FIG. 5F illustrates the relationship between top wall member 120 , front wall or bezel 130 , and moving carrier 150 which includes tail stock portion 150 a and flat plate portion 150 b . In particular, FIG. 5F illustrates the presence of brace 136 which extends from bezel 130 to top wall member 120 to which it is ultimately attached via two screws 171 and 172 (see FIG. 5 G). Since one of the objects of the invention is to provide as thin a profile as possible, while still preserving structural rigidity, it is seen that carrier plate portion 150 b also preferably includes recess 157 . The presence of recess 157 permits brace 136 to be mounted in corresponding recess 129 in top wall channel support 120 using screws 171 and 172 as shown in FIG. 5 G. Additionally, it is seen that top wall 120 and movable carrier 150 both include mating slidable portions 153 which provide improved guidance to more readily ensure vertical motion as lever 141 is actuated. Tongue and groove structures are employed to provide suitably mated sliding portions. It is also seen in FIG. 5 F and in FIG. 5G that front wall or bezel 130 includes notch 139 which is provided for ease of assembly and, in particular, for ease in passage of clip 156 (see FIG. 5 A).
In addition to the features shown above, it is seen that FIG. 5G indicates the presence and utilization of adjustable arm 155 ′. In particular, the particular form of the adjustable arm shown in FIG. 5G is that which is used to support short printed circuit cards. Additionally, it is seen that FIG. 5G illustrates the presence of tab 204 which is preferably present on the top of EMI shield plate 202 which is attached to printed circuit card 200 (see also FIGS. 5 H and 5 I). In particular, this tab preferably includes stamped or pressed prongs which slide against the interior front wall portion of bezel 130 to provide continuous electrical contact for purposes of providing continuous EMI shielding as lever 141 is actuated to move carrier 150 and board 200 into position. It is also noted that, as this motion takes place due to the actuation of lever 141 , EMI shield plate 202 also moves downward so as to move tab 203 through opening 133 in bezel 130 (see FIG. 12 B).
FIG. 5H illustrates a final assembly operation for a cartridge in accordance with the present invention. In particular, it is seen that cover 110 is slid into position and is fastened to top wall member 120 using screws 176 , 177 , and 178 , as shown. Lastly, front wall member 130 is pivoted into final position and affixed to the assembly via screws 174 and 175 , as shown. The completed assembly is shown in FIG. 5I in isometric view.
Having described cartridges for carrying printed circuit cards, attention is now directed to the printed circuit board intended for use in conjunction with the cartridges of the present invention. In particular, FIG. 6 illustrates cartridge 100 fully inserted into printed circuit board 300 . In particular, it is noted that ridge 111 on cover 110 slidably engages grooves or slots 351 in guides 350 which are affixed to printed circuit board 300 through openings in stiffener 330 . It is also noted that cartridge 100 preferably includes interlocking mechanisms 112 and 113 . If a cartridge in accordance with the present invention were to be inserted in the slot just to the right of the occupied slot in FIG. 6, its mating interlocking portion 113 would engage the corresponding mating interlocking portion 112 on the cartridge that is already shown. In this fashion when a plurality of cartridges are inserted into a printed circuit board in accordance with the present invention, there is formed an interlocking structure which provides enhanced strength, rigidity, and alignment characteristics.
FIG. 6 also illustrates the presence of a parallel row of apertures 331 and 332 present in stiffener 330 . These apertures accommodate the easy insertion of EMI spring shield member 500 which is more particularly described below (see FIGS. 13 A and 13 B). It is EMI shield spring 500 which is engaged by tab portion 203 of EMI shield plate 202 . Tab 203 is deployed downwardly through opening 133 in bezel 130 to provide continuous EMI shielding between card 200 and stiffener 330 which preferably comprises a conductive material such as metal when employed for EMI shielding purposes.
Attention is next directed to the apparatus shown in FIG. 7 . FIG. 7 illustrates a number of the cooperating subsystems of the present invention. As with FIG. 6, it illustrates the cooperative interaction between cartridge 100 and printed circuit board 300 particularly with respect to guides 350 present on board 300 . Guides 350 also include optional alignment tabs 353 which serve as helpful guides during cartridge insertion. In operation of the systems of the present invention, cartridge 100 is aligned with slots or grooves 351 (see FIG. 8) in guides 350 and is inserted so as to occupy the position as shown in FIG. 7 . At this point, lever arm 141 is actuated, preferably by a lifting motion, which causes internally disposed carrier 150 to move downward and to thereby insert card edge connector 201 into corresponding printed circuit board connector 311 . During actuation of lever arm 141 , plate 202 with tab 203 is moved likewise downward so that tab 203 makes contact with EMI spring shield 500 which is already in contact with stiffener 330 .
FIG. 7 also shows the preferable positioning for board insertion and removal mechanism 400 , or at least so much of that system as is visible in FIG. 7 . Additional aspects of board removal system 400 are more particularly described below. However, spur gear 411 and toothed arm 420 (see FIG. 11) are nonetheless visible in FIG. 7 .
FIG. 7 also indicates the inclusion of rear board edge connector 340 disposed on the back edge of board 300 . Also discernible in FIG. 7 is the preferred structure of the present invention in terms of the printed circuit board assembly itself. In particular, it is seen that board 300 includes insulative base 320 , printed circuit subboard 310 , and stiffener 330 . Stiffener 330 preferably comprises metal when employed for EMI shielding purposes. However, in those embodiments of the present invention in which EMI shielding is not a factor, nonconductive materials may be employed in the fabrication of stiffener 330 . However, in preferred embodiments of the present invention stiffener 330 preferably comprises a single stamped and formed sheet of metal.
As an additional observation with respect to FIG. 7, it is seen that, as is often the case with printed circuit board structures, certain circuit components extend upwards from its surface. Accordingly, it is seen that stiffener 330 may include selective apertures therein for the passage of components, such as capacitors 342 and/or heat sinks 341 . Those skilled in the electronic arts will readily appreciate that other components may be employed and may be positioned in different places with respect to stiffener 330 .
FIG. 8 provides a more detailed view of some of the structures seen in FIG. 7 . In particular, it is seen that circuit board connectors 311 are disposed between rows of board level guides 350 . In preferred embodiments of the present invention, guides 350 are formed from an integral polymeric structure as is readily fabricated in a molding operation.
Attention is next directed to the description of the mechanism employed in the present invention for the insertion and removal of entire circuit board 300 together with any cartridges 100 which may be inserted into and connected with the board. Preferred embodiments of this mechanism include rigid driving arm 420 with toothed portion 419 which is driven by spur gear 411 (see FIG. 11) which is affixed to plate 412 which in turn is attached to a formed portion of stiffener 330 (seen in greater detail in FIG. 11 ). Spur gear 411 preferably includes central hexagonal opening 413 for the insertion of an Allen wrench which causes rotation of gear 411 which moves drive arm 420 inwardly and outwardly in a recessed groove portion of base support member 320 . There is preferably provided at least one lever arm attached to drive arm 420 . In preferred embodiments of the present invention, two lever arms are provided. These lever arms, 421 a and 421 b , are seen in FIGS. 9 and 10. Lever arms 421 a and 421 b are pivotally attached to drive arm 420 at pin or rivet 422 . Lever arms 421 a and 421 b also include pins 423 a and 423 b respectively as best seen in FIG. 10 . These pins ride in slots 360 a and 360 b respectively formed in base support member 320 .
In what is best as described as a “back stroke motion,” as drive arm 420 is driven inwardly, drive arm 420 together with lever arms 421 a and 421 b change configuration from a “Y” configuration as seen in FIG. 10 to a “T” configuration as illustrated in FIG. 9 . As the configuration of these arms changes, edges of arms 421 a and 421 b push against pins found on the enclosure or frame into which the board is inserted. These pins are located externally to the printed circuit board shown but are present at corresponding positions 430 a and 430 b on circuit board 300 . It is these positions which correspond to the pin positions on the external enclosure. Likewise, during removal operations, the other edges of arms 421 a and 421 b press against horizontally mounted external pins found in slots 435 a and 435 b , respectively. These slots are present in base support member 320 . However, the pins which lie in these slots are in fact part of the enclosing apparatus or the frame into which the circuit board assembly is inserted. In this way, through a “reverse back stroke” operation, the entire board assembly is easily removed from the system into which it is connected.
FIG. 11 is also useful for illustrating part of the EMI shielding system of the present invention. In particular, FIG. 11 shows the inclusion of EMI spring shield 500 which is shaped to be readily inserted into apertures 331 and 332 in stiffener 330 . In particular, aperture 331 includes a forward edge which engages a forwardly facing slot or pocket (reference numeral 502 in FIG. 13 B). Accordingly, shield 500 includes an edge which is in firm electrical contact with stiffener 300 . The other edge of shield 500 includes a flexible portion 501 which extends through aperture 332 . The leading edge portion of shield spring 500 includes peak 504 which electrically contacts bezel 130 during cartridge insertion (see FIG. 12 A). FIG. 12A illustrates the insertion an edge of aperture 331 into slot or pocket 502 in spring shield 500 . FIG. 12A also illustrates the presence of printed circuit card shield plate 202 in its fully downward position extending through aperture 133 in bezel 130 . In doing so, tab 203 on plate 202 also electrically engages a portion of shield spring 500 . In particular, tab 203 engages edge 507 seen in FIG. 13 A.
FIGS. 13A and 13B provide a detailed description of the structure of EMI shield spring 500 . This spring shield preferably comprises a single sheet of stamped metal which is formed as shown. Preferable materials for this shield spring include beryllium copper ½ hard with an alternate of stainless steel ½ hard. FIG. 13A provides a top view of the desired structure, and FIG. 13B provides an end view. There are apertures in spring shield 500 between edges 505 and 507 . It is through these apertures that tab 203 is disposed so as to contact edge 507 . Region 509 is a tab region of the structure as is region 501 . Top or peak 504 engages the bottom portion of bezel 130 . Also of note is the presence of pocket or slot 502 which engages an edge of aperture 331 in stiffener 330 . In particular, it is noted that as stamped shield 500 preferably includes prongs 503 which are formed by the stamping operation employed in the manufacture of the shield spring. Prong 503 is also employed to provide improved electrical contact between shield 500 and stiffener 330 . It is further noted that FIG. 13B is particularly useful in that it identifies a plurality of surfaces or edges that are also visible in FIG. 13 A. Correspondingly numbered parts are shown in these two figures.
From the above, it is seen that the present application describes an interrelated system of structures and devices all of which are aimed at providing tightly packed, dense, well-shielded printed circuit board and cartridge structures which renders it possible to insert and remove entire printed circuit boards even when fully populated by printed circuit cards. In particular, it is seen that the printed circuit card cartridges of the present invention provide a cooperative housing and insertion structure for board level guides and which also incorporate an integrated EMI shield system which is fully operative before, during, and after card insertion. It is further seen that the system of the present invention includes a relatively stiff printed circuit board which is capable of sustaining insertion and removal forces even when fully populated with electronic printed circuit card components.
It is also seen that the present invention includes structures which provide continuous EMI shielding which mates with and matches shielding from a printed circuit card to corresponding EMI shield structures found on the printed circuit board itself. It is also seen that the cartridge preferably employed in the present invention includes pivotably mounted components which make printed circuit card insertion relatively easy. Lastly, but not limited hereto, it is seen that the system and apparatus described in the present application fulfills, either individually or collectively, in its various embodiments, all of the objectives set forth above though not necessarily all of them simultaneously.
While the invention has been described in detail herein in accordance with certain preferred embodiments thereof, many modifications and changes therein may be effected by those skilled in the art. Accordingly, it is intended by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention.
|
An electronic printed board assembly comprises a printed circuit board which employs printed circuit card connectors electrically connected to components mounted on the board. The printed circuit board includes board level guides with slots for receiving correspondingly shaped ridges disposed on outer, lower portions of printed circuit card-bearing cartridges. The guides are preferably provided on only one side for each cartridge to improve packaging density. The surface guides, together with the cartridge design, eliminate the need for physical contact with surrounding enclosures or cabinets.
| 7
|
TECHNICAL FIELD
This invention relates to hydraulically assisted power steering gears with detent mechanisms.
BACKGROUND OF THE INVENTION
A hydraulically assisted power steering gear with a detent mechanism typically has a steering gear input member and a steering gear output member. As vehicle speed increases, the detent mechanism tends to mechanically engage the output member to the input member with increasing force, mechanically positioning the output member with the input member to a mechanically balanced position. The relative orientation between the input member and the output member in the mechanically balanced position is typically determined by plungers or spheroids, rotating with the output member, being pressed into detent recesses in the input member.
A rotary hydraulic valve has a spool portion integral with the input member and a sleeve rotatively fixed to the output member. The hydraulic valve is trying to position the output member relative to the input member simultaneous with the detent mechanism trying to position the output member relative to the input member. If the valve spool portion is not in a hydraulic on center position, that is, not in a hydraulically balanced position, with respect to a valve sleeve, the valve supplies fluid to a bi-directional actuator which causes the output member, and hence the valve sleeve, to rotate back toward the hydraulically balanced position.
Because both the valve spool portion and the recesses in the input member are integral with the input member, the hydraulically balanced position cannot be selectively aligned with the mechanically balanced position by rotating the valve spool portion relative to the recesses.
SUMMARY OF THE INVENTION
This invention permits rotative repositioning of the hydraulically balanced position to the mechanically balanced position by rotatively separating the detent recesses of the input member from the valve portion of the input member. Detent recesses, normally on the input member, are placed on an end of a tubular stub shaft. The tubular stub shaft is largely disposed within the input member except for the end with the detent recesses which extends beyond the input member. The valve spool portion remains integral with the input member.
The output member and tubular stub shaft are first oriented to the mechanically balanced position. The input member is then rotated to the hydraulically balanced position. The tubular stub shaft and the input member are then rotatively fixed to one another.
It is an object of this invention to provide a power steering gear having a tubular stub shaft with detent recesses, having an input member with a valve spool portion, having a hydraulically balanced position controlled by the rotative position of the input member relative to an output member, and having a mechanically balanced position controlled by the rotative position of the tubular stub shaft relative to the output member, the input member being selectively fixed to the tubular stub shaft to align the hydraulically balanced position with the mechanically balanced position.
This and other objects and advantages will be more apparent from the following description and drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side sectional view of a steering gear.
FIG. 2 shows an enlarged view of a portion of FIG. 1 where a tubular stub shaft and an input member are axially linked by a retaining ring.
FIG. 3 shows a partially exploded isometric view of the input member, the tubular stub shaft and a torsion rod.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A hydraulically assisted power steering rack and pinion steering gear 10 has a main housing 12 with a cylindrical rotary valve portion 14 and an integral rack support portion 16. The steering gear 10 provides a link between a steering wheel 18 and a pair of steerable road wheels (not shown). The steering wheel 18 is rotatively connected to a first end 20 of an input member 22. An output member 24 is connected to the pair of steerable road wheels through a steering gear rack 26 disposed within the integral rack support portion 16 of the main housing 12. The input member 22 and the output member 24 are both disposed within the cylindrical rotary valve portion 14 of the housing and rotatable about a steering gear axis 28 coincident with a center 30 of the cylindrical rotary valve portion 14 of the main housing 12. A rotary valve 32 is disposed between the output member 24 and the input member 22. A suitable rotary valve is described in U.S. Pat. No. 3,022,772, issued to Zeigler et al. on Feb. 27, 1962 and assigned to the assignee of this invention.
A detent mechanism 34 is interposed between the output member 24 and a tubular stub shaft 36. The tubular stub shaft 36, rotatable about the steering gear axis 28, is disposed within the input member 22. Both the input member 22 and the tubular stub shaft 36 have a first end 20, 38 and a second end 40, 42. The first end 38 of the tubular stub shaft 36 is within the first end 20 of the input member 22. The second end 42 of the tubular stub shaft 36 extends beyond the second end 40 of the input member 22.
Detailed descriptions of similar steering gears having detent mechanisms interposed directly between the output member and the input member are found in U.S. Pat. No. 4,768,604 to Schipper on Sep. 6, 1988, and U.S. Pat. No. 4,759,420 to Schipper, Jr. et al. on Jul. 26, 1988, both assigned to the assignee of the present invention.
A retaining ring 44 is disposed between the tubular stub shaft 36 and the input member 22. The ring 44 is formed of wire 46 with a constant diameter 47. A center 48 of the wire 46 forms a diameter D equal to an outside diameter 50 of the tubular stub shaft 36 as best seen in FIG. 2. The ring 44 is split to allow radial expansion and contraction. The tubular stub shaft 36 accommodates the ring 44 with a tubular stub shaft retaining ring groove 52 circumscribed about the outside diameter 50 of the tubular stub shaft with a minimum depth equal to the wire diameter 47. The input member 22 accommodates the ring 44 with an input member retaining ring groove 54 circumscribed about an inside diameter 56 of the input member 22, with a depth of about one half the wire diameter 47.
A torsion rod 58 with a first end 60 and a second end 62 is disposed within the tubular stub shaft 36 such that the first end 60 of the torsion rod 58 is axially aligned with the first end 20 of the input member 22 and the first end 38 of the tubular stub shaft 36. The first end 60 and the second end 62 of the torsion rod 58 are larger in diameter than a center portion 64 of the torsion rod 58.
The second end 62 of the torsion rod 58 extends beyond the second end 42 of the tubular stub shaft 36 and into the output member 24. The second end 62 of the torsion rod 58 is rotatively fixed to the output member 24. The torsion rod 58 rotatively supports the second end 40 of the tubular stub shaft 36.
The second end 42 of the tubular stub shaft 36 has detent recesses 66 between radial splines 68, as best seen in FIG. 3. The second end 42 of the tubular stub shaft 36 has a block tooth 70 extending beyond the detent recesses 66 toward the first end 38 of the tubular stub shaft 36, also best seen in FIG. 3. The input member 22 has a block tooth groove 72 accommodating the block tooth 70. With the block tooth 70 inserted in the block tooth groove 72, the relative rotation between the input member 22 and the second end 42 of the stub shaft 36 is limited to 7°.
A valve spool portion 74 of the input member 22, proximate to the second end 40 of the input member 22, cooperates with an encircling valve sleeve 76 to function as the rotary valve 32. The valve sleeve 76 is rotatively fixed to the output member 24. The valve sleeve 76 and the output member 24 axially overlap to accommodate a drive pin 77 passing between the two of them 76 and 24. The cylindrical rotary valve portion 14 of the housing 12 serves as a valve housing to the rotary valve 32, aiding in the routing of fluid between the valve 32 and a steering actuator, or steering piston within a cylinder (not shown).
The valve sleeve 76 and the valve spool portion 74 have a hydraulically balanced position relative to each other where fluid is ported equally to both sides of the steering piston. The torsion rod 58, when fixed at its first end 60 to the first end 20 of the input member 22, maintains the valve spool portion 74 and valve sleeve 76 in the hydraulically balanced position in an absence of steering wheel torque. An application of torque to the steering wheel 18 by the vehicle operator tends to torsionally deflect the center portion 64 of the torsion rod 58, producing relative rotative displacement between the valve sleeve 76 and the valve spool portion 74. A torsional stiffness of the center portion 64 controls a steering effort required by a vehicle operator to steer the road wheels.
Displacement away from the hydraulically balanced position results in fluid being ported principally to a selected side of the steering piston. Porting pressurized fluid to one side of the steering piston results in the steering piston being stroked, or displaced. The steering piston in turn axially displaces the rack 26, thereby rotating the output member 24 and the valve sleeve 76 until the hydraulically balanced position is again achieved. Determination of the input member 22 to output 24 member orientation corresponding to the hydraulically balanced position is usually done on a flow bench by varying the input member 22 to output member 24 orientation until flow to both sides of the piston is equalized.
The output member 24 has a pinion portion 78 with teeth 80 engaging the rack 26. The output member 24 has a flange 82 proximate to the pinion portion 78. The flange 82 is circumferentially sealed with the cylindrical rotary valve portion 14 of the housing 12. Opposite the flange 82 from the pinion portion 80 is a detent portion 88 of the output member. The detent portion 88 of the output member 24 is proximate to the second end 40 of the input member 22.
The output member 24 has a cavity 92 in the detent portion 88, centered about the steering gear axis of rotation 28. The cavity 92 is sufficiently large to accommodate the insertion of the second end 42 of the tubular stub shaft 36. A blind hole 94 at a bottom 96 of the cavity 92 accommodates insertion of the second end 62 of the torsion rod 58 into the output member 24. The cavity 92 has radial splines 97 complementary to the splines 68 of the stub shaft 36 which limit relative rotation between the output member 24 and the stub shaft 36 to 3°.
The detent portion 88 of the output member 24 has sockets 98 corresponding in number and location to the detent recesses 66 in the tubular stub shaft 36. The sockets 98 lie in a plane perpendicular to the steering gear axis of rotation 28 and are oriented radially about the steering gear axis of rotation 28. Spheroids 100, or detent engaging elements, are disposed in the sockets 98, and protrude beyond the sockets 98 even when the spheroids 100 are pressed into the detent recesses 66. When the sockets 98 are aligned with the recesses 66 in the tubular stub shaft 36, the spheroids 100 simultaneously protrude uniformly beyond the detent portion 88 of the output member 24.
An annular piston 102 has a piloting portion 104 joined to a dish portion 106. The piloting portion 104 pilots on the detent portion 88 of the output member 24. The piloting portion 104 of the annular piston 102 is slidably disposed between the sockets 98 and the output member flange 82. The piloting portion 104 is sealed against the output member 24. The dish portion 106 is sealed against the cylindrical rotary valve portion 14 of the housing 12. The dish portion 106 of the annular piston 102 has a chamfered side 112 facing the sockets 98. The chamfered side 112 contacts the spheroids 100.
A spring 114 between the output member flange 82 and the annular piston 102 provides a spring force pressing the chamfered side 112 of the annular piston 102 against the spheroids 100, in turn pressing the spheroids 100 into the detent recesses 66. Force from the spring 114 against the annular piston 102 seats the spheroids 100 in the detent recesses 66, thereby rotating the tubular stub shaft 36 to a mechanically balanced position relative to the output member 24. A detent apply chamber 116 between the output member flange 82 and the annular piston 102 is supplied with fluid at a pressure which increases with vehicle speed The pressure increases the force against the annular piston 102, increasing the force against the spheroids 100. A means for supplying fluid at a pressure which increases with vehicle speed is provided by an auxiliary pump 115 to the chamber 116 through a detent pressure port 117 as described in U.S. Pat. No. 4,768,604 and U.S. Pat. No. 4,759,420.
Alignment of the mechanically balanced position with the hydraulically balanced position is achieved in the following manner. The steering gear 10 is completely assembled except for fixing the first ends 20, 38, 60 of the input member 22, the stub shaft 36, and the torsion rod 58 together. The output member 24 is held in place during the alignment procedure. The spring 114 acting against the annular piston 102 forces the detent mechanism 34, and consequently the stub shaft 36 and the output member 24, into the mechanically balanced position.
After mounting the steering gear 10 on a flow bench, with the stub shaft 36 and the output member 24 remaining in the mechanically aligned position, the input member 22 is rotated relative to the output member 24 until the hydraulically balanced position is reached. The torsion rod 58, rotatively fixed at its second end 62 to the output member 24 remains in a neutral position, uncoupled at its first end 60. The torsion rod 58 has no residual torsion within it in the neutral position. With the stub shaft 36 and the input member 22 and the torsion rod 58 being simultaneously so aligned, their first ends, 20, 38, 60 are cross drilled accommodating a locking pin 118 rotatively fixing the first ends 20, 38, 60 of the three members 22, 36, 58 to each other. This done, torque induced in the torsion rod 58 by rotatively displacing the first ends 20, 38, 60 relative to the output member 24 restores the steering gear 10 to both the hydraulically balanced and the mechanically balanced positions simultaneously when the steering wheel 18 is released.
Obviously, many modifications and variations of the present invention are possible in light of the above teaching. It is therefore to be understood, that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
|
A power steering gear with a hydraulic valve and a detent mechanism allows simultaneous hydraulic and mechanical balancing. The hydraulic valve is rotatively separate from the detent mechanism to allow separate balancing. The hydraulic valve is integral with an input member. The detent mechanism is integral with a stub shaft which is concentric with but rotatively independent of the input member. The stub shaft and the input member are rotatively fixed to each other when both the hydraulic valve and the detent mechanism are balanced.
| 1
|
TECHNICAL FIELD
The invention relates to the use of various waste products in cementitious compositions, such as cemented mine backfill, or other stabilized earths. Such waste products may include ferrous or non-ferrous slags, as well as fossil fuel combustion residues.
BACKGROUND ART
By-products of metallurgical processes, such as slags which result from the smelting of both ferrous and non-ferrous ores, and combustion products of coal from fossil fuel powered generating stations, such as fly ash or clinker, all represent the product of a significant investment of energy which is normally lost upon the subsequent disposal of these materials, heretofore considered as waste.
The term `slag` as used in this application refers to the vitreous mass which remains after the smelting of a metallic ore, a process which entails the reduction of the metallic constituents in the ore to a molten state.
The terms `ferrous slag` or `blast furnace slag` refer to that slag which remains after the smelting of iron ore. Alternately, `non-ferrous slag` is that slag which remains after the smelting of a non-ferrous ore such as copper, nickel, lead, or zinc, whether it be done in a blast furnace or otherwise. Therefore, a slag considered non-ferrous in the metallurgical sense may contain appreciable amounts of iron due to the presence of this compound as an impurity within the ore.
Fly ash is a combustion product resulting from the burning of coal which has been ground to a relatively fine particle size. Coal which is not as finely ground produces both fly ash and a coarse, incombustible residue known as clinker.
Iron blast furnace slag, fly ash and various `natural` slags and ashes have been known for some time to have pozzolanic properties. Waste industrial slags, however, do not contain the correct quantities of essential ingredients of Portland cements. Iron blast furnace slag comes closest with a CaO/SiO 2 ratio of approximately 1. To acquire such pozzolanic properties, however, such slags must be cooled to an amorphones (or highly vitreous) state by rapid quenching, such as by immersion in a large quantity of high pressure water. It is well known for example, that granulated blast-furnaces lag obtained in the production of pig iron can be mixed with Portland cement clinker and the mixture finely ground to bring out the inherent hydraulic properties of the slag.
In most applications today where ferrous slag or fly ash is used in backfilling, one finds a combination of a small quantity of Portland cement providing some initial set and strength, and slag or fly ash, which reacts with residual CaO from the cement reactions to form calcium silicates which provide the balance of the strength required over a period of time. To enable the use of non-ferrous slags as cement, however, the chemical composition of typical nonferrous slags must generally be modified to produce a product capable of competing with Portland cement, i.e. to one capable of achieving high early strength as well as a high ultimate strength within an acceptable time frame.
Applicants have determined that a higher quality, less expensive cemented backfill may be produced, without the use of Portland cement, by adjusting the proportions of both CaO and Al 2 O 3 in non-ferrous slag. This adjustment then converts the slag from a `low-grade` pozzolan to a `high-grade` pozzolan wherein the necessary aluminate reaction can be harnessed by adjusting the sulphate ion and calcium hydroxide concentrations. Further, the methods for making cement from non-ferrous slag may also be extrapolated and used to prepare improved cements utilizing ferrous slags or fossil fuel combustion residues.
SUMMARY OF THE INVENTION
The invention relates to a method for making cementitious compositions from a residue of waste industrial products such as non-ferrous slags, fossil fuel combustion residue or ferrous slags. This method includes the step of grinding the vitreous waste residue whose composition may or may not have been altered by the addition of CaO and/or Al 2 O 3 , to a predetermined particle size, and adding calcium hydroxide or CaO, and a compound containing a sulphate anion to form a mixture with water, which is then allowed to cure to the final cementitious compositions.
The Ca(OH) 2 or CaO added after the waste residue has been ground is to raise the pH, in the presence of the water to an alkaline value to activate the alumina component and provide a high early strength.
Many countries, including the United States, Canada, Chile, South Africa, Australia and the Scandinavian countries, produce or export a great deal of both ferrous and non-ferrous metals. This results in the production of significant quantities of slag, produced as a by-product of the required smelting operations. Blast furnace slags are currently used as additives in some low strength concretes whereas, except for railway ballast and granular fill type applications, the feasibility of potential utilizations of non-ferrous slags and fly ashes has been comparatively disregarded, leading to the disposal of substantial quantities of these commodities with resulting large accumulations in areas surrounding the smelters and power stations.
The economic feasibility of sub-surface mining techniques depends upon an ability to fill the cavities created by the removal of the ore in order to establish and retain safe working conditions. One accepted technique for performing this function involves the addition of Portland cement of the fill to act as a binder in creating a hardened cementitious composition.
The Portland cements used in this manner are specially formulated to primarily comprise specific compounds, such as tri-calcium silicates, di-calcium silicates and tri-calcium aluminates which, on hydration, provide the desired cementing or binding action. The principal constituents of these Portland cements, i.e. CaO and SiO 2 , are present in a high ratio of about 3:1 to strongly promote the calcium silicate reactions.
The difficulty and expense involved in transporting large quantities of Portland cement to often isolated mining locations has prompted a search for cheaper additives or substitutes which can reproduce the cementitious effect of Portland cement at a reduced cost. Thus, cemented fills introduce a broad new flexibility into mine planning and design; however, cost considerations limit potential applications. Any means of reducing cemented fill costs for a given fill duty, therefore, broadens the potential application for the material.
In general, if a lower cost binder whiich allows the formation of a slurry with mine tailings and/or sand at the same viscosity as that of a Portland cement slurry and which develops adequate compressive strength in adequate times to prevent collapse was available, lower grade orebodies could be mined economically. Applicants' invention serves just such a function.
The class of materials described under the broad term of `pozzolans` offers potential cost savings in cemented fill practice. A pozzolan is any material which can provide silica to react with calcium hydroxide in the presence of water to form stable, insoluble cementitious hydrated calcium silicates, or related, more complex silicates. The silicates formed by pozzolanic action are closely related to some of those formed by the hydration of Portland cement.
A preferred particle size is between 2500 and 5000 Blaine, although larger or smaller particles will work in this invention. A preferred pH range is between about 10 and 14 and this range is achieved by the addition of an alkaline compound.
The curing of samples must be done under enclosed conditions at saturated humidity.
The application of heat during mixing and curing of samples greatly enhances the strength/time relationship and temperature is a very important parameter in the successful application of the invention.
In these methods, a predetermined amount of Portland cement, aggregate, fillers, tailings, or other inert material can be added to the mixture prior to adding the water.
The compound containing CaO or Al 2 O 3 may be added to a furnace during the generation of the slag, or it may be added to said slag after the slag has been formed and before it is granulated. A preferred CaO containing compound is lime for both composition modification and pH adjustment. A preferred Al 2 O 3 containing compound is fly ash. Also, preferred compounds containing a sulphate anion include sodium sulphate or gypsum.
Finally, the invention relates to the cementitious compositions produced by the previously described methods.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As one skilled in the art would realize, the chemical analysis of various slags from either ferros or non-ferrous ore smelting operations as well as that of the fly ash or clinker which results from fossil fuel combustion, can vary over a wide range. Average typical analyses for such materials are set forth in Table I. This table includes the major components of the slags, but a minor amount of additional components such as metal oxides, sulphides, etc. may also be present.
TABLE I______________________________________COMPOSITION OF TYPICAL SLAGS Weight Percent CaO SiO.sub.2 Al.sub.2 O.sub.3 Fe.sub.2 O.sub.3______________________________________Nickel Reverberatory Slag 2-10 32-36 2-10 44-56Copper Reverberatory Slag 1-8 33-40 2-10 47-50Iron Blast Furnace Slag 35-50 28-38 10-20 3-5Non-Ferrous Blast Furnace 15-20 32-38 2-10 30-40SlagFossil Fuel Combustion 2-15 38-67 15-38 3-13Residue (Fly Ash)______________________________________
The present invention relates to a composition and a method for obtaining useful cementitious products comprised of such waste residues by adjusting and balancing various important components to control the cementitious reactions in the final compositions. As shown in Table I, non-ferrous slags typically have relatively low calcium oxide and alumina contents. Such amounts of calcium oxide and alumina are often insufficient to provide for the required calcium sulpho-aluminate and calcium silicate reactions and thus, such slags are not suitable for use on their own as cements unless their chemistry is appropriately modified.
Such a modification of the calcium oxide content can be carried out using a variety of methods. During the formation of slag in a furnace, additional lime or limestone may be added during the smelting process, with a corresponding increase in the final calcium oxide content of the slag. Similarly a modification of the aluminium oxide content can be achieved by the addition of, say fly ash, during the smelting process.
Once a slag of the correct composition has been made and granulated to a high glass content it must be ground, together with the gypsum if necessary, to a predetermined fineness, preferably between about 2500 and 5000 Blaine.
Thus, the addition of water and an alkaline material, preferably lime, serves to activate this composition. Differentiation is necessary, however, between lime used as an activator and lime added to the furnace feed to increase the CaO content of the slag, this being the lime which subsequently plays a major role in the cementitious reactions. It is necessary that this CaO be incorporated into the amorphous structure of the slag to enhance its disordered chemical state and increase its reactivity.
The alkaline material, added in order to activate the mixture, adjusts the pH upwardly to about twelve and allows the formation of gels and AlO 2 ions. Unless gypsum (CaSO 4 2H 2 O) or some other sulphate ion containing materials are added, however, the alumina component remains unreactive. In order for the cementious compound to be successful, its alumina component chemistry must approach that of the compound Ettringite, a calcium monosulpho-aluminate compound with the approximate formula Ca 6 Al 2 (So 4 ) 3 (OH) 12 .26H 2 O. The traditional `pozzolanic` slag-lime-water system is generally deficient in sulphate radical and unless this added from some extraneous source, the desired cementitious reactions will not occur. It is possible that in certain ores, the sulphate radical may exist in the mill tailings in a form in which it would be available for the cementitious reactions but for most cases, additional sulphate ions must be added to the slag. Thus, it is critical to adjust the sulphate content to a range which, when combined with the other ingredients, provides the approximate stoichiometric ratio found in the mineral ettringite. The sulphate anion can be added as either gypsum or sodium sulphate or other.
The pH of the mix may be raised to the requird alkaline value by addition of an alkali metal hydroxide or other base, or by the addition of alkaline materials such as sodium carbonate, sodium bicarbonate or potash, provided they are accompanied by the addition of free lime.
By adjusting all of these components within the parameters stated above, a cementitious composition is formed, having a portion which forms ettringite-like structures, thus obtaining sufficient strength and stability in the final cementitious product.
With respect to ferrous slags, a similar procedure could be followed. Such slags, however, usually contain a much higher calcium oxide and alumina content than non-ferrous slags and their compositions would not need adjusting. the other steps described above would be followed in an essentially identical fashion to those for non-ferrous slags in order to achieve the desired cementitious compositions. Fly ash or other fossil fuel combustion residue would be treated in the same manner as ferrous slags.
As would be clearly understandable to one skilled in the art, the cementitious compositions of the present invention may be used alone, or they may be mixed with a wide variety of fillers, aggregate, accelerators, retarders or other additives. Also, such cementitious compositions can be substituted for all or a portion of the Portland cement component of ordinary cementitious compositions or concrete. Such cements can also be mixed with high aluminous cements, pozzolans or other materials to form specialty cements for specific applications.
While it is apparent that the invention disclosed herein is calculated to provide an improved cementitious system over those described in the prior art, it will be appreciated that alternate embodiments may be devised by those skilled in the art. It is therefore intended that the appended claims cover all modifications or embodiments as fall within the true spirit and scope of the present invention.
|
Methods for producing cementitious compositions from waste products, such as non-ferrous slags, or fossil fuel combustion residue, or ferrous slags, whereby the CaO and alumina contents of the waste products are adjusted as necessary to enable them to combine with a sulphate additive at elevated pH and so couple the faster reactions of the mineral Ettringite with the slower ones of the calcium silicates.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to gel compounds within conduits or buffer tubes and more specifically to the reduction of dripping of the gel compounds at higher temperatures while providing additional protection to optical fibers from water penetration.
2. Description of Related Art
Fiber optic cables have been used by the telecommunications industry for a number of years to transmit information at very high rates over long distances. Fiber optic cables come in a variety of configurations, including: cables with a centrally located single buffer tube containing one or more optical fibers; cables with a plurality of buffer tubes stranded in a helical or alternating helical arrangement about a central strength member; and cables with slotted cores in which a plurality of optical fibers reside.
The buffer tubes within the ribbon cable generally contain one or more fiber optic ribbons centrally located within the buffer tube and a gel compound surrounding the optical fiber ribbons. An example of this can be seen in FIGS. 1-4. As shown in these figures, the fiber optic ribbons 3 are centrally located within buffer tube 1 . As can be further seen from FIGS. 1-4, a gel compound 2 surrounds the fiber optic ribbons 3 . The gel compound 2 serves a number of purposes. One purpose is to provide a cushioning media between the buffer tube 1 and the fiber optic ribbons 3 to thereby prevent the fiber optic ribbons 3 from contacting the sides of the buffer tube 1 . The cushioning media dissipates radial crushing force and in addition, the gel compound 2 provides delayed motion response to the fibers under scanning bending loads. Such loads occur during the installation, when cables are pulled around the corners of the ducts or over the sheaves. The same applies to the earlier stages of manufacture when buffer tube 1 is bent over the sheaves and radially compressed by caterpillars. The artificial increase in the inertia of the ribbons 3 is provided by the viscous gel media and results in time delay for fibers to accommodate the load and to move slower than in a non-gel media toward the tube walls 1 . When the fiber optic ribbons 3 contact the sides of the buffer tube 1 , signal attenuation problems occur due to micro-bending and high stress. The gel compound 2 also serves to prevent exterior items from coming into contact with the fiber optic ribbons 3 if the buffer tube 1 is penetrated. For example, the gel compound 2 protects the fiber optic ribbons 3 from water that might penetrate the buffer tube 1 .
Several problems occur in these conventional buffer tubes, especially ones in which the buffer tube 1 diameter is large (for example, greater than 0.310 inches). First, when the temperature of the gel compound 2 increases, the viscosity and yield stress of the gel compound 2 decreases. If the yield stress of the gel compound 2 decreases below a critical value, the gel compound 2 may begin to flow. For example, if the buffer tube 1 is physically positioned in a vertical manner, as shown in FIG. 5, and the buffer tube 1 is heated, the gel compound 2 within the buffer tube 1 may begin to flow towards the bottom of the buffer tube 1 , leaving a cavity 4 .
In more detail, as the temperature of the buffer tube 1 increases, the buffer tube 1 expands, thereby increasing the diameter and length of the buffer tube 1 , according to the difference between the coefficient of thermal expansion (“CTE”) of the buffer tube material 1 and gel compound 2 . As for the gel compound 2 , as noted above, as its temperature increases, the viscosity and yield stress of the gel compound 2 decreases. As shown in FIG. 5, gravity provides a downward force to the gel compound 2 while frictional forces (F 1 and F 2 ) with the tube wall are transmitted through the material by the yield stress of the gel compound 2 . Friction between the gel compound 2 and the buffer tube 1 is labeled F 1 while the fiction between the gel compound 2 and the fiber optic ribbons 3 is labeled F 2 . Consequently, as the temperature of the gel compound 2 increases, the yield stress of the gel compound 2 decreases and the ability of the gel to transmit friction forces F 1 and F 1 through the gel compound 2 decreases. Since the downward force of gravity remains constant during an increase in temperature of the gel compound 2 , when the temperature of the gel compound 2 increases, the downward force of gravity on the material becomes greater than the upward force that can be transmitted through the material through the yield stress of the gel compound 2 . As a result, the gel compound 2 may flow downward.
Once the gel compound 2 “runs away,” it does not provide adequate protection to the fiber optic ribbons 3 . The fiber optic ribbons 3 tend to contact the buffer tube walls 1 , which in turn causes attenuation problems. Therefore, it is an object of the present invention to improve the compound flow performance of gel compound-filled fiber optic cables.
Additionally, gel compound 2 may be “forced” out of the buffer tube 1 when heated due to the difference between the CTE of the buffer tube 1 and the CTE of the gel compound 2 . As stated earlier, when heated, both the buffer tube 1 and the gel compound 2 expand according to their respective CTE. If the CTE of the buffer tube 1 is less than the CTE of the gel compound 2 , then the gel compound 2 expands more than the buffer tube 1 . Since the gel compound 2 is expansionally limited in the radial direction by the buffer tube 1 , if the gel compound 2 expands more than the buffer tube 1 when heated, the additional expansion of the gel compound 2 is directed in the axial direction. As a result, gel compound 2 is “forced” out of the ends of the buffer tube 1 .
Another problem occurs when the gel compound-filled buffer tubes 1 contain relatively large air bubbles 6 . The air bubbles 6 are often formed by the upward movement and coalescence of smaller air bubbles that were not completely removed from the gel compound 2 under vacuum conditions. Additionally, air bubbles 6 can be entrapped in the gel compound 2 during the extrusion of the gel compound 2 and buffer tube 1 . In horizontal position, coalesced bubbles 6 form continuous air passages. Air bubbles 6 can significantly ease water penetration and can further help water, that has penetrated the buffer tube 1 , to move axially within the buffer tube 1 . Exposing optical fiber 3 to water can result in optical fiber deterioration.
Another problem with the conventional buffer tubes is the stability or integrity of the ribbon stack shape under the bending loads. In particular, when the stack twist laylength is long and the tube or cable is bent about a small-radius object, the ribbon stack may collapse. The ribbons 3 may slide sideways and “fall” sideways causing ribbon damage and fiber attenuation. Thus, it is desirable to provide means for holding the stack with initial, typically rectangular shape of its cross section.
SUMMARY OF THE INVENTION
According to one aspect of the invention, optical fibers are provided in a conduit along with water swellable material and a gel compound. In one of the preferred embodiments, the conduit is a buffer tube.
More specifically, the present invention solves the above-described problems and limitations by placing water swellable yarns and/or water absorbing particles within gel compound-filled conduits or the buffer tubes. The water swellable yarns and particles, when in contact with water that has penetrated the buffer tube, begin to swell. As a result, the yarns and particles provide many beneficial effects. First, when water penetrates the buffer tube and comes in contact with the water swellable yarns, the yarns volumetrically expand and fill out the volume taken by the air bubble, as well as break air channels in the horizontally positioned portions of the tubes. Second, the yarns help to compensate for the expansion of the buffer tube walls caused by the increase in temperature by making the expansion and CTE of the gel-yarn system closer to that of the buffer tube material. Finally, the yarns themselves provide surface area for the gel compound to contact which in turn provides additional friction forces that help to keep the gel compound from “flowing” downward.
In a preferred embodiment of the present invention, water swellable yams having whiskers (increased total surface area) are disposed between the fiber optic ribbon stacks and the walls of the buffer tube. The water swellable yarns vary in size and surround the fiber optic ribbon stacks.
Further objects, features and advantages of the invention will become apparent from a consideration of the following description and the appended claims when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The above aspects of the present invention will become more apparent by describing in detail embodiments thereof with reference to the attached drawings, in which:
FIG. 1 is a plan view of a conventional buffer tube;
FIG. 2 is a side view of a conventional buffer tube with a transparent front of the buffer tube;
FIG. 3 is a side view of a conventional buffer tube;
FIG. 4 is a side view of a conventional buffer tube taken along the IV—IV line of FIG. 1;
FIG. 5 is side view of a conventional buffer tube taken along the IV—IV line of FIG. 1 showing the forces acting on the gel compound when the temperature of the buffer tube is increased;
FIG. 6 is a perspective view of a buffer tube according to a preferred embodiment of the present invention;
FIG. 7 is a side view of the buffer tube of FIG. 6 showing the forces acting on the gel compound when water swellable yarns are embedded in the gel compound;
FIG. 8 is an overhead view of the buffer tube of FIG. 6;
FIG. 9 is an overhead view of another embodiment of the present invention when water swellable particles are embedded in the gel compound.
FIG. 10 is a plan view of a buffer tube of the present invention having optical fibers circumferentially arranged within the buffer tube; and
FIG. 11 is a perspective view of a buffer tube of the present invention having a yarn helically disposed around optical fibers.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, embodiments of the present invention will be described in detail with reference to the attached drawings. The present invention is not restricted to the following embodiments, and many variations are possible within the spirit and scope of the present invention. The embodiments of the present invention are provided in order to more completely explain the present invention to one skilled in the art.
Referring to FIG. 6, the present invention solves many of the problems created when a buffer tube 1 containing a single ribbon or single stack of ribbons 3 centrally located and surrounded by gel compound 2 , is penetrated by water. The buffer tube 1 can be made of any type material and can be any shape or size. Generally, the buffer tube 1 is cylindrical in shape. The fiber optic ribbons 3 can be assembled in stacks (as shown) or can be individual if necessary. The gel compound 2 is also not limited in any manner.
The present invention, as shown in FIGS. 6 and 9, embeds water swellable yarns 5 and/or particles 6 in the gel compound 2 , between the walls of the buffer tube 1 and the fiber optic ribbon stack 3 . The water swellable yarns 5 can be disposed in a number of ways. For example, the water swellable yarns 5 can run axially parallel to the fiber optic ribbon 3 or even be wrapped around the fiber optic ribbon 3 in a helical manner. In this case, the yarns 5 will provide the stability of the ribbon stack under bending conditions. The water swellable yarns 5 do not have to be evenly dispersed within the buffer tube 1 . For example, the water swellable yarns 5 can be places closer to the buffer tube walls 1 than to the fiber-optic ribbons 3 . Although FIG. 6 shows only one water swellable yarn 5 , any number of yarns can be used. As shown in FIG. 8, the size and shape of the yarns can vary as well as the type. For example, although the figures show the yarns 5 with whiskers, the present invention can be practiced using water swellable yarns 5 with and/or without whiskers. Water swellable yarns 5 can also be replaced by any other material that volumetrically expands when in contact with water.
As described earlier, a first problem arises when the buffer tube 1 and gel compound 2 become heated. By adding the water swellable yarns 5 , the problem of the gel compound 2 “running” downward can be diminished. As shown in FIG. 7, adding water swellable yarns 5 and/or particles 6 to the buffer tube 1 results in two additional upward forces F 3 , F 4 that help prevent the gel compound 2 from running downward.
More specifically, the addition of the water swellable yarns 5 increases the amount of surface area with which the gel compound 2 may contact. The additional surface area results in two additional forces F 3 , F 4 that act upon the gel compound 2 . As a result, more upward forces act upon the gel compound 2 to help compensate for any decrease in force caused by the decrease in viscosity of the gel compound 2 when the temperature is increased.
Additionally, by selecting water swellable yarn 5 and/or particles 6 having a CTE which is less than the CTE of the gel compound 2 , the CTE of the gel-yarn system is lowered. In fact, it is possible to select yarns having a negative CTE (i.e. yarns that volumetrically contract when heated). In a preferred embodiment, yarns 5 and/or particles 6 are selected in such a manner that the resulting CTE of the gel-yarn system matches or is substantially equivalent to the CTE of the buffer tube 1 . Consequently, when heated, both the buffer tube 1 and the gel-yarn system expand by the same amount. As a result, gel compound 2 is not “forced” out of the buffer tube 1 in the axial direction.
Also, since the water swellable yarns 5 and/or particles 6 occupy some of the volume inside the buffer tube 1 , less gel compound 2 may be consequently used. Using less gel compound 2 results in at least two beneficial effects. First, since gel compound 2 is expensive, using less means the cost of manufacturing the fiber optic cable is decreased. Second, since the force acting in the downward direction (i.e. gravity) is a function of the mass of the gel compound 2 , replacing some of the gel compound 2 with water swellable yarns having less mass than the gel compound 2 decreases the downward force due to gravity. A decrease in the force of gravity means that less upward force (i.e. friction forces F 1 , F 2 , F 3 , and F 4 ) is needed to keep the gel compound 2 from running down the fibers. When the gel compound 2 is held in place, it prevents the fiber optic ribbons 3 from contacting the walls of the buffer tube 1 and also prevents other materials (i.e. water) that might penetrate the buffer tube 1 from contacting the fiber optic ribbons 3 .
A second problem occurs when air bubbles 6 are entrapped in the gel compound 2 . However, the air bubbles 6 are reduced by embedding water swellable yarns 5 in the gel compound 2 . When water penetrates the buffer tube 1 , and comes in contact with the water swellable yarns 5 , the water swellable yarns 5 volumetrically expand. This expansion “pushes” the gel compound 2 towards both the buffer tube walls 1 and the fiber optic ribbon stack 3 . Since the total volume within the buffer tube 1 is fixed, an increase in volume of water swellable yarns forces a decrease in the volume of the air bubbles 6 . If enough water contacts the water swellable yarns 5 , its volume will have expanded such that the air bubbles 6 can be effectively eliminated.
As shown in FIGS. 8 and 9, the water swellable yarns 5 of the present invention can be oriented in a number of ways. Water swellable yarns are commercially available and manufactured by such companies as FiberLine and Lantor, Inc. The number, size and type of the strands of yarn used can also vary. Super absorbent powders and water-blocking super-absorbent polymers are currently well developed for many applications including medical, baby care and cable sectors. These are available from several manufacturers including Scapa Polymerics. Mixing the powders 6 with gel compound will result in a gel impregnated with super-absorbent polymers with tailorable concentration, properties and performance.
For example, in one embodiment, there may be three strands of yarns disposed within the buffer tube 1 with each of the three strands being a different size. Further, two of the strands may be oriented axially parallel to the fiber optic ribbons 3 while the remaining strand may be disposed helically around the fiber optic ribbons 3 . The yarns 5 in a preferred embodiment have whiskers, however, the present invention may be practiced with yarns 5 that do not have whiskers. The yarns 5 with whiskers may also be used to “drag” the gel compound 2 into the buffer tube 1 which speeds manufacturing of the buffer tubes 1 . Finally, the present invention is not limited to only water swellable yarns. Other materials may be used proved they volumetrically expand when contacted by water.
The buffer tubes of the present invention can be made in a number of ways. Typically, an assembled stack of fiber ribbons is pulled through a die. Gel compound is injected in the die (from the inside) and a hot thermoplastic material is extruded over the gel-stack system (from the outside) to form a buffer tube with gel compound and ribbons inside. The buffer tube is then moved through a water-cooling channel and wound on the reel. In a preferred embodiment, the water swellable yarns 5 are pulled with the assembled stack of fiber ribbons through the die and the water swellable particles 6 are embedded in the gel compound prior to extruding the gel compound.
The yarns most likely will be applied during the buffering/stranding process of the ribbon buffer tubes. The yarns are wound onto a delivery spool and then delivered along with the other optical units into the tube while the polymer is being extruded. That is, ribbons are “stranded” and then “buffered” usually in a single process step. These terms, (stranded and buffered) are commonly used for manufacturing optical units in the industry. The advantages to this are 1) being able to control yarn tensions (which are critical to maintain desired stack integrity) and 2) applying them in the “stacks” “final” formation just prior to entering the buffer tube. Also, it allows you to apply them in the desired helical formation of the “stack”. The “stack” can then orient itself in an ideal center position-cushions will help to center the stack within the polymer tube, which can prevent attenuation degradation due to the potential for the optical units to engage the tube wall.
The above description of the preferred embodiments has been given by way of example. From the disclosure given, those skilled in the art will not only understand the present invention and its attendant advantages, but will also find apparent various changes and modifications to the structures and methods disclosed. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the invention, as defined by the appended claims, and equivalents thereof.
|
A fiber optic buffer tube containing fiber optic ribbons centrally located within the buffer tube and a gel compound surrounding the fiber optic ribbons. Disposed within the gel compound, between the walls of the buffer tube and the fiber optic ribbons are water swellable yarns and/or particles. The water swellable yarns and/or particles volumetrically expand when in contact with water that has penetrated the buffer tube. The water swellable yarns/particles also provide greater surface area which helps to hold gel compound, at elevated temperature, within the tube and thus to prevent the fiber optic ribbons from coming into contact with the walls of the buffer tube, thereby preventing signal attenuation problems.
| 6
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a continuation of U.S. patent application Ser. No. 10/685,206, filed on Oct. 14, 2003, which is based upon and claims benefit of U.S. Provisional Patent Application Ser. No. 60/418,936 entitled “System and Method for Providing Check Fraud Protection”, filed with the U.S. Patent and Trademark Office on Oct. 15, 2002 by the inventors herein, the specifications of both of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention disclosed herein relates generally to the recovery of losses associated with unauthorized use of negotiable instruments, and more particularly to a fraud protection system and method for enabling a consumer to recover losses due to forged signatures, forged endorsements, or altered information on personal checks.
[0004] 2. Background of the Prior Art
[0005] Attempted check fraud at commercial banks is a growing problem. Check fraud can be one of the most damaging personal frauds. A victim of check fraud can suffer not only loss of all their financial holdings, but damage to their credit report as well.
[0006] Check fraud is generally perpetrated in one of several manners, such as:
FORGED SIGNATURES—legitimate blank checks with an imitation of the payer signature; FORGED ENDORSEMENTS—often involves the use of a stolen check, which is then endorsed and cashed or deposited by someone other than the payee; COUNTERFEIT CHECKS—due to the advancement in color copying and desktop publishing capabilities, this is the fastest-growing source of fraudulent checks today; ALTERED CHECKS—information on a legitimate check, such as payee or check amount, changed to benefit the perpetrator; and CHECK KITING—the process of depositing a check from one bank account into a second bank account without the sufficient funds to cover it.
[0012] According to a leading accounting firm, more than 500 million checks are forged annually, with losses totaling more than $10 billion.
[0013] According to the National Check Fraud Center, check fraud and counterfeiting are among the fastest-growing problems affecting the nation's financial system, producing estimated annual losses of $10 billion, and continues to rise annually at an alarming rate.
[0014] According to a report issued by the American Banker, an industry bankers' magazine, estimates of losses from check fraud will grow by 2.5% annually in the coming years.
[0015] Many processes and techniques have been developed to thwart the growing problem of check fraud. Special inks, microprinting, encryption of machine-readable code, and specially designed checkbooks to disclose loss of checks are some methods suggested to guard against check fraud. Even with the multitude of schemes to prevent incidents of check fraud, the continued growth indicates that most courses of action are ineffective in preventing such occurrence, such that consumers continue to lose significant funds through the ongoing check fraud ailment. Efforts must be directed to recovery of losses attributed to such check fraud.
[0016] Ordinarily, for a consumer to recover losses arising from victimization by check fraud, such consumer must generally investigate the fraud on their own, report such fraud to their bank or financial institution to seek reimbursement, and initiate criminal and/or civil proceedings as appropriate, if necessary. Such steps are generally unfamiliar to the average consumer, and the apprehension of such tasks can present a barrier to entry.
[0017] Accordingly, there has been found to remain a need for a simple method for a consumer victimized by check fraud to recover from losses associated with specific forms of check fraud, such as forged signatures, forged endorsements, and alterations to legitimate checks.
SUMMARY OF THE INVENTION
[0018] It is, therefore, an object of the present invention to enable a process for recovering losses due to check fraud that avoids the disadvantages of the prior art.
[0019] It is another object of the present invention to enable a method by which a consumer can recover losses due to specific modes of check fraud. A related object is to enable a method by which a consumer can recover losses directly from such consumer's check printer.
[0020] It is another object of the present invention to enable a method by which a consumer can recover losses due to check fraud in the nature of forged signatures. It is another object of the present invention to enable a method by which a consumer can recover losses due to check fraud in the nature of forged endorsements. It is yet another object of the present invention to enable a method by which a consumer can recover losses due to check fraud in the nature of altered instruments.
[0021] Another object of the present invention is the provision of a claim form for reporting loss to the consumer's check printer.
[0022] Another object of the present invention is the provision of limited durable power of attorney by which a consumer can assign any claim arising from the check fraud to the check printer.
[0023] Another object of the present invention is the provision of a novel method for recovering losses arising from specific modes of check fraud.
[0024] A specific object of the invention is the provision of a negotiable instrument wherein a designated symbol is imprinted on the instrument to indicate the protection for that instrument.
[0025] Another object of the invention is to enable a method in which, upon occurrence and reporting of a check fraud event involving a protected check, a new series of protected checks is issued to the authorized check writer.
[0026] In accordance with the above objects, a system and method for a consumer to protect against loss associated with specified forms of check fraud are provided. Upon purchasing checks, a consumer can, for an additional fee, subscribe to a check fraud protection program. The subscription will enable the consumer to obtain reimbursement from the check printer for the consumer's losses due to predetermined causes of check fraud. The consumer reciprocally assigns any right of recovery from the consumer's bank or financial institution to the check printer, which can then seek reimbursement from the bank, or financial institution and institute proceedings against the fraud perpetrator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The above and other features, aspects, and advantages of the present invention are considered in more detail, in relation to the following description of embodiments thereof shown in the accompanying drawings, in which:
[0028] FIG. 1 is an illustration of a check for describing features of the present invention.
[0029] FIG. 2 is an illustration of an insert accompanying checks purchased under an embodiment of the present invention.
[0030] FIG. 3 is a claim form for use in a preferred embodiment of the present invention.
[0031] FIGS. 4 a and 4 b is a durable power of attorney for use in a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The invention summarized above may be better understood by referring to the following description, which should be read in conjunction with the accompanying drawings in which like reference numbers are used for like parts. This description of an embodiment, set out below to enable one to practice an implementation of the invention, is not intended to limit the preferred, embodiment, but to serve as a particular example thereof. Those skilled in the art should appreciate that they may readily use the conception and specific embodiments disclosed as a basis for modifying or designing other methods and systems for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent assemblies do not depart from the spirit and scope of the invention in its broadest form.
[0033] FIG. 1 shows a view of the face of a prepared check, indicated generally as 10 . On the face of the check are the following data items: the name and address of the account holder 13 ; the name of the payee 16 ; the issuing bank number with routing number 19 ; the checking account number 22 ; a check number 25 ; the check date 28 ; the check amount 31 ; the name of the issuing bank 34 ; and the signature of the payer 37 .
[0034] Indication of some security features may also be seen on the face of the check 10 . For example, it is common to use microprinting to create the signature line 40 . Such microprinting appears as a dotted line when photocopied. The stylized MP symbol 43 indicates the presence of microprinting. The padlock symbol 46 is a certification mark indicating that the check 10 contains certain security features.
[0035] Pursuant to one feature of a preferred embodiment of the instant invention, additional indicia 50 is provided on the face of the check indicating that the particular check 10 is protected by a check fraud protection program as disclosed herein. As explained in greater detail below, while a series of checks 10 having consecutive check numbers is issued to an account holder, it is intended that all checks in such series according to the instant invention bear such indicia 50 , and thus that the check fraud protection program disclosed herein applies check fraud protection to every one of the checks in such series.
[0036] In operation, the system of the present invention operates as follows:
a. A consumer orders a box of checks from a check printing source and provides to the check printer the appropriate information to be printed on the check, such as the name and address of the account holder 13 ; the issuing bank number with routing number 19 ; the name of the issuing bank 34 and checking account number 22 ; and a beginning check number 25 for the box of checks. b. During the ordering process, the consumer is presented the option of subscribing to a check fraud protection program for all the checks in the box. c. Upon election by the consumer to purchase such check fraud protection, the check printer adds an indicia, such as 50 to every check printed in the box. The check printer also records the range of numbers of the checks in the box. Typically, a box contains two hundred (200) checks in single format or .one hundred fifty (150) checks in duplicate format. The check printer sends the box of printed checks to the consumer and includes an insert, such as illustrated in FIG. 2 , informing the consumer that the checks in the box are included under the check fraud protection plan. d. Upon the occurrence of an identified check fraud event (as described in greater detail below) against any of the checks in the box, the consumer reports the occurrence to the check printer using a reimbursement request form to obtain reimbursement directly from the check printer. An exemplary reimbursement request form is illustrated in FIG. 3 . The consumer also provides the check printer a power of attorney, including an assignment of the right of recovery by the consumer, to enable the check printer to pursue an appropriate action against the responsible banking or financial institution. An exemplary power of attorney form is illustrated in FIG. 4 . In addition to such reimbursement request form, a police report and/or other proof of fraud is required. e. Upon notification of such reimbursement request, the check printer prints a new box of checks which, when properly executed by the authorized account holder, will draw funds from a new account that receives the account holder's funds after the original, compromised account is closed.
[0042] Check fraud events for which reimbursement may be requested preferably include:
[0043] Forged Signatures: protection applies to legitimate blank checks that are forged with an authorized signature 37 ( FIG. 1 ), as the payer, and that results in a debit to the checking account.
[0044] Forged Endorsements: protection applies to a legitimate check that is endorsed and cashed or deposited by someone other than the designated payee 16 ( FIG. 1 ) based upon a fraudulent and false endorsement. Such protection, however, does not apply to a check that bears a legitimate original endorsement that is secondarily fraudulently endorsed.
[0000] Altered Checks: protection applies to legitimate checks that contain altered information such as payee identification 16 , check amount 31 , or other alteration to benefit the party altering the check.
[0045] Checks employed by the system and method of the invention described herein preferably only include those checks within the range of numbers purchased in the order at the time of the check fraud protection subscription. Such checks should be imprinted with indicia 50 indicating that the checks are, in fact, secured by the check fraud protection program disclosed herein. The check fraud protection program may only be purchased at the time the original checks are purchased. For accuracy, the check printer maintains a database record of all check numbers for which the check fraud protection program has been purchased. In order to be effective, the consumer must subscribe all the boxes of checks in a particular order. Protection expires once all checks in the box have been used or two years from the time of purchase, whichever is sooner.
[0046] The check fraud protection program described herein is not an insurance policy although a commercial insurance provider may insure the organization providing such fraud protection. The fraud protection program is designed to facilitate the consumer's recovery of losses arising from identified check fraud events, such that the consumer obtains benefits directly from the check printer by assigning any claims against the responsible banking/financial institution to the check printer. Accordingly, the consumer obtaining such fraud protection need not and should not seek any reimbursement from the responsible banking/financial institution.
[0047] The protection may be limited, such as to a maximum of $25,000.00 per box of checks, regardless of the number of checks for which reimbursement requests are presented and/or the number of requests made. Protection may apply only to personal checks purchased according to the program. Such protection does not apply to business checks, deposit tickets, and checks not included in a box of checks for which a subscription was purchased, even if such checks were also purchased from the same check printer. Furthermore, protection may be limited to only frauds committed in the country where the consumer is a resident.
[0048] Only designated losses are reimbursable pursuant to the check fraud protection program. The amount reimbursable includes all actual amounts paid from the consumer's account and all bank/financial institution/retailer fees arising from the fraud, not to exceed the limits of such check fraud protection program.
[0049] The invention has been described with references to a preferred embodiment. While specific values, relationships, materials and steps have been set forth for purposes of describing concepts of the invention, it will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the basic concepts and operating principles of the invention as broadly described. It should be recognized that, in the light of the above teachings, those skilled in the art can modify those specifics without departing from the invention taught herein. Having now fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with such underlying concept. It is intended to include all such modifications, alternatives and other embodiments insofar as they come within the scope of the appended claims or equivalents thereof. It should be understood, therefore, that the invention may be practiced otherwise than as specifically set forth herein. Consequently, the present embodiments are to be considered in all respects as illustrative and not restrictive.
|
A method for a consumer to protect against loss associated with specified forms of check fraud. Upon purchasing checks, a consumer can subscribe to a check fraud protection program, for an additional fee. The subscription will enable the consumer to obtain reimbursement from the check printer for the consumer's losses due to specified causes. The consumer reciprocally assigns any right of recovery from the consumer's bank or financial institution to the check printer, which can then seek reimbursement from the bank, or financial institution and institute proceedings against the fraud perpetrator. Protection may be obtained for forged signatures, forged endorsements and altered check. A symbol to indicate such protection is also disclosed.
| 6
|
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/434,294, filed May 7, 2003, which in turn claims benefit of U.S. Provisional Patent Application No. 60/379,134 which was filed on May 7, 2002. Each of these applications is incorporated herein by reference as if set forth in full herein.
GOVERNMENT SUPPORT
[0002] This invention was made with Government support under Grant Number DABT63-97-C-0051 awarded by DARPA. The Government has certain rights.
FIELD OF THE INVENTION
[0003] This invention relates to the field of electrochemical deposition and more particularly to the field of electrochemical deposition using conformable contact masks that are formed separate from a substrate to control deposition, such as for example in Electrochemical Fabrication (e.g. EFAB™) where such masks are used to control the selective electrochemical deposition of one or more materials according to desired cross-sectional configurations so as to build up three-dimensional structures from a plurality of at least partially adhered layers of deposited material.
BACKGROUND
[0004] A technique for forming three-dimensional structures (e.g. parts, components, devices, and the like) from a plurality of adhered layers was invented by Adam L. Cohen and is known as Electrochemical Fabrication. It is being commercially pursued by Microfabrica Inc. (formerly MEMGen® Corporation) of Burbank, Calif. under the name EFAB™. This technique was described in U.S. Pat. No. 6,027,630, issued on Feb. 22, 2000. This electrochemical deposition technique allows the selective deposition of a material using a unique masking technique that involves the use of a mask that includes patterned conformable material on a support structure that is independent of the substrate onto which plating will occur. When desiring to perform an electrodeposition using the mask, the conformable portion of the mask is brought into contact with a substrate while in the presence of a plating solution such that the contact of the conformable portion of the mask to the substrate inhibits deposition at selected locations. For convenience, these masks might be generically called conformable contact masks; the masking technique may be generically called a conformable contact mask plating process. More specifically, in the terminology of Microfabrica Inc. such masks have come to be known as INSTANT MASKS™ and the process known as INSTANT MASKING™ or INSTANT MASK™ plating. Selective depositions using conformable contact mask plating may be used to form single layers of material or may be used to form multi-layer structures. The teachings of the '630 patent are hereby incorporated herein by reference as if set forth in full herein. Since the filing of the patent application that led to the above noted patent, various papers about conformable contact mask plating (i.e. INSTANT MASKING) and electrochemical fabrication have been published:
1. A. Cohen, G. Zhang, F. Tseng, F. Mansfeld, U. Frodis and P. Will, “EFAB: Batch production of functional, fully-dense metal parts with micro-scale features”, Proc. 9th Solid Freeform Fabrication, The University of Texas at Austin, p 161, August 1998. 2. A. Cohen, G. Zhang, F. Tseng, F. Mansfeld, U. Frodis and P. Will, “EFAB: Rapid, Low-Cost Desktop Micromachining of High Aspect Ratio True 3-D MEMS”, Proc. 12th IEEE Micro Electro Mechanical Systems Workshop, IEEE, p 244, January 1999. 3. A. Cohen, “3-D Micromachining by Electrochemical Fabrication”, Micromachine Devices, March 1999. 4. G. Zhang, A. Cohen, U. Frodis, F. Tseng, F. Mansfeld, and P. Will, “EFAB: Rapid Desktop Manufacturing of True 3-D Microstructures”, Proc. 2nd International Conference on Integrated MicroNanotechnology for Space Applications, The Aerospace Co., April 1999. 5. F. Tseng, U. Frodis, G. Zhang, A. Cohen, F. Mansfeld, and P. Will, “EFAB: High Aspect Ratio, Arbitrary 3-D Metal Microstructures using a Low-Cost Automated Batch Process”, 3rd International Workshop on High Aspect Ratio MicroStructure Technology (HARMST'99), June 1999. 6. A. Cohen, U. Frodis, F. Tseng, G. Zhang, F. Mansfeld, and P. Will, “EFAB: Low-Cost, Automated Electrochemical Batch Fabrication of Arbitrary 3-D Microstructures”, Micromachining and Microfabrication Process Technology, SPIE 1999 Symposium on Micromachining and Microfabrication, September 1999. 7. F. Tseng, G. Zhang, U. Frodis, A. Cohen, F. Mansfeld, and P. Will, “EFAB: High Aspect Ratio, Arbitrary 3-D Metal Microstructures using a Low-Cost Automated Batch Process”, MEMS Symposium, ASME 1999 International Mechanical Engineering Congress and Exposition, November, 1999. 8. A. Cohen, “Electrochemical Fabrication (EFAB™)”, Chapter 19 of The MEMS Handbook, edited by Mohamed Gad-EI-Hak, CRC Press, 2002. 9. “Microfabrication—Rapid Prototyping's Killer Application”, pages 1-5 of the Rapid Prototyping Report, CAD/CAM Publishing, Inc., June 1999.
[0014] The disclosures of these nine publications are hereby incorporated herein by reference as if set forth in full herein.
[0015] The electrochemical deposition process may be carried out in a number of different ways as set forth in the above patent and publications. In one form, this process involves the execution of three separate operations during the formation of each layer of the structure that is to be formed:
1. Selectively depositing at least one material by electrodeposition upon one or more desired regions of a substrate. 2. Then, blanket depositing at least one additional material by electrodeposition so that the additional deposit covers both the regions that were previously selectively deposited onto, and the regions of the substrate that did not receive any previously applied selective depositions. 3. Finally, planarizing the materials deposited during the first and second operations to produce a smoothed surface of a first layer of desired thickness having at least one region containing the at least one material and at least one region containing at least the one additional material.
[0019] After formation of the first layer, one or more additional layers may be formed adjacent to the immediately preceding layer and adhered to the smoothed surface of that preceding layer. These additional layers are formed by repeating the first through third operations one or more times wherein the formation of each subsequent layer treats the previously formed layers and the initial substrate as a new and thickening substrate.
[0020] Once the formation of all layers has been completed, at least a portion of at least one of the materials deposited is generally removed by an etching process to expose or release the three-dimensional structure that was intended to be formed.
[0021] The preferred method of performing the selective electrodeposition involved in the first operation is by conformable contact mask plating. In this type of plating, one or more conformable contact (CC) masks are first formed. The CC masks include a support structure onto which a patterned conformable dielectric material is adhered or formed. The conformable material for each mask is shaped in accordance with a particular cross-section of material to be plated. At least one CC mask is needed for each unique cross-sectional pattern that is to be plated.
[0022] The support for a CC mask is typically a plate-like structure formed of a metal that is to be selectively electroplated and from which material to be plated will be dissolved. In this typical approach, the support will act as an anode in an electroplating process. In an alternative approach, the support may instead be a porous or otherwise perforated material through which deposition material will pass during an electroplating operation on its way from a distal anode to a deposition surface. In either approach, it is possible for CC masks to share a common support, i.e. the patterns of conformable dielectric material for plating multiple layers of material may be located in different areas of a single support structure. When a single support structure contains multiple plating patterns, the entire structure is referred to as the CC mask while the individual plating masks may be referred to as “submasks”. In the present application such a distinction will be made only when relevant to a specific point being made.
[0023] In preparation for performing the selective deposition of the first operation, the conformable portion of the CC mask is placed in registration with and pressed against a selected portion of the substrate (or onto a previously formed layer or onto a previously deposited portion of a layer) on which deposition is to occur. The pressing together of the CC mask and substrate occur in such a way that all openings, in the conformable portions of the CC mask contain plating solution. The conformable material of the CC mask that contacts the substrate acts as a barrier to electrodeposition while the openings in the CC mask that are filled with electroplating solution act as pathways for transferring material from an anode (e.g. the CC mask support) to the non-contacted portions of the substrate (which act as a cathode during the plating operation) when an appropriate potential and/or current are supplied.
[0024] An example of a CC mask and CC mask plating are shown in FIGS. 1A-1C . FIG. 1A shows a side view of a CC mask 8 consisting of a conformable or deformable (e.g. elastomeric) insulator 10 patterned on an anode 12 . The anode has two functions. One is as a supporting material for the patterned insulator 10 to maintain its integrity and alignment since the pattern may be topologically complex (e.g., involving isolated “islands” of insulator material). The other function is as an anode for the electroplating operation. FIG. 1A also depicts a substrate 6 separated from mask 8 . CC mask plating selectively deposits material 22 onto a substrate 6 by simply pressing the insulator against the substrate then electrodepositing material through apertures 26 a and 26 b in the insulator as shown in FIG. 1B . After deposition, the CC mask is separated, preferably non-destructively, from the substrate 6 as shown in FIG. 1C . The CC mask plating process is distinct from a “through-mask” plating process in that in a through-mask plating process the separation of the masking material from the substrate would occur destructively. As with through-mask plating, CC mask plating deposits material selectively and simultaneously over the entire layer. The plated region may consist of one or more isolated plating regions where these isolated plating regions may belong to a single structure that is being formed or may belong to multiple structures that are being formed simultaneously. In CC mask plating, as individual masks are not intentionally destroyed in the removal process, they may be usable in multiple plating operations.
[0025] Another example of a CC mask and CC mask plating is shown in FIGS. 1D-1G . FIG. 1D shows an anode 12 ′ separated from a mask 8 ′ that comprises a patterned conformable material 10 ′ and a support structure 20 . FIG. 1D also depicts substrate 6 separated from the mask 8 ′. FIG. 1E illustrates the mask 8 ′ being brought into contact with the substrate 6 . FIG. 1F illustrates the deposit 22 ′ that results from conducting a current from the anode 12 ′ to the substrate 6 . FIG. 1G illustrates the deposit 22 ′ on substrate 6 after separation from mask 8 ′. In this example, an appropriate electrolyte is located between the substrate 6 and the anode 12 ′ and a current of ions coming from one or both of the solution and the anode are conducted through the opening in the mask to the substrate where material is deposited. This type of mask may be referred to as an anodeless INSTANT MASK™ (AIM) or as an anodeless conformable contact (ACC) mask.
[0026] Unlike through-mask plating, CC mask plating allows CC masks to be formed completely separate from the fabrication of the substrate on which plating is to occur (e.g. separate from a three-dimensional (3D) structure that is being formed). CC masks may be formed in a variety of ways, for example, a photolithographic process may be used. All masks can be generated simultaneously prior to structure fabrication rather than during it. This separation makes possible a simple, low-cost, automated, self-contained, and internally-clean “desktop factory” that can be installed almost anywhere to fabricate 3D structures, leaving any required clean room processes, such as photolithography to be performed by service bureaus or the like.
[0027] An example of the electrochemical fabrication process discussed above is illustrated in FIGS. 2A-2F . These figures show that the process involves deposition of a first material 2 which is a sacrificial material and a second material 4 which is a structural material. The CC mask 8 , in this example, includes a patterned conformable material (e.g. an elastomeric dielectric material) 10 and a support 12 which is made from deposition material 2 . The conformal portion of the CC mask is pressed against substrate 6 with a plating solution 14 located within the openings 16 in the conformable material 10 . An electric current, from power supply 18 , is then passed through the plating solution 14 via (a) support 12 which doubles as an anode and (b) substrate 6 which doubles as a cathode. FIG. 2A , illustrates that the passing of current causes material 2 within the plating solution and material 2 from the anode 12 to be selectively transferred to and plated on the substrate 6 . After electroplating the first deposition material 2 onto the substrate 6 using CC mask 8 , the CC mask 8 is removed as shown in FIG. 2B . FIG. 2C depicts the second deposition material 4 as having been blanket-deposited (i.e. non-selectively deposited) over the previously deposited first deposition material 2 as well as over the other portions of the substrate 6 . The blanket deposition occurs by electroplating from an anode (not shown), composed of the second material, through an appropriate plating solution (not shown), and to the cathode/substrate 6 . The entire two-material layer is then planarized to achieve precise thickness and flatness as shown in FIG. 2D . After repetition of this process for all layers, the multi-layer structure 20 formed of the second material 4 (i.e. structural material) is embedded in first material 2 (i.e. sacrificial material) as shown in FIG. 2E . The embedded structure is etched to yield the desired device, i.e. structure 20 , as shown in FIG. 2F .
[0028] Various components of an exemplary manual electrochemical fabrication system 32 are shown in FIGS. 3A-3C . The system 32 consists of several subsystems 34 , 36 , 38 , and 40 . The substrate holding subsystem 34 is depicted in the upper portions of each of FIGS. 3A to 3C and includes several components: (1) a carrier 48 , (2) a metal substrate 6 onto which the layers are deposited, and (3) a linear slide 42 capable of moving the substrate 6 up and down relative to the carrier 48 in response to drive force from actuator 44 . Subsystem 34 also includes an indicator 46 for measuring differences in vertical position of the substrate which may be used in setting or determining layer thicknesses and/or deposition thicknesses. The subsystem 34 further includes feet 68 for carrier 48 which can be precisely mounted on subsystem 36 .
[0029] The CC mask subsystem 36 shown in the lower portion of FIG. 3A includes several components: (1) a CC mask 8 that is actually made up of a number of CC masks (i.e. submasks) that share a common support/anode 12 , (2) precision X-stage 54 , (3) precision Y-stage 56 , (4) frame 72 on which the feet 68 of subsystem 34 can mount, and (5) a tank 58 for containing the electrolyte 16 . Subsystems 34 and 36 also include appropriate electrical connections (not shown) for connecting to an appropriate power source (not shown) for driving the CC masking process.
[0030] The blanket deposition subsystem 38 is shown in the lower portion of FIG. 3B and includes several components: (1) an anode 62 , (2) an electrolyte tank 64 for holding plating solution 66 , and (3) frame 74 on which feet 68 of subsystem 34 may sit. Subsystem 38 also includes appropriate electrical connections (not shown) for connecting the anode to an appropriate power supply (not shown) for driving the blanket deposition process.
[0031] The planarization subsystem 40 is shown in the lower portion of FIG. 3C and includes a lapping plate 52 and associated motion and control systems (not shown) for planarizing the depositions.
[0032] Another method for forming microstructures from electroplated metals (i.e. using electrochemical fabrication techniques) is taught in U.S. Pat. No. 5,190,637 to Henry Guckel, entitled “Formation of Microstructures by Multiple Level Deep X-ray Lithography with Sacrificial Metal layers. This patent teaches the formation of metal structures utilizing mask exposures. A first layer of a primary metal is electroplated onto an exposed plating base to fill a void in a photoresist, the photoresist is then removed and a secondary metal is electroplated over the first layer and over the plating base. The exposed surface of the secondary metal is then machined down to a height which exposes the first metal to produce a flat uniform surface extending across the both the primary and secondary metals. Formation of a second layer may then begin by applying a photoresist layer over the first layer and then repeating the process used to produce the first layer. The process is then repeated until the entire structure is formed and the secondary metal is removed by etching. The photoresist is formed over the plating base or previous layer by casting and the voids in the photoresist are formed by exposure of the photoresist through a patterned mask via X-rays or UV radiation.
[0033] The '630 patent as well as the other conformable contact mask plating (i.e. Instant Mask Plating) and electrochemical fabrication (i.e. EFAB) publications noted above describe copper as a sacrificial material and nickel as a structural material. The copper is the preferred material for selective deposition while the nickel is the preferred material for blanket deposition. In most applications after formation of the nickel structure it is desirable to reveal or release it by separating it from the copper sacrificial material. The '630 patent proposes that this removal be performed by an etching operation and that useful etching compositions for selectively stripping copper from nickel structures include (1) solutions of ammonium hydroxide and copper sulfate or (2) solutions of ammonium hydroxide and sodium chlorite. This prior art patent indicates that a preferred etchant is Enstrip C38 commercially available from Enthone OMI. The patent goes further and indicates that etching can also be performed in the presence of (1) vibrations, e.g., ultrasound applied to the etchant or the substrate that was plated, and (2) pressurized jets of etchant contacting the metal to be etched.
[0034] In September of 1998, Adam Cohen placed an enquiry onto the “mems-talk” mailing list at http://mail.mems-exchange.org. In this enquiry Mr. Cohen indicated that he was seeking suggestions concerning a Cu etchant that didn't cause pitting or other damage to Ni. He further indicated that Enthone's Enstrip C38 caused pitting at least sometimes. In October of 1998, Mr. Cohen received three responses to this enquiry: (1) recommendation to use a copper etching process that showed no pitting problems with nickel—the etchant was HNO3:H3PO4:CH3COOH at 0.5:50.0:49.5 (volume) and was used at room temperature; (2) recommendation to use a caustic etchant and in particular Cu(NH3)4++ mixed with ammonia; and (3) recommendation to try 50% NH4OH mixed with 50% H2O2 in a 1:1 ratio.
[0035] A need remains in the field of conformable contact mask plating and electrochemical fabrication for improved post deposition processing and in particular for processes that separate copper from nickel while minimizing the pitting of nickel, and more particularly to provide an improved process of separating copper from nickel when the nickel structure has a complex geometry with copper needing to be removed from small but extended or even intricate passages within the nickel structure.
SUMMARY OF THE INVENTION
[0036] It is an object of certain aspects of the invention to provide improved post deposition processing for structures produced by conformable contact mask plating or electrochemical fabrication.
[0037] It is an object of certain aspects of the invention to provide an improved process for separating copper from nickel.
[0038] It is an object of certain aspects of the invention to provide a generalized copper removal process that can be used to remove copper from a complex nickel structure without damaging the nickel.
[0039] Other objects and advantages of various aspects of the invention will be apparent to those of skill in the art upon review of the teachings herein. The various aspects of the invention, set forth explicitly herein or otherwise ascertained from the teachings herein, may address any one of the above objects alone or in combination, or alternatively may not address any of the objects set forth above but instead address some other object ascertained from the teachings herein. It is not intended that all of these objects be addressed by any single aspect of the invention even though that may be the case with regard to some aspects.
[0040] A first aspect of the invention provides an electrochemical fabrication process for producing a three-dimensional structure from a plurality of adhered layers, the process that includes: (A) supplying a plurality of preformed masks, wherein each mask includes a patterned conformable dielectric material that includes at least one opening through which deposition can take place during the formation of at least a portion of a layer, and wherein each mask includes a support structure that supports the patterned conformable dielectric material; (B) selectively depositing a first material onto the substrate to form a portion of a layer and depositing at least a second material to form another portion of the layer, wherein the substrate may include previously deposited material, and wherein one of the first material or the second material is a structural material and the other is a sacrificial material; (C) forming a plurality of layers such that each successive layer is formed adjacent to and adhered to a previously deposited layer, wherein said forming includes repeating operation (B) a plurality times; and (D) after formation of a plurality of layers, separating at least a portion of the sacrificial material from the structural material using an etching solution that includes ammonium hydroxide, a chlorite salt, and a nitrate salt; and wherein at least a plurality of the selective depositing operations include (1) contacting the substrate and the conformable material of a selected preformed mask; (2) in presence of a plating solution, conducting an electric current through the at least one opening in the selected mask between an anode and the substrate, wherein the anode including a selected deposition material, and wherein the substrate functions as a cathode, such that the selected deposition material is deposited onto the substrate to form at least a portion of a layer; and (3) separating the selected preformed mask from the substrate.
[0041] A second aspect of the invention provides a process for producing a structure, wherein the process includes: (A) supplying at least one preformed mask that includes a patterned conformable dielectric material that includes at least one opening through which deposition can take place during the formation of at least a portion of a layer, and wherein at the least one mask includes a support structure that supports the patterned conformable dielectric material; and (B) selectively depositing at least a first material onto the substrate, the depositing including (1) contacting the substrate and the conformable material of the preformed mask; (2) in presence of a plating solution, conducting an electric current through the at least one opening in the selected mask between an anode and the substrate, wherein the anode including a selected deposition material, and wherein the substrate functions as a cathode, such that the selected deposition material is deposited onto the substrate to form at least a portion of a layer; and (3) separating the selected preformed mask from the substrate; (C) depositing at least a second material onto the substrate after depositing the at least first material; and (D) after formation of at least one layer, separating at least a portion of the sacrificial material from the structural material using an etching solution that comprises ammonium hydroxide, a chlorite salt, and a nitrate salt.
[0042] A third aspect of the invention provides a process of etching a first material from a structure, including: (A) supplying a structure including at least a first material and a second material; and (B) placing the structure in an etching solution that includes ammonium hydroxide, a chlorite salt, and a nitrate salt.
[0043] Other aspects of the invention will be understood by those of skill in the art upon reviewing the teachings herein. Other aspects of the invention may involve apparatus that can be used in implementing one or more of the above method aspects of the invention. These other aspects of the invention may involve various combinations of the aspects presented above, addition of various features of one or more embodiments, as well as other configurations, structures, functional relationships, and processes that have not been specifically set forth above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] FIGS. 1A-1C schematically depict side views of various stages of a CC mask plating process, while FIGS. 1D-1G schematically depict a side views of various stages of a CC mask plating process using a different type of CC mask.
[0045] FIGS. 2A-2F schematically depict side views of various stages of an electrochemical fabrication process as applied to the formation of a particular structure where a sacrificial material is selectively deposited while a structural material is blanket deposited.
[0046] FIGS. 3A-3C schematically depict side views of various example subassemblies that may be used in manually implementing the electrochemical fabrication method depicted in FIGS. 2A-2F .
[0047] FIGS. 4A-4F schematically depict the formation of a first layer of a structure using adhered mask plating where the blanket deposition of a second material overlays both the openings between deposition locations of a first material and the first material itself.
[0048] FIG. 4G depicts the completion of formation of the first layer resulting from planarizing the deposited materials to a desired level.
[0049] FIGS. 4H and 4I respectively depict the state of the process after formation of the multiple layers of the structure and after release of the structure from the sacrificial material).
[0050] FIG. 5 provides a table of copper etchants and various properties associated with them.
[0051] FIG. 6 depicts a plot of etching rate versus C-38 copper stripper concentration.
[0052] FIG. 7 depicts a scanning electron microscope image of a nickel structure damaged by an etchant process that included excessive vibration.
[0053] FIG. 8 depicts a nickel structure that was pitted by etching with C-38.
[0054] FIG. 9 depicts a plot of etched length of a copper wire versus etching time.
DETAILED DESCRIPTION
[0055] FIGS. 1A-1G , 2 A- 2 F, and 3 A- 3 C illustrate various features of one form of electrochemical fabrication. Other electrochemical fabrication techniques are set forth in the '630 patent referenced above, in the various previously incorporated publications, in various other patents and patent applications incorporated herein by reference. Still others may be derived from combinations of various approaches described in these publications, patents, and applications, or are otherwise known or ascertainable by those of skill in the art from the teachings set forth herein. All of these techniques may be combined with those of the various embodiments of various aspects of the invention to yield enhanced embodiments. Still other embodiments may be derived from combinations of the various embodiments explicitly set forth herein.
[0056] FIGS. 4A-4I illustrate various stages in the formation of a single layer of a multi-layer fabrication process where a second metal is deposited on a first metal as well as in openings in the first metal so that the first and second metal form part of the layer. In FIG. 4A a side view of a substrate 82 is shown onto which patternable photoresist 84 is cast as shown in FIG. 4B . In FIG. 4C a pattern of resist is shown that results from the curing, exposing, and developing of the resist. The patterning of the photoresist 84 results in openings or apertures 92 ( a )- 92 ( c ) extending from a surface 86 of the photoresist through the thickness of the photoresist to surface 88 of the substrate 82 . In FIG. 4D a metal 94 (e.g. nickel) is shown as having been electroplated into the openings 92 ( a )- 92 ( c ). In FIG. 4E the photoresist has been removed (i.e. chemically stripped) from the substrate to expose regions of the substrate 82 which are not covered with the first metal 94 . In FIG. 4F a second metal 96 (e.g. silver) is shown as having been blanket electroplated over the entire exposed portions of the substrate 82 (which is conductive) and over the first metal 94 (which is also conductive). FIG. 4G depicts the completed first layer of the structure which has resulted from the planarization of the first and second metals down to a height that exposes the first metal and sets a thickness for the first layer. In FIG. 4H the result of repeating the process steps shown in FIGS. 4B-4G several times to form a multi-layer structure are shown where each layer consists of two materials. For most applications, one of these materials is removed as shown in FIG. 4I to yield a desired 3-D structure 98 (e.g. component or device).
[0057] In some preferred conformable contact mask plating and electrochemical fabrication embodiments, deposition and etching of a sacrificial material, such as copper, are essential steps. The sacrificial material serves as a mechanical support for the structural material during structure formation. Additionally, since the sacrificial material, like the structural material, is conductive, additional material can be deposited over the entire layer without constraint. Thus the use of a sacrificial material eliminates virtually all geometrical restrictions, allowing the structural material on a layer to overhang and even be disconnected from that on the previous layer. Furthermore, the use of a sacrificial material may allow a broader range of structural materials to be used in that the sacrificial material can be deposited in a selective process (e.g. by a conformable contact mask process) while the structural material may be deposited in some other manner (e.g. blanket deposition) where fewer deposition limitations may exist.
[0058] The basic rules governing etching are as follows:
[0059] 1. Selectivity: Etchants should only remove sacrificial materials. No or little effect on main materials should occur.
[0060] 2. Completion: A sacrificial material needs to be removed completely.
[0061] 3. Speed: The shorter the etching time, the higher the throughput.
[0062] 4. Integration: An etching process should not damage delicate structures.
[0063] Wet etching is a fast, cheap process and can also remove materials from blind geometries. Usually, to remove a metal, it must be of an oxidized form so as to transition from the metallic to an ionic state. Therefore, the active ingredient in a metal etchant needs to be an oxidizing agent. Alternatively, electrochemical anodic etching provides the required oxidizing action by passing a current of cations from a workpiece. An acid or alkaline complexing agent may be included to increase the etching rate. Other additives may also be included. Common oxidizing agents used for stripping copper include chlorite, ferric chloride, cupric chloride, persulfate, organic nitro compounds, and peroxide.
[0064] In electrochemical fabrication, a fast reliable copper etching process without negative effect on structural material (e.g. nickel) and associated structures is desirable to achieve the final structures (e.g. microstructures).
[0065] Some common copper etchants were evaluated for use in electrochemical fabrication and are listed in FIG. 5 . In the evaluation (1) etching rates for the etchants were determined from either tests or from references, (2) Ni compatibility was determined, and (3) the etching processes for each etchant were examined. Copper foil samples were used for measuring etching rates and had dimensions of 2 cm by 4 cm by 60 μm and a purity of 99.5%. To hold the samples in the etchant solutions, a hole was drilled with a diameter of 0.48 cm in each sample. Etching time was variable depending on actual reaction rate of each etchant at room temperature (˜20° C.). The etching rate in each etchant was determined from the difference in measured weight of the copper foil before and after the test.
[0066] Although these etchants were reported to be nickel compatible, etchants with slow etching rate and bubble formation during the etching process were not considered further. A slow etching rate means more process time while vigorous bubble formation could induce stress in free standing structures such as beams and cantilevers, could break delicate microstructures, or could inhibit etchant access into small passages. Though most of the etchants were successful in removing thin sacrificial copper films, their slow etching rates and/or bubble formation make them impractical for removing relatively large amounts of copper in electrochemical fabrication or similar cases. Of the etchants evaluated the ENSTRIP® C-38 stripper had an etching rate of 460 μm/hr and appeared to be the most promising.
[0067] ENSTRIP® C-38 stripper (Enthone-OMI Inc. of New Haven, Conn.) is a two-component, ammoniacal immersion stripper designed to quickly remove copper from steel and stainless steel substrates. The recommended C-38 stripper is formed from two primary components, Enstrip C-38A at 75% by volume and Enstrip C-38B at 25% by volume. It is recommended that the Enstrip C-38 solution should only be operated within the pH range of 9.3 to 10.5 and within a temperature range from room temperature to a maximum of 38° C. If the solution pH becomes too low, it is recommended that 27% ammonium hydroxide be added in small increments until the pH is brought into the right range. It is believed that the two main components of the C-38 solution are sodium chlorite, NaClO 2 , and ammonium hydroxide, NH 4 OH. The C-38 solution can dissolve up to 8 ounces of copper per gallon of solution. The C-38 basic reaction mechanism is believed to be:
[0068] On the etching surface:
[0000] ClO 2 − +H 2 O+2 e − →ClO − +2OH −
[0000] 2Cu−2 e − →2Cu +
[0000] Cu + +2NH 3 →[Cu(NH 3 ) 2 ] +
[0069] In the bulk solution:
[0000] ClO 2 − +H 2 O+2 e − →ClO − +2OH −
[0000] 2[Cu(NH 3 ) 2 ] + +4NH 3 −2 e − →2[Cu(NH 3 ) 4 ] 2+
[0070] C-38 does not attack nickel significantly. Experiments showed that the nickel corrosion rate in C-38 is only about 72 μm/yr. For a short etching time, the actual amount of etched nickel is negligible. To extend the range of electrochemical fabrication structural materials beyond nickel, the etching rates of other metals and alloys were tested in C-38. Samples with a known area and weight were immersed into C-38 at room temperature for a known time. The etching rate was calculated from the corresponding weight loss. The test results are listed in the following table. Compatibility of Metals and Alloys in C-38
[0000]
Testing
Etching Rate in C38 at 20° C.
Material
Form of Material
(μm/hr)
Cu
Cu foil, 99.5%
~460
Ni
Ni Deposit from Ni sulfamate
~0
bath
Fe
Mild steel, >99%
0.02
Au
Gold Mirror
~0
Ag
Silver wire, 99.99%
0.41
Pt
Platinum wire
~0
Sn
Tin round, 99.85%
0.02
Pb
Lead wire, 99.92%
0.08
Zn
Zinc wire, 99.9%
Dissolved quickly
Sn—Ag
Solder wire, 96%-4%
0.02
Pd—Sn
Solder wire, 60%-40%
0.10
Fe—Ni
~0
[0071] Zinc is not suitable for use as an unprotected structural material but may be useful as a sacrificial material since it is quickly dissolved in C-38. All other metals and alloys that were tested were determined to be useful as structural materials when C-38 is the etchant.
[0072] The etching rate of copper in C-38 can be adjusted downward by diluting the full strength C-38. A plot of etching rates versus C-38 concentration is shown in FIG. 6 . For real microstructure release, the etching rate will be lower and will depend on actual geometric complexity since an etching rate is determined by rates of (1) fresh etchant delivery to etching surface and (2) reaction products delivery to the bulk solution. For example, one experiment indicated that the etching rate of an epoxy embedded copper wire with a diameter of 0.64 mm was only about 180 μm/hr for first two hours. Stirring the etchant solution improved etching rate. One test showed that the etching rate for copper wires (d=0.64 mm) embedded in epoxy in C-38 at 36° C. when ultrasonically stirred (i.e. agitated) was 2.7 times as large as that when stirring with a magnetic stirring bar during a 24 hour period. Although stirring or agitating can improve etching rates, if too violent such as by excess ultrasonic agitation, damage to microstructures can result. An example of what excess stirring can do to structures produced by electrochemical fabrication is shown in the scanning electron microscope (SEM) image of FIG. 7 , in which ultrasonic stirring was used to help release the microstructure. It appears that the vibration ruptured the structure at edge 102 of the nickel deposit 104 on nickel substrate 106 . As opposed to the vibrations themselves being too violent, another possible explanation is that the frequency of the vibrations excited resonance in the deposited structure which resulted in its failure.
[0073] The C-38 wet etching process is followed by a drying process to remove the liquid from the microstructure. Because of the surface tension of the rinse water, the released free-standing structures can tend to stick to the substrate. Once a structure is attached to the substrate by sticking, the mechanical force needed to dislodge it usually is large enough to damage the structure. In some MEMS processes, it has been proposed that this problem be overcome by use of freezing-sublimation or a CO 2 supercritical drying process. However, these techniques can be process intensive, time consuming and often require sophisticated high-pressure apparatus. In electrochemical fabrication, a relatively simple method is preferred. After rinsing the part, it is immediately transferred into an alcohol solution where the alcohol is made to replaces the water from around the structure. The structure is then immediately transferred to an oven at ˜60° C. for 5-10 minutes to evaporate the alcohol and dry the structure.
[0074] The preferred procedure for releasing structures (i.e. copper from nickel structures) produced by electrochemical fabrication involves surrounding the combined copper/nickel structure with a diluted C-38 etchant without any stirring. The preferred dilution is about one part C-38 by volume to about four to five parts H2O. In some embodiments though, the level of dilution may range from as low as about one part C-38 to about ten parts water and as high as undiluted C-38. The etching endpoint is reached when a blue substance stops appearing from the structure and in particular from any cavities or ports within the structure. The structure is then dipped into a Di water tank and is slowly moved through the water so as to displace the etchant with the water. The structure is then transferred to an alcohol tank where the structure is slowly moved through the alcohol to displace the water with alcohol and it is thereafter removed from the tank and dried in an oven.
[0075] Nickel is considered to be a slightly noble metal. It resists corrosion in many environments due to its high passivation tendency. Usually there is a passive oxide or hydrated oxide film on the nickel surface which produces good corrosion resistance. In neutral and moderately alkaline solutions, a passive surface layer of Ni(OH) 2 and perhaps NiO forms on the nickel surface, while the passive film is possibly NiOOH in strongly oxidizing neutral and alkaline conditions such as in a C-38 environment (i.e. in an alkaline oxidizing solution).
[0076] Passive films protecting metals and alloys break down locally in certain corrosion environments and pitting results. Local points undergo anodic dissolution to form pits on the surface, while the major part of the surface remains passive. Usually, the diameter of pits is in the range of tens of micrometers and the depth of pits is equal to, or more than, their diameter. Obviously, formation of pits on nickel is unacceptable to microstructures. C-38 works well in etching copper without attacking nickel. However, occasionally pits have been observed to form on the nickel substrate and nickel deposits. FIG. 8 shows an SEM image of pits 112 on a nickel deposit 104 . A possible explanation for these phenomena is that chlorite is not very stable and could decompose by light, temperature, and catalysts to produce hypochlorite and/or chloride ions, especially for aged or used C-38 solutions. In addition, as indicated in the above basic reaction equations hypochlorite is also produced during the etching process. Hypochlorite could attack nickel to form pits. Based on these possibilities, some preferred electrochemical fabrication etching processes involving C-38 include one or more of, and more preferably all of, (1) minimizing the C-38's contact with light, high temperature, or air during its storage period; (2) mixing the two components just before etching to ensure the freshness of the etchant; and (3) checking the pH of the C-38 prior to each use to make sure it has a pH between 9.3 and 10.5.
[0077] Additional preferred electrochemical fabrication etching processes add a corrosion inhibitor to the C-38 to help prevent pitting. The use of a corrosion inhibitor in combination with the etchant may be done alone or in addition to the above noted handling and checking preferences. The preferred inhibitor for use in etching electrochemical fabrication structures with a Chlorite based etchant like C-38 is sodium nitrate, NaNO 3 .
[0078] Corrosion inhibitors are chemical compounds which, when added in small concentration to a corrosion environment, can greatly increase the corrosion resistance of an exposed metal. It is known that nitrate can be used as a pitting inhibitor for steels, stainless steels, aluminum and its alloys. For nickel it is believed that the anti-pitting mechanism of NaNO 3 is due to the preferential adsorption of NO 3 — on the nickel surface. In this way, NO 3 − ions prevent aggressive ions like ClO − from adsorbing on the surface to cause pitting. The presence of the nitrate can shift a pitting potential (E pit ) to a more noble value. Its efficiency can be evaluated by a pitting scan which is a potentiodynamic polarization curve measurement in which E pit is determined from the anodic polarization curve as the potential where the current density sharply increases due to breakdown of the passive film and formation of pits. Pits initiate and grow above E pit , but not below. The more positive the E pit , the better the efficiency of the inhibitor.
[0079] A test was performed to determine if the present of NaNO 3 could raise the E pit value. The test was performed using polished nickel disks having diameters of 1.27 cm. Pitting scans were conducted in 0.5 N NaCl solution with and without NaNO3 (1 g/100 ml) using an EG&G 273A Potentiostat/Galvanostat in accordance with ASTM G5 and G61. The scan rate was 0.166 mV/s. E pit increased by about 90 mV in the presence of 1 g/100 mL of NaNO 3 . An additional test indicated that when only 0.1 g/100 ml NaNO 3 was added, no shift of E pit occurred. It is believed that a concentration of NaNO 3 sufficient to raise the E pit value by about 10 mV would yield some improvement in performance though having it be raised to about 30 mV or more preferably by about 50 mV would be better. In any event, an effective quantity of an antipitting agent may be empirically determined by those of skill in the art in view of the teachings herein such that pitting is eliminated or brought down to a tolerable level.
[0080] An experiment was performed to determine the effect of the presence of NaNO 3 on the copper etching rate. The determined etching rate of copper foil in C-38 containing 1 g/100 ml NaNO 3 was 430 μm/hr compared to 460 μm/hr without NaNO 3 suggesting that the presence of NaNO 3 has only a small effect on copper etching and that the effectiveness of the etchant remains. Experiments have also shown that pitting is reduced when etching with C-38 in combination with a small amount of NaNO 3 (sodium nitrate). It is believed that the concentration of C-38 may be lowered to about 0.5 g/100 ml and still have obtain a benefit from the process and raised well above the 1 g/100 ml concentration level without bringing harm to the etching process though a point may be reached where little additional benefit is added by the increased concentration.
[0081] Wet chemical sacrificial etching is dependent on the reacting species reaching the etching surface (e.g. by diffusion). If the etching area is relatively large and open to the etchant, and the etching length of the sacrificial layer is short (e.g. <100 μm), the etchant can always be sufficiently supplied at the etching front. This etching mode is called reaction-limited etching. However, if the etching length is very long compared to the channel width such as in narrow channel etching or where the etchant flow is severely restricted due to cavities or structures with irregularly shaped interfaces, the etchant may be depleted at the etching front. This is known as the diffusion-limited etching mode. In this mode, etching may become extremely slow or even stop. FIG. 9 depicts a plot of etched copper length versus time in a one-dimensional etching test that was carried out in C-38 at 38° C. aided by ultrasonic stirring for a 40 μm diameter copper wire (one end of an epoxy embedded copper wire is exposed to the etchant). With time, the etching rate dramatically decreased and after 5 hours, etching practically stopped.
[0082] To eliminate the limitation of diffusion of chemical species in wet chemical etching, it is believed that some form of electrochemical anodic etching may be used to assist in the removal of copper particularly from complex geometries such as narrow passages and blind cavities. Besides the chemical etching effect of an etchant itself on copper, electrochemical anodic etching provides also for anodic dissolution by passing current through the etchant to the surface to be etched. In addition, the applied electric field can drive copper ions through the etchant away from the structure being etched toward a cathode while simultaneously attracting anions to the surface of the structure, thus creating higher material transfer rate and helping to bring unreacted fluid closer to the copper front due to mass conservation effects.
[0083] Preliminary electrochemical anodic etching of both the DC and biased AC type were investigated for use with electrochemical fabrication produced structures. C-38 was used as the etchant. Based on these preliminary investigations, electrochemical etching seems to be a promising copper etching technique.
[0084] Various other embodiments of the present invention exist. Some of these embodiments may be based on a combination of the teachings herein with various teachings incorporated herein by reference. Some embodiments may not use any blanket deposition process and/or they may not use a planarization process. Some embodiments may involve the selective deposition of a plurality of different materials on a single layer or on different layers. Some embodiments may use blanket depositions processes that are not electrodeposition processes. Some embodiments may use selective deposition processes on some layers that are not Instant Mask processes and are not even electrodeposition processes. Some embodiments may use nickel as a structural material while other embodiments may use different materials such as gold, silver, or any other electrodepositable materials that can be separated from the copper and/or some other sacrificial material. In some embodiments, the depth of deposition will be enhanced by pulling a CC mask away from the substrate as deposition is occurring in a manner that allows the seal between the conformable portion of the CC mask and the substrate to shift from the face of the conformal material to the inside edges of the conformable material.
[0085] In view of the teachings herein, many further embodiments, alternatives in design and uses of the instant invention will be apparent to those of skill in the art. As such, it is not intended that the invention be limited to the particular illustrative embodiments, alternatives, and uses described above but instead that it be solely limited by the claims presented hereafter.
|
An electrochemical fabrication process for producing three-dimensional structures from a plurality of adhered layers is provided where each layer comprises at least one structural material (e.g. nickel) and at least one sacrificial material (e.g. copper) that will be etched away from the structural material after the formation of all layers have been completed. A copper etchant containing chlorite (e.g. Enthone C-38) is combined with a corrosion inhibitor (e.g. sodium nitrate) to prevent pitting of the structural material during removal of the sacrificial material. A simple process for drying the etched structure without the drying process causing surfaces to stick together includes immersion of the structure in water after etching and then immersion in alcohol and then placing the structure in an oven for drying.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to vehicle safety and pre-warning technology and more particularly, to a vehicle door opening warning system, which gives audio and visual warning signals when the car door is being opened, and limits the opening angle of the car door when a sensor at the car door senses the approaching of a car from behind.
2. Description of the Related Art
Following fast development of technology, many vehicle security and safety related products have been continuously created to enhance driving safety. A vehicle may be equipped with rearview monitor system for enabling the driver to view any vehicle or object approaching from behind. However, this rearview monitor system has its rearview dead angle. When a car driver or a person in a car is opening a car door of the car, the driver or person may be unaware of a car or moving object from behind, causing an accident. Even an experienced car driver may be unable to control any person sharing the car from opening the car door upon a sudden approaching of car or object from behind. Further, a vehicle may be equipped with a variety of signal lights, however, no warning light is designed to give a visual pre-warning signal when a car door is going to be opened.
SUMMARY OF THE INVENTION
The present invention has been accomplished under the circumstances in view. It is one object of the present invention to provide a vehicle door opening warning system, which gives audio and visual warning signals when the car door is being opened. It is another object of the present invention to provide a vehicle door opening warning system, which limits the opening angle of the car door when a sensor at the car door senses the approaching of a car from behind.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit block diagram of a vehicle door opening warning system in accordance with the present invention.
FIG. 2 is a schematic drawing of a part of the present invention, illustrating the related component parts of the vehicle door opening warning system installed in a car door of a car.
FIG. 3 is schematic drawing a part of the present invention, illustrating one normally closed contact switch and one normally opened contact switch of the vehicle door opening warning system mounted in the car door frame of the car.
FIG. 4 is a schematic drawing of a part of the present invention, illustrating the positioning of the car door-opening control unit of the vehicle door opening warning system in the car door of the car.
FIG. 5 is an elevational view of the car door-opening control unit of the vehicle door opening warning system in accordance with the present invention.
FIG. 6 is a schematic side view of a part of the present invention, illustrating the stop bar moved to the first position.
FIG. 7 is a schematic side view of a part of the present invention, illustrating the stop bar moved to the second position.
FIG. 8 is a schematic side view of a part of the present invention, illustrating the stop bar moved to the third position.
FIG. 9 is a schematic side view of a part of the present invention, illustrating the handle of the car door in the non-operative position and the related normally closed contact switch in the closed-circuit position.
FIG. 10 corresponds to FIG. 9 , illustrating the handle of the car door biased and the related normally closed contact switch in the open-circuit position.
FIG. 11 is a schematic side view of the car door-opening control unit of the vehicle door opening warning system in accordance with the present invention, illustrating the through hole of the linkage in alignment with the photo sensor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1˜5 , a vehicle door opening warning system in accordance with the present invention is shown comprising a car door-opening control unit 1 installed in a linkage 51 of a car that extends out of a car door frame that is movable to open/close a car door 5 that is hinged to the car door frame, a normally closed contact switch 2 and a normally opened contact switch 21 mounted in the car door frame of the car, an approaching object sensor 3 mounted in the free end of the car door 5 , one or a series of warning lights 31 mounted in the free end of the car door 5 , a buzzer 32 , a relay 33 , a battery 34 , and a controller 4 .
The car door-opening control unit 1 comprises a holder frame 11 having a through hole 12 for the passing of the linkage 51 , an electromagnetic valve (solenoid) 14 mounted at a bottom side inside the holder frame 11 and operable to move a reciprocating rod 141 up and down, a stop bar 13 pivotally mounted in the holder frame 11 and having the free end 131 thereof supported on the reciprocating rod 141 and movable with the reciprocating rod 141 to one of a first position where the free end 131 of the stop bar 13 is stopped at a first stop portion 511 of the linkage 51 to prohibit the car door 5 from being opened, a second position where the free end 131 of the stop bar 13 is stopped at a second stop portion 512 of the linkage 51 to prohibit the car door 5 from being opened, and a third position where the free end 131 of the stop bar 13 is released from the linkage 51 for allowing the car door 5 to be opened. When a person is opening the car door 5 , the normally closed contact switch 2 is released from the pressure of the car door 5 for allowing the battery power supply of the battery 34 to be conducted through normally closed contact switches 162 and 53 to the controller 4 to operate the approaching object sensor 3 and the warning lights 31 , causing the approaching object sensor 3 to sense any approaching object (car) and the warning lights 31 to give a visual warning signal (to give off light or to flash). If the approaching object sensor 3 senses the approaching of an external object (car) at this time, it gives a signal to the controller 4 , causing the controller 4 to drive the buzzer 32 in giving an audio warning signal and to switch on the relay 33 in starting the electromagnetic valve 14 to that the electromagnetic valve 14 extends out the reciprocating rod 141 to lift the free end 131 of the stop bar 13 to the first position where the free end 131 of the stop bar 13 is stopped at the first stop portion 511 of the linkage 51 to prohibit the car door 5 from being opened (see FIG. 6 ). After the external object passed and the approaching object sensor 3 senses no signal, the controller 4 receives no signal from the approaching object sensor 3 and switches off the relay 33 to cut off the battery power supply from the electromagnetic valve 14 , allowing the free end 131 of the stop bar 13 to be lowered with the reciprocating rod 141 to the third position for allowing the car door 5 to be opened. If the approaching object sensor 3 senses a signal again at this time, the controller 4 switches on the relay 33 to start the electromagnetic valve 14 again, enabling the free end 131 of the stop bar 13 to be lifted by the reciprocating rod 141 to the second position where the free end 131 of the stop bar 13 is stopped at a second stop portion 512 of the linkage 51 to prohibit the car door 5 from being opened (see FIG. 7 ).
Further, the normally closed contact switch 53 is mounted in the car door 5 at an inner side relative to the handle 52 of the car door 5 . When the handle 52 is operated to open the car door 5 , a connected rod 521 of the handle 52 is forced to open the normally closed contact switch 53 , causing the controller 4 to switch off the approaching object sensor 3 and the warning lights 31 (see FIG. 1 , FIG. 9 and FIG. 10 ). When the car door 5 is closed, the normally opened contact switch 21 conducts the battery power supply to the controller 4 , driving the approaching object sensor 3 into the standby mode for further sensing operation after a next opening action of the car door 5 .
Further, a manual push button 16 is disposed at one side relative to the car door-opening control unit 1 operable to move a link 161 that is connected to the reciprocating rod 141 of the electromagnetic valve 14 and to open the normally closed contact switch 162 . When the manual push button 16 is pressed by a person in an emergency or car crash, the normally closed contact switch 162 is opened to cut off the battery power supply from the car door-opening control unit 1 , and the reciprocating rod 141 of the electromagnetic valve 14 is moved to lower the stop bar 13 from the linkage 51 , allowing the car door 5 to be opened by a person (see FIG. 8 ).
The car door-opening control unit 1 further comprises a photo sensor 15 , which gives a signal to the controller 4 to switch off the sensor 3 when the linkage 51 is moved to open the car door 5 and to aim a through hole 513 thereof at the photo sensor 15 (see FIG. 11 ).
In conclusion, the invention provides a vehicle door opening warning system, which controls the opening angle of the car door to prevent a car crash and gives audio and visual warning signals when the car door is being opened.
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.
|
A vehicle door opening warning system for a car includes a sensor for sensing the approaching of another car from behind when a person is opening the car door, a car door-opening control unit stops the car door from being opened when the sensor senses the approaching of the other car from behind, and a warning light and a buzzer are activated to give a visual warning signal and an audio warning signal when the car door is being opened.
| 1
|
TECHNICAL FIELD
[0001] The invention relates to a method for producing patterned textile labels and to an installation for carrying out the method.
BACKGROUND
[0002] A method and in installation of the type initially mentioned are known, for example, from DE 36 27 315 A or WO 00/73 559. The labels produced there have, in addition to a regular pattern, individual pattern parts for which spaces provided with basic designs of specific configuration are reserved in a specific region (space holders). Design pattern parts, that is to say finished design parts, are inserted into the space regions automatically from an electronic store. These pattern parts may be variable. The finished design parts already possess all the information for controlling the production machine, for example a Jacquard weaving machine.
[0003] It is relatively difficult, however, in the case of a continuous production of labels, to provide each label with a markedly different individual pattern part. At all events, the spaces where variable data can be inserted are fixed and limited. A further difficulty is that the pattern parts have to be prefabricated, therefore it is not possible in a simple way to change, for example, the width, the length or another parameter. There has to be a fundamental redesign, thus incurring high costs. Furthermore, the transitions from one pattern part to another must be coordinated exactly with one another in terms of weave, which is difficult to implement. Moreover, there is no safety against wrongly assigning an individual pattern part many times.
SUMMARY OF THE INVENTION
[0004] The object of the invention is to improve a method and an installation of the type initially mentioned in such a way that labels having pattern parts individually different from one another can be produced continuously in a simple and reliable way.
[0005] Since the virtual label consisting of N individual labels distributed over the width and length of the virtual label and having a pattern and N individual pattern parts different from label to label is produced, and the virtual label thus produced is subdivided into N individual labels, this ensures that the individual labels produced in the batch size N are also actually different from one another.
[0006] The width of the virtual label corresponds to the number of warp threads used in a production machine, for example a weaving machine. N may be of any desired size. Preferably, a length is used which corresponds to the length of a cloth web capable of being wound on a winding beam. The batch size N may also depend on the labels capable of being packaged in a packaging unit.
[0007] The labels may in each case be provided with at least one second pattern part which may be a continuous numbering which may be distributed continuously, preferably in the longitudinal direction of the virtual label, in rows lying next to one another. The individual pattern parts may also be a bar code or counterfeit-proof additional code which can be generated by a random generator. Pattern parts may also be various graphic figures, such as images, logos or the like. Other individual pattern parts may also be envisaged, such as various forenames and/or family names. The individual pattern part may also consist of a series of objects, plants, animals or the like.
[0008] The virtual label is provided at the start and at the end with identifying information, in order, for example, to identify or inscribe a batch size. Pattern-free intermediate zones for subdividing the virtual labeling to individual labels or label webs are provided between the individual labels in the virtual label V in the longitudinal direction and/or in the width direction. These intermediate zones may be formed by a pattern-free ground fabric part. The intermediate zones may also be formed in the longitudinal direction by fabric-free zones, in that the virtual label is produced in longitudinal strips distributed over the width.
[0009] The virtual label is first produced in the design mode and only then converted by means of a converter into a pattern mode capable of being processed by the production machine. These individual pattern parts may be generated manually, semiautomatically and fully automatically. Particularly in the latter case, it is advantageous if a computer-controlled pattern device with a CAD system having design software and with at least one generator for generating the individual pattern parts is used for the design mode.
[0010] The pattern device may be arranged independently of the production machine, and data transfer to the production machine may take place by means of a data line or preferably by means of a data carrier. In this case, the pattern device may preferably be arranged advantageously even independently of the user of the production machine, on the premises of the manufacturer. The person operating the production machine can then transmit the desired pattern and the desired individual pattern parts as a model to the operator of the pattern device who then sets up the necessary control program, what is known as the master program, the control signals for the production machine, then determines returns it to the user for controlling the production machine.
[0011] The production machine may be a printing machine, on which a textile web is printed with the virtual label. It is appreciably more advantageous to use a Jacquard weaving machine for producing the virtual label. The virtual label may be woven with a selvedge on a multi-section Jacquard needle ribbon weaving machine without fabric-width repeat repetition. Higher performances can be achieved by means of a method when the virtual label is produced on a Jacquard broad-weaving machine without fabric-width repeat repetition.
[0012] The virtual label, then, may be produced continuously on such a production machine as a ribbon or broad web and subdivided into individual labels, independent of the production machine, and at all events also folded to the final shape in a folding machine. However, it is also possible for the virtual label to be cut in the longitudinal and/or width direction during production on the production machine.
[0013] It is advantageous if the virtual label is produced for a production machine which has a production counter, in order to detect the number of labels produced for the most diverse possible applications, such as a check of the batch size produced for a customer for the labels, and/or for license accounting for the machine and/or software manufacturer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Exemplary embodiments of the invention are designed in more detail below with reference to the drawings in which:
[0015] FIG. 1 shows a plan view of an individual label;
[0016] FIG. 2 shows a diagrammatic illustration of a Jacquard broad-weaving machine, partially in a graphic illustration and partially as a block diagram;
[0017] FIG. 3 shows a plan view of a further individual label;
[0018] FIG. 4 shows a virtual label consisting of the individual labels of FIG. 3 ; and
[0019] FIG. 5 shows a diagrammatic illustration of a three-section needle ribbon weaving machine.
DETAILED DESCRIPTION OF THE INVENTION
[0020] FIG. 1 shows a label E consisting of a ground fabric 2 which is produced from ground warp threads 4 and ground weft threads 6 . Figure weft threads 8 serve for generating a pattern M and individual pattern parts T, the latter being different from one another from label to label.
[0021] FIG. 2 shows a diagram of a preferred production machine, preferably designed as a Jacquard broad-weaving machine, with a Jacquard device 10 which, via heddles and heddle eyes 14 , opens the warp threads 4 to a shed 16 , into which, on the one hand, the ground weft threads 6 and, on the other hand, the figure weft threads 8 are shut and tied off with the ground fabric 2 and also the patterns M and the pattern parts T.
[0022] The Jacquard broad-weaving machine contains a control device 18 which at all events has a production counter 20 . The control device 18 is fed by a pattern device 22 which either may be connected directly to the control device or may be arranged separately from the Jacquard broad-weaving machine, for example in a pattern center. In the latter case, the data of the pattern device 22 may be transmitted via a data carrier, for example a diskette, or via a data line, for example a CAM network.
[0023] The pattern device 22 contains a design part 22 a with a CAD system 23 a , in which a desired pattern is prepared, furthermore first control means 23 b and, if appropriate, further control means 23 c which are, for example, generators, in order to prepare one or more individual pattern parts T. Furthermore, the pattern device comprises a converter 22 b (design device) which converts the virtual label V prepared in a design part 22 a into a machine-readable form which can be processed by the control device 18 of the production machine 10 , in the present example the Jacquard device of a weaving machine. The control means 23 b , 23 c may be manually actuated devices, semiautomatic devices or fully automatic devices, the latter, in particular, containing corresponding software.
[0024] By means of the control program generated in the pattern device 22 , that is known as the master program, the Jacquard broad-weaving machine can be controlled and the cloth web W indicated in FIG. 2 can be produced. This cloth web has woven in it individual labels E 1 to E 3 which lie next to one another and have in each case a common pattern M and pattern parts T 1 to T 3 individual from one another. Such individual rows of labels are lined up with another in the warp direction. A virtual label V determined by the master program is obtained, containing N individual labels E, which have pattern parts T 1 to T N which are, however, different from one another. The labels are separated in the width direction through intermediate zones 25 which consist of ground fabric. The virtual label V thus produced may be subdivided in the longitudinal direction, by means of a first severing device 24 , into individual strips which are then cut into individual labels E along the intermediate zone 25 by means of a second severing device 28 . In the example shown, the first severing device 24 is made of thermal cutting elements 28 which may consist of a resistance wire or of an ultrasonic device. The second severing device 26 may be designed in a similar way to the first severing device 24 . In the example shown, indicated by the scissors 30 that the second severing device 26 operates mechanically.
[0025] FIGS. 3 and 4 show a further label E with a pattern M and with a first pattern part T and a second pattern part Z which has a length l of, for example, 70 mm and a width b of, for example, 30 mm. The control program then, is then designed, for example, in such a way that 10 labels E 1 to E 10 are arranged so as to be distributed in a longitudinal row in the longitudinal direction of the cloth web W, and these are followed, over the width, by further rows with continuous numbering E 11 to E 20 , E 21 to E 30 , and so on and so forth, up until E N , the virtual label V thus being formed, which has a length L and a width B. The width B of the virtual label V corresponds to a repeat width of the Jacquard weaving machine. If a label has a length of l=70 mm and width b=30 mm and 10 rows are arranged next to one another, then, in the case of a batch size of N=50,000, a virtual label with the length L=150 m and the width B=0.3 m is obtained. The length L of the virtual label V is expediently selected at most as large as the length of the cloth web capable of being wound on a cloth beam. The rows of labels may in each case be wound up into a roll in which the labels carry continuous numbering.
[0026] The second pattern part Z of the label of FIGS. 3 and 4 contains coded additional information (Z) which can be generated at the control means 23 c of the pattern device 22 of FIG. 23 c . The control means 23 c contain a random generator which assigns a coded sign Z x for every label E 1 to E N , in addition to the continuous number T 1 to T N , as is indicated in FIG. 4 , in order to give a product provided with such a label, for example, copyright protection, multi-theft security or the like.
[0027] FIG. 5 illustrates a further individual label V which is produced on a three-section needle ribbon weaving machine. The individual labels are in this case distributed to the individual weaving points 32 1 , 32 2 , 32 3 . Thus, the labels E 1 to E a are generated at the first weaving point 32 1, the labels E a+1 to E b at the weaving point 32 2 , and the remaining labels E b+1 to E N at the third weaving point 32 3 , in each case strips are connected to one another in terms of content only by means of mutually coordinated numbering and arrangement of the pattern parts T 1 to T N . Moreover, the labels have an additional coded pattern part Z x .
[0028] According to the present method and by means of the present installation, for example, a customer can send the graphics of his label in Tif format to a pattern center, with an indication of the position of the pattern part, for example a numbering. This pattern center prepares, for the arrangement and shape of the pattern part and for the design and arrangement of the individual pattern part, a master program which is then sent back, for example in the form of a programmed diskette, to a customer, for example the weaver, in order to process it in a Jacquard weaving machine.
LIST OF REFERENCE SYMBOLS
[0000]
E label
M pattern
T pattern part
V virtual label
W cloth web
Z pattern part (addition)
L length of the virtual label
B width of the virtual label
l length of the label
b width of the label
2 ground fabric
4 ground warp thread
6 ground weft thread
8 figure weft thread
10 Jacquard device
12 heddle
14 heddle eye
16 shed
18 control device
20 production counter
22 pattern device
22 a design part
22 b converter (design device)
23 a CAD device
23 b control means
23 c control means
24 first severing device
25 intermediate zone
26 second severing device
28 thermal cutting element
30 scissors
32 weaving point
|
The invention relates to a method for producing patterned textile labels during which a production machine, which is controlled by a pattern device ( 22 ), provides labels (E 1 to E N )with a pattern (M), which is the same for all labels, and with pattern sections (T 1 to T N ) that are different from one another. In order to improve production, a virtual label (V) is created from N individual labels E 1 to E N )which are distributed over the width (B) and the length (L) of the virtual label (V) and which have N individual pattern sections (T 1 to T N ) that are different from one another, and then virtual label (V) is then divided into individual labels (E 1 to E N ).
| 3
|
BACKGROUND OF THE INVENTION
The present invention relates to the storage and shipment of articles conventionally packaged and sold in blister packs. A "blister pack" refers to the conventional packaging arrangement including a card, usually formed of medium to heavy gauge cardboard, and a clear, rigid or moderately stiff plastic blister projecting from the plane of the card on one side of the card. The card from which the blister projects extends beyond the edge of the blister in length, width, or both, to provide space on which appropriate graphics can be printed which describe the product and its attributes. The blister itself can contain a single product item, such as a single package of a cosmetic, or can contain a plurality of items such as screws, nails, thumbtacks, and other such items conventionally sold in bulk quantities.
While blister pack items are a convenient method of displaying a product in a store, they present difficulties in shipment, and storage. These difficulties include the uneven geometric configuration and the uneven weight distribution, which prevent convenient stacking. In addition, the sheer number of such items in a given shipment leads to difficulties in counting the items; and if the items are packed loose in a carton for shipment there can be damage to the cards and the blisters. Thus, a need exists for a convenient way of holding a number of blister pack items in a manner in which they can easily and compactly be stored and shipped.
SUMMARY OF THE INVENTION
In one aspect, the device of the present invention comprises a pair of sheets having essentially the same outer dimensions, or a sheet of stiff material hinged in the center, and comprising a plurality of holes dimensioned so that the blister itself but not the card to which the blister is attached can pass freely through said holes, and further comprising means integral with said device for securing the opposed edges of the sheets to each other when the device is holding blister packs.
By "stiff" is meant that the material from which the sheet is formed is rigid or at least capable of standing on its own when the sheet is folded at an angle about its hinge.
In another aspect, the present invention comprises a package assembly comprising, in combination, the sheet of the present invention folded over on itself about the hinge, such that the two sections of the sheet are held to each other by the securing means, and further comprising a plurality of blister packs in back-to-back position relative to each other and held between the two halves of the sheet, wherein the blisters protrude through the openings in said sheet.
In yet another aspect, the present invention comprises a pair of sheets held to each other by the securing means, and further comprising a plurality of blister packs in back-to-back positions.
The device can further include holes through which price labels can be attached to each card of a blister pack.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front plan view of one embodiment of the packaging device of the present invention.
FIG. 2 is a perspective view of the packaging device of FIG. 1 together with blister packs.
FIG. 3 is a perspective view of the packaging device of FIG. 1 in its closed form carrying a plurality of blister pack items.
FIG. 4 is a front plan view of another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is useful, as indicated, for the convenient and compact storage and shipment of a plurality of blister packs. The device is capable of convenient and compact storage and reuse.
Turning first to FIG. 1, the packaging device of the present invention comprises a sheet 1 of material, which is preferably medium to heavy gauge cardboard. Sheet 1 can include a hinge 2, which can be simply a crease formed across the center of the sheet 1. Hinge 2 divides sheet 1 into two sections which are preferably of equal size. A plurality of openings 3 in the sheet are formed in sheet 1. The openings 3 can be symmetrically arranged on each side of hinge 2. While two openings 3 are depicted, there can be two, three or more openings on each side of hinge 2.
Sheet 1 also comprises integral fastening means for securing the two halves of sheet 1 together when the two halves are folded together about hinge 2. In the embodiment shown, the securing means includes a plurality of tab means 4 which can be formed by appropriate cuts into the sheet 1. Each tab means is formed by two vertical cuts and one horizontal cut, thereby forming two tabs 5 which can be bent out of the plane of sheet 1 when necessary. The securing means further comprises a plurality of openings 6 of a size and location so that the openings 6 registrably correspond with the tabs 5 when the two sections of sheet 1 are folded together about hinge 2. Thus, when the two halves are folded together the tabs 5 are bent out of the plane of sheet 1 and forced through the holes 6 thereby forming a releasable fricition lock which holds the two halves of sheet 1 together. The tabs 5 should be of the same width as the holes 6 or can be slightly wider to improve the friction. The tab means 4 and holes 6 are preferably located adjacent to the edge of the respective sections of sheet 1, between the openings 3 and the edge. Another embodiment of the present invention comprises two sheets of the type depicted in FIG. 1 and described herein, without the hinge 2. In this embodiment, to hold blister packs one attaches two sheets 1 to each other using means 4 and respective openings 6.
It will be appreciated that the size of sheet 1, and of the openings 3, can vary depending on the size of the blister packs and the associated cards which one desires to package within the packaging device of the present invention. Preferably, the height and width of sheet 1 are sufficient (whether or not the sheet is hinged) so that no part of the card attached to a blister protruding through an opening 3 extends beyond any edge of sheet 1. This feature protects the card from unnecessary damage during handling. In addition, where two or more openings 3 are provided on the same side of a hinge 2, they should be spaced far enough apart so that blister packs can be placed side by side with the blisters protruding through their respective openings 3 without a blister being impeded by the card of an adjacent blister pack. It is permissible for cards of adjacent blister packs to overlap each other, provided that the hinge 2 is not covered and provided that the cards do not impede passage of adjacent blisters through their respective openings. As indicated above, it is necessary that the opening 3 be large enough to fully accommodate the blister itself, but smaller than the card to which the blister is attached.
To use the device in the present invention one simply selects a sheet 1 having the necessary dimensions as dictated by the size and shape of the blister and card associated with the blister pack to be packaged. Then, a number of blister packs equal to the number of openings 3 in the sheet 1 are selected and placed such that each blister extends through one of the openings 3 in the selected sheet. As seen in FIG. 2, all blister packs to be held by a given sheet 1 are positioned with cards 7 on the same side of sheet 1 and blisters 8 protruding through the respective openings. Sheet 1 if folded in half along hinge 2. This folding brings the cards 7 of the blister packs on opposite sides of hinge 2 into back-to-back contact with each other. This folding also brings the holes 6 into registration with the means 4. The final step is to force the tabs 5 of means 4 through the corresponding holes 6, as seen in FIG. 3, thereby fastening the two halves of sheet 1 to each other in a sturdy manner which can nonetheless be readily unfastened when the package reaches the destination at which the blister packs will eventually be removed.
Alternatively, two sheets 1 having essentially the same dimensions and configuration are selected and blister packs are placed with their blisters protruding through the openings, wherein all the cards are on the same side of each sheet. Then, the sheets are brought together with the cards in back-to-back relation, and the sheets are fastened to each other using means 4, 5 and 6.
Referring to FIG. 4, the sheet 1 can be provided with additional openings 9 located so that a portion of each card of a blister pack held in the device can be seen through the opening 9. When the blister packs are packaged as described above part of the front of the card (that is, the side which will be visible to a prospective customer) will be visible through opening 9. It is a simple matter to attach conventional price labels, such as those of the type having a gummed back, to each card through the openings 9. This is much easier and faster than attaching such labels to each card after the blister packs have been removed from the packaging device 1.
The device of the present invention provides numerous significant advantages. Among them are the light weight, low cost and simple storage of the sheet itself, and the ease and rapidity with which blister pack items can be packaged into the device. Packages comprising the device folded and locked around a plurality of blister packs are also highly advantageous. They can be easily packed into cartons for shipment; packing is facilitated in that the blisters protruding from adjacent packages interfit with each other so that adjacent packages are separated by the thickness of one blister (see FIG. 3 in which a second device 10 is shown in phantom). Packaging and handling are also facilitated because the packages have an even weight distribution so they are less likely to tip over when being handled. Labeling or price tags can conveniently be attached to the outside of the sheet, and the contents of the blisters remain visible. In addition, the task of counting the number of blister packs in a shipment is eased because one needs only to count the number of assembled packages.
|
A device for the convenient storage and shipment of conventional blister-pack articles comprises two sheets of material, optionally hinged in the middle, each sheet containing a plurality of openings therethrough. Each opening is configured so that one blister itself can pass easily through the opening, but the card to which the blister is attached cannot pass through the opening. Means are provided on each sheet to hold them closed together when the sheets are holding blister packs.
| 1
|
This application is a Divisional of application Ser. No. 08/802,408 now U.S. Pat. No. 5,942,768, filed Feb. 18, 1997; which itself is a Continuation of Ser. No. 08/539,558, filed Oct. 5, 1995 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor circuit having a plurality of thin-film transistors (TFTs) and a manufacturing method thereof. The semiconductor circuit that is manufactured according to the invention is formed on either an insulating substrate such as glass or a semiconductor substrate such as single crystal silicon. In particular, the present invention is effectively applied to a semiconductor circuit, such as a monolithic active matrix circuit (used in, for instance, a liquid crystal display), having a matrix circuit that is required to have a small off-current with a small variation and peripheral circuits for driving it which are required to operate at high speed and to have a small-variation on-current.
2. Description of the Prior Art
In recent years, various studies have been made of insulated-gate semiconductor devices having a thin-film active layer (also called an active region) on an insulating substrate. In particular, thin-film insulated gate transistors, i.e., thin-film transistors (TFTs), have been studied eagerly. The TFTs, which are formed on a transparent, insulating substrate, are intended to be used for controlling individual pixels in a display device having a matrix structure such as a liquid crystal display. The TFTs are classified into an amorphous silicon TFT, a crystalline silicon TFT, etc. depending on a semiconductor material used and its crystal state.
In general, having a small field-effect mobility, amorphous semiconductors cannot be used for a TFT that is required to operate at high speed. Therefore, to manufacture circuits having higher performance, crystalline silicon TFTs have been studied and developed recently. As methods for obtaining a crystalline silicon film, there are known a method in which amorphous silicon is thermally annealed for a long time at a temperature of about 600° C. or higher, and an optical annealing method in which amorphous silicon is illuminated with strong light such as laser light.
Having a larger field-effect mobility than amorphous semiconductors, crystalline semiconductors can operate at higher speed. Since crystalline silicon can provide not only an NMOS TFT but also a PMOS TFT in a similar manner, a CMOS circuit can be formed by using crystalline silicon. For example, among active matrix type liquid crystal display devices, there is known one having a monolithic structure (i.e., a monolithic active matrix circuit) in which peripheral circuits (drivers, etc.) are also constituted of CMOS crystalline TFTs.
FIG. 1 is a block diagram showing a monolithic active matrix that is used in a general liquid crystal display. A source driver (column driver) and a gate driver (row driver) are provided as peripheral driver circuits. A large number of pixel circuits each constituted of a switching transistor and a capacitor are formed in an active matrix circuit area (pixel area). The pixel transistors of the matrix circuit are connected to each of the peripheral driver circuits via source lines or gate lines having the same number of columns or rows. TFTs used in the peripheral circuits, particularly peripheral logic circuits such as a shift register, are required to operate at high speed. Therefore, those TFTs are required to allow passage of a large current with a small variation in a selected state (on-current).
On the other hand, to assure a long-term holding of charge in the capacitor, TFTs used in the pixel circuit are required to have a sufficiently small leak current (off-current) with a small variation in a non-selected state, i.e., while a reverse-bias voltage is applied to the gate electrode. Specifically, the off-current should be smaller than 1 pA, and the variation should be less than 10%. On the other hand, the on-current need not be so large.
Although the above characteristics are physically contradictory, it is required that TFTs having such characteristics be formed on the same substrate at the same time, which means that all the TFTs should have a large on-current and a small off-current both with a small variation. It is easily understood that it is technically very difficult to satisfy such requirements.
For example, it is known that crystallizing an amorphous silicon film by optical annealing such as laser annealing is effective for obtaining a TFT having a large on-current (i.e., a large field-effect mobility). However, it is empirically known that it is impossible to attain both of a large field-effect mobility and a small off-current variation at the same time.
Also known is a method of crystallizing an amorphous silicon film by thermal annealing. Although this method can reduce an offcurrent variation, it cannot provide a large field-effect mobility. The present invention is to solve such a difficult problem.
SUMMARY OF THE INVENTION
The present inventors have found that it becomes possible to proceed crystallization more easily and provide better crystallinity than in the conventional methods of using thermal annealing or optical annealing by bringing a very small amount of an element of Ni, Pt, Pd, Cu, Ag, Fe, or the like, or its compound substantially in close contact with the surface of an amorphous silicon film and then performing thermal annealing or optical annealing (laser annealing, rapid thermal annealing (RTA), or the like). For example, when the thermal annealing is employed, the crystallization time can be shortened and the crystallization temperature can be lowered from the conventional cases.
It has been confirmed that the above advantages are obtained because Ni, Pt, Pd, Cu, Ag, Fe, or the like serves as a catalyst element for accelerating crystallization of an amorphous silicon film. More specifically, the above catalyst elements form a crystalline silicide with amorphous silicon at a crystallization energy lower than that of amorphous silicon. Then, after the catalyst element in the silicide moves to the location of amorphous silicon ahead, silicon enters the site of the silicide which was occupied by the catalyst element, thus forming crystalline silicon. As the catalyst element moves through amorphous silicon, a crystallized region is formed.
Thus, it has been confirmed that the crystallization of an amorphous silicon film utilizing a catalyst element proceeds in two steps that respectively correspond to the following modes:
(1) The mode in which crystallization that occurs at a region where a catalyst element is introduced. Although it is not appropriate to strictly define the crystallization direction, it may be said that crystal growth proceeds perpendicularly to a substrate.
(2) The mode in which a crystal-grown region expands as catalyst element moves from the region where it was introduced to a region where it was not, so that crystal growth proceeds parallel with the substrate.
In particular, as for the crystal growth mode (2), growth of columnar crystals parallel to a substrate has been confirmed by observations using a TEM (transmission electron microscope). In the following description, the crystal growth mode (1) and a resulting crystallized region are called vertical growth and a vertical growth region, and the crystal growth mode (2) and a resulting crystallized region are called lateral growth and a lateral growth region.
For example, if a thin coating of a catalyst element, or its compound or the like is formed on an amorphous silicon film by a certain means so as to be substantially in close contact with the latter and then thermal annealing is performed, the coated portion is initially crystallized mainly by the vertical growth and thereafter a region surrounding that portion is crystallized by the horizontal growth.
The crystallinity can be improved by performing proper optical annealing after the above crystal growth by thermal annealing. The main effects of the optical annealing are to increase the field-effect mobility and reduce the threshold voltage.
The vertical growth and the lateral growth have a difference in the degree of crystal orientation. In general, the vertical growth does not provide so high a degree of crystal orientation in which orientation in the (111) plane with respect to the substrate surface is dominant to a small extent. In contrast, remarkable orientation is found in the lateral growth. For example, where a silicon film is coated with a silicon dioxide film or a silicon nitride film and then crystallized by thermal annealing, orientation in the (111) plane mainly occurs. Specifically; in an X-ray diffraction measurement, the ratio of a reflection intensity of the (111) plane to the sum of reflection intensities of the (111), (220) and (311) planes amounts to more than 80%.
The above tendency becomes more remarkable if optical annealing is performed after the crystallization by thermal annealing; the above ratio increases to more than 90%.
Where a silicon film surface is crystallized by thermal annealing without coating it, orientation in the (220) plane is also enhanced, so that reflection intensities of both (111) and (220) planes become larger than 90%.
To effect the lateral growth, a catalyst element needs to be introduced selectively. This is usually done such that a hole for introduction is opened by photolithography in a coating of a material whose main component is silicon dioxide, silicon nitride or silicon oxynitride which coating is formed on an amorphous silicon film and then a thin film, a cluster, or the like of a catalyst element or its compound is formed by sputtering, CVD, spin coating, or some other method. The studies of the present inventors have revealed that if the hole diameter is less than 7 μm, a crystal growth defect occurs at a very high probability.
This is disadvantageous for use in a high-integration area such as peripheral logic circuits. In particular, such a manufacturing method is not applicable to the cases of design rules of 5 μm or less. On the other hand, the lateral growth does not cause any problem in an active matrix circuit where a sufficient distance is secured between adjacent TFTs.
However, it has become apparent that the lateral growth need not be employed for peripheral logic circuits. The investigations of the present inventors have revealed that while the lateral growth and the vertical growth do not cause a large difference in field-effect mobility, however, it can be increased by up to about two times by an optical annealing subsequent to thermal annealing. A typical field-effect mobility is 50 to 80 cm 2 /Vs when only thermal annealing is performed. By additionally performing, for instance, laser annealing, an increased value of 100 to 200 cm 2 /Vs was obtained. Either value is sufficiently large for TFTs in peripheral logic circuits.
It is not necessary to change the conditions of the above optical annealing for a vertical growth region and a lateral growth region. This is advantageous in terms of mass productivity because optical annealing for a single substrate can be performed under substantially the same conditions (except unintentional variations of conditions).
On the other hand, the vertical growth and the lateral growth cause large differences in the magnitude of the off-current and its variation. That is, while both of the off-current and its variation are small with the lateral growth, both of them tend to be large with the vertical growth.
The present invention is characterized in that by utilizing the above features of the vertical growth and the lateral growth, crystallization is effected by the lateral growth for TFTs of an active matrix circuit and by the vertical growth for TFTs of peripheral logic circuits. The peripheral logic circuits mean those included in a source driver and a gate driver. In such circuits as analog switches, either the vertical growth or the lateral growth may be employed.
The present invention is characterized in that a region crystallized by the lateral growth is used for TFTs of an active matrix circuit. In this case, there are several variations for the arrangement of TFTs as shown in FIG. 4 . In FIG. 4, reference numeral 401 denotes a region where a catalyst element has been introduced, i.e., a region that has been crystallized by the vertical growth. A region 402 that has been crystallized by the lateral growth develops around the region 401 .
As shown in FIG. 4, if the catalyst-added region 401 has a rectangular shape, the lateral growth region 402 assumes an elliptical shape. In one case (in the case of TFT1), a gate electrode 404 is formed generally parallel with the region 401 and crystal growth is effected in the direction from a drain 405 to a source 403 , or the direction opposite thereto.
In another case (in the case of TFT2 in FIG. 4 ), a gate electrode 407 is formed generally perpendicularly to the region 401 and portions of a source 406 and a drain 408 are crystallized approximately at the same time. It has been confirmed that the above two cases do not cause much difference.
In an active matrix circuit, a catalyst element may be added linearly so as to be generally parallel with source lines or gate lines. FIGS. 5 (A) and 5 (B) show examples where catalyst-added regions 501 and 506 are parallel with gate lines 502 and 507 , respectively. FIG. 5 (A) shows a case corresponding to TFT2 in FIG. 4 in which case a catalyst is added generally perpendicularly to gate electrodes of TFTs 503 to 505 . FIG. 5 (B) shows a case corresponding to TFT1 in FIG. 4 in which case a catalyst element is added generally parallel with gate electrodes of TFTs 508 to 510 . Catalyst-added regions may be provided generally parallel with source lines in a similar manner.
As described above, orientation in the (111) plane and the (220) plane is remarkable in a lateral growth region, and is not so remarkable in a vertical growth region. Therefore, in the present invention, a crystalline silicon semiconductor (lateral growth regions) for such elements as TFTs of an active matrix circuit, resistors and capacitors is given orientation in the (111) or (220) plane, and a crystalline silicon semiconductor for peripheral circuits is given a lower degree of orientation than that for the active matrix circuit.
If the thermal annealing for crystallization is performed at a temperature higher than the crystallization temperature of an amorphous silicon thin film, there can be obtained crystallinity equivalent to that obtained when laser annealing is also performed. The crystallization temperature of an amorphous silicon thin film is approximately in the range of 580 to 620° C. although it depends on the film deposition method and conditions. By performing a heat treatment at a temperature higher than this temperature (as high a temperature as possible is preferred as long as it is allowable), a crystalline silicon film having superior crystallinity can be obtained. It is preferred that the upper limit of the temperature of this heat treatment be set at about 1,100° C. To employ a heat treatment at such a high temperature, it is necessary to use a quartz substrate or a glass substrate capable of withstanding such a high temperature.
In the present invention, the vertical crystal growth utilizing a catalyst element is performed to obtain a crystalline silicon semiconductor for peripheral logic circuits having a high integration degree. As a result, TFTs having a large field-effect mobility can be obtained irrespective of the integration degree. On the other hand, the lateral crystal growth utilizing a catalyst element is performed for an active matrix circuit. As a result, TFTs having a small off-current with a small variation can be obtained. In particular, if the heat treatment for crystallization is performed at a temperature higher than the crystallization temperature of an amorphous silicon thin film, superior crystallinity can be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a general configuration of a monolithic active matrix circuit;
FIGS. 2 (A) to 2 (F) show manufacturing steps of TFTs according to Embodiment 1;
FIGS. 3 (A) to 3 (G) show manufacturing steps of TFTs according to Embodiment 2;
FIG. 4 shows an example of an arrangement of TFTs of an active matrix circuit and a lateral growth region; and
FIGS. 5 (A) and 5 (B) show examples of arrangements of TFTs of an active matrix circuit and catalyst-added regions.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
This embodiment relates to a process for manufacturing an active matrix circuit (pixel circuit) and peripheral logic circuits to be used in a liquid crystal display device on a single glass substrate at the same time. A crystalline silicon film for constituting TFTs of the active matrix circuit is obtained such that a catalyst element for accelerating crystallization is introduced into a region in the vicinity of a region to be crystallized and crystal growth is effected parallel with a substrate from the catalyst-added region by performing a heat treatment.
A crystalline silicon film for constituting TFTs of the peripheral logic circuits is obtained such that a catalyst element for accelerating crystallization is introduced into a region including a region where the TFT is to be formed and the entire area of the latter region is crystallized by performing a heat treatment.
FIGS. 2 (A) to 2 (F) are conceptual sectional views showing manufacturing steps of TFTs of a peripheral logic circuit and an active matrix circuit. In those figures, a region where a peripheral logic circuit is to be formed (peripheral circuit region) is shown on the left side and a region where pixels are to be formed (pixel region) is shown on the right side. Although the peripheral circuit region and the pixel region are shown adjacent to each other in those figures, actually they are not arranged in such a manner.
Although in those figures the TFT of the pixel region is shown such that a catalyst-added region and a gate electrode are arranged generally parallel with each other like TFT1 in FIG. 4, they may be arranged generally perpendicularly to each other like TFT2 in FIG. 4 .
Manufacturing steps will be described below. First, a substrate 201 (Corning 7059 or some other borosilicate glasses) was cleaned, and a 2,000-Å-thick silicon oxide undercoat film 202 was formed by plasma CVD with TEOS (tetra ethoxy silane) and oxygen used as material gases.
Then, an amorphous silicon film 203 added with almost no conductivity-imparting impurities (phosphorus, boron, etc.) was deposited by plasma CVD or LPCVD at a thickness of 300 to 1,500 Å, for instance, 500 Å. Immediately thereafter, a silicon oxide film 204 was deposited by plasma CVD at a thickness of 100 to 2,000 Å, for instance, 200 Å. Portions of the amorphous silicon film 203 were exposed by selectively etching the silicon oxide film 204 . After this step, the silicon oxide film 204 was completely removed in the peripheral circuit region that is shown on the left side of the figures, so that the surface of the amorphous silicon film 203 was exposed. The silicon oxide film 204 was selectively removed in the pixel region that is shown in the right side of the figures.
A very thin (several tens of angstroms) oxide film was formed on the surface of the amorphous silicon film 203 which were exposed in the above step, to prevent a solution from being repelled by the surface of the amorphous silicon film 203 in an ensuing solution applying step. This oxide film may be formed by thermal oxidation, illumination with ultraviolet light, or a treatment with a solution having a strong oxidizing ability such as an aqueous solution of hydrogen peroxide.
Then, a very thin film 205 of nickel acetate was formed on the surface of the amorphous silicon film 203 by applying thereto a nickel acetate solution containing nickel, which is a catalyst element for accelerating crystallization. Since this film is extremely thin, there is a possibility that it does not constitute a complete film. This step was performed by spin coating or spin drying. An appropriate range of the density (in terms of weight) of nickel in the acetate solution was 1 to 100 ppm. It was 10 ppm in this embodiment. (FIG. 2 (A))
Thereafter, crystallization was effected by performing thermal annealing at 400 to 580° C., at 550° C. in this embodiment, for 4 hours. As a result, the almost entire amorphous silicon film 203 of the peripheral circuit region changed to a crystalline silicon film 206 . In the pixel region, a crystalline silicon film 208 was obtained in a lateral growth region 208 . An amorphous silicon film 207 was left in a region that is away from the nickel-added region. (FIG. 2 (B))
After the silicon oxide film 204 was removed, to improve the crystallinity, KrF excimer laser light (wavelength: 248 nm) was applied to the entire surface by 2 to 20 shots per one location. The optimum energy density was 250 to 300 mJ/cm 2 . However, since the optimum energy density depends on each silicon film, it was determined by preliminarily setting the conditions. The laser light illumination conditions were set in the same manner for the entire substrate surface. Although the energy density of the laser light illumination naturally has a temporal variation (fluctuation) and a microscopic observation will reveal variations of the number of shots of the laser light illumination and the accumulated illumination energy from one location to another, such variations are not intended ones. In this embodiment, the laser light illumination was performed under such conditions as limit the variation of the accumulated illumination energy within 10% in an arbitrary 1-cm 2 area.
Other excimer lasers such as a XeCl excimer laser (wavelength: 308 nm), an ArF excimer laser (193 nm) and a XeF excimer laser (353 nm), and other pulsed oscillation lasers were successfully used.
This step may be performed by a rapid thermal annealing (RTA).
A measurement by a secondary ion mass spectrometry (SIMS) showed that the nickel concentration in the resulting crystallized silicon film was typically 1×10 18 to 1×10 19 atoms/cm 3 in the vertical growth region 206 and 1×10 17 to 5×10 18 atoms/cm 3 in the lateral growth region 208 .
After completion of the above steps, island-like active regions 209 to 211 were formed by dry-etching the silicon film. Although the active layers 210 and 211 partially include the amorphous silicon region 207 , this causes no problem because the amorphous silicon region 207 does not constitutes the channel forming regions of the TFTs.
In the active layer 211 , the region where nickel was directly introduced (i.e., the region that was not covered with the silicon oxide film 204 when nickel acetate was applied) was positioned so as not to overlap with the channel forming region of the TFT, for the following reason. It has been confirmed that in a region where nickel is directly introduced (i.e., a vertical growth region), nickel comes to exist at a higher concentration than in a lateral growth region. In TFTs of the pixel area which are required to have a small off-current with a small variation, a vertical growth region should not occupy at least part of the channel forming region. (FIG. 2 (C))
Then, a 1,500-Å-thick silicon oxide film 212 to serve as a gate insulating film was formed by plasma CVD using monosilane (SiH 4 ) and dinitrogen monoxide (N 2 O) as materials. In this embodiment, monosilane of 10 SCCM and dinitrogen monoxide of 100 SCCM were introduced into a reaction chamber, and the following conditions were employed. Substrate temperature: 430° C.; reaction pressure: 0.3 Torr; and applied power: 250 W (13.56 MHz). These conditions depend on the reaction apparatus used. The deposition rate of the silicon oxide film under the above conditions was about 1,000 Å/min, and its etching rate with a mixed solution (20° C.) of hydrofluoric acid, acetic acid, and ammonium fluoride (at a ratio of 1:50:50) was about 1,000 Å/min.
Subsequently, a polycrystalline silicon film (containing phosphorus at 1 to 2% to improve conductivity) was deposited by low-pressure CVD at a thickness of 2,000-8,000 Å, for instance, 4,000 Å, and etched to form gate electrodes 213 to 215 .
Then, the active layers 209 to 211 were doped with impurities for imparting N-type and P-type conductivity by ion doping (also called plasma doping) in a self-alignment manner with the gate electrodes 213 to 215 used as a mask. In this embodiment, the TFT of the pixel region was of a P-channel type. That is, the active layers 210 and 211 were doped with a P-type impurity and the active layer 209 was doped with an N-type impurity. The known CMOS technology may be used for the doping of impurities of different conductivity types.
In this embodiment, phosphine (PH 3 ) was used as an N-type doping gas and diborane (B 2 H 6 ) was used as a P-type doping gas. The acceleration voltage was 60 to 100 kV, for instance, 90 kV, for the former case and was 40 to 80 kV, for instance, 70 kV, for the latter case. The dose was 1×10 14 to 8×10 15 atoms/cm 2 , for instance, 4×10 14 atoms/cm 2 for the N-type impurity and 1×10 15 atoms/cm 2 for the P-type impurity. In this manner, an N-type impurity region 216 and P-type impurity regions 217 and 218 were formed.
Then, to activate the doped impurities, thermal annealing was performed at 400 to 550° C. for 1-12 hours, for instance, at 450° C. for 2 hours. Since the catalyst element for accelerating crystallization of amorphous silicon was included in the active layers, the thermal annealing of such a low temperature and short period was sufficient for the activation and the resistivity of the impurity regions was reduced to about 1 kΩ/square or less, which feature is common to the invention. (FIG. 2 (D))
Thereafter, an insulating film 219 , which was composed of two layers of a 500-Å-thick silicon nitride film (having a passivation effect of preventing water and movable ions from being entering into the TFT) and a 4,000-Å-thick silicon oxide film, was formed as a first interlayer insulating film by plasma etching. After contact holes were formed in the insulating film 219 , electrodes and wiring lines 220 to 223 of the TFTs were formed by using a metal material such as a multilayered film of titanium and aluminum (in this embodiment, a 500-Å-thick titanium film and a 4,000-Å-thick aluminum film). (FIG. 2 (E))
Further, a 2,000-Å-thick silicon oxide film 224 was formed as a second interlayer insulating film by plasma CVD. After a contact hole was formed for the impurity region of the TFT of the pixel region for which impurity region a pixel electrode was to be formed, a pixel electrode 225 was formed by depositing a 800-Å-thick ITO (indium tin oxide) film by sputtering and etching it. (FIG. 2 (F))
In the above manner, the pixel area and the peripheral circuit area of the active matrix liquid crystal display device were formed on the same glass substrate at the same time.
Embodiment 2
FIGS. 3 (A) to 3 (G) are sectional views showing manufacturing steps of this embodiment. The left side and the right side of the figures show a logic circuit region and a pixel region, respectively. Although in an actual circuit the logic circuit is a CMOS circuit including N-channel TFTs and P-channel TFTs, for simplicity the figures show only an N-channel TFT in the logic circuit region. An N-channel TFT was used also in the pixel region. In this embodiment, the TFTs have a structure in which lightly doped impurity regions are provided adjacent to the source and drain. The differences between the N-channel TFT and the P-channel TFT are only in the kind and concentrations of a doping impurity of the source/drain and the low-concentration impurity regions.
First, a 2,000-Å-thick silicon oxide undercoat film 302 was formed on a substrate (Corning 7059) 301 by sputtering. An intrinsic (I-type) amorphous silicon film was deposited by plasma CVD at a thickness of 300 to 1,000 Å, for instance, 500 Å. Further, a 200-Å-thick silicon oxide film 303 was formed by sputtering, and etched in the same manner as in Embodiment 1 to form regions for introduction of a catalyst element (nickel). A nickel acetate film was then formed by spin coating.
Then, the amorphous silicon film was crystallized by performing thermal annealing at 550° C. for 4 hours in a nitrogen atmosphere, to form a vertical growth region 304 and a lateral growth region 306 . A region 305 was left amorphous.
Thereafter, the crystallinity was improved by laser light illumination. In this embodiment, a KrF excimer laser was used and its appropriate energy density range was from 250 to 350 mJ/cm 2 . After the laser light illumination, thermal annealing was again performed at 550° C. for 1 hour to reduce strain due to the laser annealing. (FIG. 3 (A))
By etching the silicon film thus crystallized, an island-like active layer 307 (for the logical circuit TFT) and an island-like active layer 308 (for the pixel TFT) were formed.
After a 1,200-Å-thick silicon oxide film 309 was deposited by thermal CVD with monosilane (SiH 4 ) and oxygen (O 2 ) used as materials, thermal annealing was performed at 1 atm and 400 to 500° C. for 1 to 12 hours in a dinitrogen monoxide (N 2 O) atmosphere.
Subsequently, an aluminum film was deposited by sputtering at a thickness of from 2,000 to 8,000 Å, for instance, 4,000 Å. To improve adhesiveness with a photoresist, a very thin (50 to 200 Å) anodic oxide film (not shown) was formed on the aluminum film. After photoresist masks 310 and 311 were formed by a known photographic method with application of a photoresist, the aluminum film was etched to form gate electrodes 312 and 313 . To prevent abnormal crystal growth (hillock) in heat treatment or the subsequent anodic oxidation step, aluminum was mixed with scandium (Sc) or yttrium (Y) at 0.1 to 0.5 wt %. The photoresist mask that was used as the mask of the above etching was left as it was on the gate electrodes 312 and 313 . (FIG. 3 (B))
Then, anodic oxide films 314 and 315 were formed at a thickness of 1 to 5 μm, for instance, 2 μm, by anodic oxidation in which a current was caused to flow through the above structure in an electrolyte. The anodic oxidation may be performed by using an acid aqueous solution of citric acid of 3 to 20%, nitric acid, phosphoric acid, chromic acid, sulfuric acid, or the like and applying a constant voltage of 10 to 30 V to the gate electrodes 312 and 313 . In this embodiment, the anodic oxidation was performed by using an oxalic acid solution (pH=0.9 to 1.0; 30° C.) and applying 10 V. The thickness of the anodic oxide films 314 and 315 were controlled by the anodic oxidation time.
The thus-obtained anodic oxide films 314 and 315 were porous ones. In the above anodic oxidation step, the thin anodic oxide film between the gate electrodes 312 and 313 and the photoresist masks 310 and 311 suppressed current leakage from the photoresist, and anodic oxidation was allowed to proceed on the side faces of the gate electrodes 312 and 313 . (FIG. 3 (C))
After the photoresist masks 310 and 311 were removed, a voltage was applied to the gate electrodes 313 and 314 in an electrolyte. This time, an ethylene glycol ammonia solution (pH=6.9 to 7.1) containing at least one of tartaric acid of 3-10%, boric acid and nitric acid. Better oxide films were obtained when the temperature of the solution was about 10° C., i.e., lower than the room temperature. Thus, anodic oxide films 316 and 317 were formed on the top and side faces of the gate electrodes 312 and 313 . The thickness of the anodic oxide films 316 and 317 was approximately proportional to the application voltage, and 2,000-Å-thick anodic oxide films were formed with an application voltage of 150 V. Being dense and hard, the anodic oxide films 316 and 317 were effective in protecting the gate electrodes 312 and 313 in subsequent heating steps. (FIG. 3 (D))
Subsequently, the silicon oxide film 309 was etched by dry etching. Since the porous anodic oxide films 314 and 315 were not etched in this etching step, silicon oxide films 318 and 319 under those films 314 and 315 were also not etched and were left as they were. (FIG. 3 (E))
Then, the anodic oxide films 314 and 315 were etched with a mixed acid of phosphoric acid, acetic acid, and nitric acid. In this etching step, only the anodic oxide films 314 and 315 were etched at an etching rate of about 600 Å/min. The gate insulating films 318 and 319 under those films 314 and 315 were left as they were.
Thereafter, the active layers 307 and 308 were doped with an impurity (phosphorus) by ion doping with the gate electrodes 312 and 313 and the gate insulating films 318 and 319 used as a mask. Two-step doping was performed by using phosphine (PH 3 ) as a doping gas. In the first step, the acceleration voltage and the dose were set at 80 kV and 5×10 12 atoms/cm 2 . In this doping step, ions penetrated through the gate insulating films 318 and 319 and reached the regions thereunder. Because of a low dose, lightly doped impurity regions 322 and 323 were formed.
In the second doping step, the acceleration voltage and the dose were set at 30 kV and 5×10 14 atoms/cm 2 . In this doping step, ions could not penetrate through the gate insulating films 318 and 319 , and were mainly implanted into the silicon-exposed regions of the active layers. Because of a high dose, heavily doped impurity regions (source and drain) 320 and 321 were formed. In forming actual circuits, doping of a P-type impurity was also conducted.
After the doping, impurities were activated by laser annealing. In this embodiment, a KrF excimer laser (wavelength: 248 nm) was used and its appropriate energy density range was 200 to 300 mJ/cm 2 . Instead of the laser annealing, thermal annealing as in Embodiment 1 was successfully used for the impurity activation. Further, a successful result was obtained when thermal annealing was performed after the laser annealing. (FIG. 3 (F))
Subsequently, an interlayer insulating film 324 composed two layers of a 500-Å-thick silicon nitride film and a 4,000-Å-thick silicon oxide film was formed by plasma CVD. After contact holes were formed in the insulating film 324 , source electrodes and wiring lines were formed by using a multilayered film of titanium and aluminum. (FIG. 3 (G))
Then, a 2,000-Å-thick silicon oxide film (second interlayer insulating film) 325 was formed by plasma CVD. After a contact hole was formed in the pixel TFT, a pixel electrode 326 made of a transparent conductive film was connected to the TFT through the hole. With the above steps, a monolithic active matrix circuit was completed. (FIG. 3 (G))
Embodiment 3
In this embodiment, a Corning 1737 glass substrate is used in the configuration of Embodiment 1 or 2. Since the Corning 1737 glass substrate has a strain point of 667° C., it can withstand a heat treatment that is conducted at a temperature lower than that point.
According to experiments, the crystallization temperature of amorphous silicon films deposited by plasma CVD is about 590° C. This embodiment is characterized in that a crystalline silicon film is obtained by a heat treatment of 650° C. and 4 hours.
Where the heat treatment is performed at a temperature higher than the crystallization temperature of an amorphous silicon film, a crystalline silicon film having superior crystallinity can be obtained with action of an element of nickel introduced.
As described above, according to the present invention, peripheral logic circuits and an active matrix circuit can be constructed effectively. In particular, by utilizing a metal element that accelerates crystallization of silicon, superior crystallinity can be obtained, to thereby enable construction of peripheral logic circuits and an active matrix circuit having necessary characteristics.
|
Thin-film transistors (TFTs) of peripheral logic circuits and TFTs of an active matrix circuit (pixel circuit) are formed on a single substrate by using a crystalline silicon film. The crystalline silicon film is obtained by introducing a catalyst element, such as nickel, for accelerating crystallization into an amorphous silicon film and heating it. In doing so, the catalyst element is introduced into regions for the peripheral logic circuits in a nonselective manner, and is selectively introduced into regions for the active matrix circuit. As a result, vertical crystal growth and lateral crystal growth are effected in the former regions and the latter regions, respectively. Particularly in the latter regions, the off-current and its variation can be reduced. The vertical growth and the lateral growth have a difference in the degree of crystal orientation. In general, the vertical growth does not provide so high of a degree of crystal orientation in which orientation in the (111) plane with respect to the substrate surface is dominate to a small extent. In contrast, remarkable orientation is found in the lateral growth. For example, the ratio of a reflection intensity of the (111) plane to the sum of reflection intensities of the (111), (220) and (311) planes can amount to more than 80 or 90%.
| 7
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to road vehicles, particularly to road vehicles having load-restraining mechanisms.
2. Prior Art
Vacuum restraint systems are known in which a sheet of flexible impermeable material is put over a load on an air-impermeable base and in which the periphery of the sheet is then sealed to the base by an airtight seal. The space within the sheet is then partially evacuated; the reduced pressure holds the sheet tightly down onto the load so holding the load firmly on the base. Such systems find particular application for loads which may have to be stored for long periods and may have to be transported. It is usual therefore to use a separate pallet as the base. It has been proposed that a vacuum restraint system should be used for holding a load on a vehicle but the work involved in making the airtight seal, e.g. by tucking the whole periphery of the sheet into a groove formed in the base and then inflating a tube, on the peripheral edge of the sheet, to hold the sheet tightly in the groove, is uneconomic if the goods are to be on the vehicle only for a short time.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a vacuum restraint system on a vehicle which can be used with no more effort than is involved in the roping of a waterproof sheet over the load yet which serves to hold even a complex-shaped load, possibly of many discrete articles, firmly in place.
According to the present invention there is provided a road vehicle including a vehicle body having a support surface for receiving a load, an air impermeable flexible oversheet for covering, in use, the load supported by the support surface to form with the support surface a restriction to air flowing into the space formed between the oversheet and the support surface and means for continuously applying suction to the space to collapse the oversheet around the load to restrain the load from movement with respect to the support surface.
With this construction, the continuous suction holds the oversheet down onto the load and onto the support surface. The suction tends to seal the gaps between the sheet and the support surface structure so restricting leakage of air into the region under the sheet. A pressure differential is thus obtained which, acting over the large area of the sheet, provides firm restraint of the load.
The vehicle may include means for securing at least one edge of the oversheet to the support surface.
An air impermeable undersheet may be secured to the support surface, the load being received, in use, on at least part of the undersheet. In this case the undersheet may have a first portion, which is secured to the support surface and which, in use, receives the load, and a second portion which, in use, can be wrapped around at least a part of the load. In this latter case, an aperture is provided in said undersheet connected to said suction means for continuously applying suction.
Means may be provided for releasably securing the oversheet to the undersheet.
At least one further oversheet may be provided each further sheet having means for securing one of its edges to the support surface. Means for releasably securing each of the further oversheets to at least one other sheet may be provided.
The means for continuously applying suction may include a pump connected to said space via an aperture in the support surface, or an aperture in a headboard of the vehicle, or an aperture in the undersheet, or an aperture in that oversheet which, in use, is in contact with the load.
The means for securing the oversheet to the support surface and the means for securing each of the further sheets to the support surface may comprise conventional fastening systems. For securing sheets together or for securing a sheet on to a flat surface, a fastener such as a "Velcro" fastener may be used.
Similarly any of the means for releasably securing may comprise conventional releasable fastening systems.
Each of the means for securing and means for releasably securing form, in use, a restriction to the air flow into said space.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a road vehicle with an air impermeable sheet indicated in dotted lines;
FIG. 2 is a plan view of the air impermeable sheet of FIG. 1 on a different scale;
FIG. 3 is a schematic side view of the vehicle of FIG. 1 having a load and sheet mounted on it;
FIG. 4 is the vehicle of FIG. 3 when suction is applied;
FIG. 5 is a diagram illustrating suction means used in the vehicle of FIGS. 1, 3 and 4; and
FIG. 6 is a scrap transverse sectional view of part of the assembly of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a vehicle 9 having a load platform 10 which is substantially air impermeable and a headboard 11. Apertures 12 in the headboard are connected by an air suction duct 13 to a pump 14 forming a source of suction. The pump is, in this embodiment, driven by an electric motor 15 powered from the vehicle's battery 16 with a control unit 17 which conveniently is located in the driver's cab.
FIG. 2 shows a plan view of an air impermeable sheet 18. Apertures 19 in the sheet at one end thereof correspond to apertures 12 in the headboard. In use rectangular portion EIGK of the sheet 18 is secured to the headboard 11 of the vehicle, with the apertures 12 and 19 aligned. The edges of the sheet may be secured to the upper surface 20 of the load platform 10 (as C to D in FIG. 1) or alternatively they may be secured to the underneath of the load platform 10 as shown in FIG. 6 and as is shown in FIG. 1 for the edge F to H of FIG. 2 which is secured underneath the tail part of platform 10. The edges of the sheet 18 may be secured by any conventional fastening means, e.g. they may be fixed by ropes passing through eyelets in the sheet and secured on cleats, or other fasteners such as "Velcro" fasteners may be used. Referring to FIG. 6, co-operating "Velcro" fastener strips 21, 22 on the sheet 18 and side 23 of the vehicle platform are shown as well as a part of a rope 24 for securing on a cleat such as cleat 25 on the underside of platform 10. The solid lines IK, IJ, JL and KL in FIG. 1 represent the top of the maximum volume contained by the sheet 18 of FIG. 2 when mounted on the vehicle 9.
When not in use that part of the sheet 18, which is not secured to the headboard 11, may be stored at the end of the load platform 10 nearest the headboard 11. In operation a load 26 (FIGS. 3, 4 and 6) is placed on the load platform 10 and is covered by the sheet 18 the edges of which are secured to the load platform (see FIG. 3). The motor-driven pump 14 is then switched on and air is evacuated through apertures 12 and 19 from the space within the sheet 18, creating a partial vacuum in this space, which causes the sheet 18 to collapse around the load, as shown in FIG. 4, and hence restrain the load from movement with respect to the load platform 10.
The pump is then run continuously until the vehicle completes its journey. When the pump is switched off the sheet 18 ceases to retain the load 26, which can then be uncovered and unloaded. As the pump is run continuously, the fastening means does not need to form a seal between the sheet 18 and the load platform 10, but merely needs to sufficiently restrict the flow of air for the initial partial vacuum to be formed. The suction tends to pull the sheet 18 close against the load and vehicle structure, thereby helping to restrict the inward leakage of air. Even a small pressure difference on the two sides of sheet 18 creates a substantial force over the load tending to secure the load firmly on the vehicle.
If the load platform 10 is not air impermeable it may be covered by an air impermeable undersheet 27 (FIG. 6). This undersheet preferably has a greater area than the load platform 10, so that it can be wrapped around at least a part of the load 26 as shown at 28. In this case the undersheet 27 has apertures aligned with the aforementioned apertures 12, 19. When the sheet 18 is placed over the load 26 it will be pulled against the undersheet 27 by the suction, and hence provide a further partial seal. Both the undersheet 27 and the oversheet 18 may be provided with "Velcro" strips or other releasable fastening means (as shown for example at 29, 30 in FIG. 6) so that they can be fastened together before the pump motor 15 is switched on.
The sheet 18 may be replaced by a set of sheets an edge of each of which is securable along a respective edge of the load platform 10. When the load is placed on the load platform 10, the sheets are each thrown over the load and secured to their respective opposite side, wrapping the load in a criss-cross of sheets. Each sheet may be provided with strips of "Velcro" fastener for fastening it to the other sheets. This use of a number of separate oversheets is particularly suitable for irregularly shaped loads. In arrangements employing a number of sheets, the overlap of the sheets form restrictions to the flow of air into the space around the goods; the suction draws the sheets into close contact.
|
A load-carrying vehicle has either an air-impermeable load platform or an air-impermeable sheet over the platform and has a further air-impermeable sheet put over the goods on the platform. Continuous extraction of air from within the sheet, despite possible leakage of air into the sheet around its periphery, causes a significant reduction in pressure so that the sheet holds the goods onto the platform.
| 1
|
BACKGROUND OF THE INVENTION
Ruminants possess the unique ability to utilize non-protein nitrogen sources to fulfill a major portion of their dietary protein requirements. These include urea and ammonium salts of organic acids such as ammonium lactate, ammonium acetate and ammonium propionate. It has been proven that ammonium salts are equivalent to soybean meal and superior to urea and nitrogen supplements when fed to feed lot cattle. See "Fermentative Conversion of Potato-Processing Wastes Into a Crude Protein Feed Supplement by Lactobacilli", Forney, L. J. et al, Vol. 18, Developments In Industrial Microbiology, Proceedings of the Thirty-Third General Meeting of the Society for Industrial Microbiology, Aug. 14-20, 1976, Jekyl Island, Ga., pages 135-143. Thus it has been suggested that potato wastes, when properly treated, may be used as a feed.
In a non-related field the present problems attendant to sewage waste disposal are well documented. The studies currently being conducted and the processes being tested to effectively handle sewage materials are innumerable. Raw primary sludge usually contains 10 8 total bacteria per milliliter (including coliform and gram negative bacteria). The efficiency of secondary treatment plants is highly variable and cannot be relied upon to produce bacteriologically safe effluent and sludge. The bacterial concentration of digested sludge typically ranges from 10 4 to 10 8 per milliliter. The application of raw sludge to landfill is restricted as being dangerous. The percentage of digested sludge applied to the land is expected to increase as more stringent controls are imposed on ocean and fresh water dumping as well as on air pollution from incineration.
It should be noted that proper temperature, moisture and organic nutrients found in the soil and agricultural land may actually stimulate after-growth of pathogenic bacteria. Members of each group of sewage pathogens such as salmonella and shigella can survive sewage treatment and although they remain in reduced numbers after treatment they can be recovered from the receiving soil. Enteric bacteria may survive for months in the soil therefore surviving longer than the growing season for crops. Contaminated fruits and vegetables could present a health hazard if eaten raw even after a germicidal wash. Therefore although land fill for treated sewage is being encouraged the above additional problems are presented.
The above referenced article teaches that bacteria can be successfully used with waste from potato processing and that the wastes from the potato processing will support the growth of a specific bacteria to produce a feed for ruminants. However, in the described process additional growth supplements (minerals, yeast extract, trypticase and buffers) are also necessary to support the growth of the bacteria. Further the described process requires the use of carbon dioxide to stimulate the growth of the lactobacilli.
I have discovered a process wherein sewage whether raw or digested can be made suitable for use either as animal feed or as a safe and effective fertilizer for crops utilizing specific bacteria and a carbohydrate.
SUMMARY OF THE INVENTION
My invention is broadly directed to a process for the treatment of sewage (sludge) either raw or digested which treatment will render the sewage acceptable either as an animal feed, or as a fertilizer or an environmentally acceptable landfill or the like. My process includes innoculating sewage with a bacteria selected from the genus lactobacillus and admixing therewith a carbohydrate. This stimulates the growth of the lactobacilli and lowers the pH of the sewage. A pH of 4.5 or less is usually required to eliminate the growth of non-lactobacilli bacteria. In my invention the pH is lowered to about 4.0 resulting in a bactericidal and/or bacteriostatic condition for all bacterial other than lactobacilli. In my invention the process is preferably carried out at ambient temperatures of between about 5°-53° C. say for example 24°-40° C., preferably 30°-35° C.
My method in one embodiment uses common sludge and an industrial carbohydrate rich waste which are combined without further nutrient addition and lactobacilli is added. The lactobacilli treated waste quickly acquires a pH of less than 4.5, preferably 4.0 or less resulting in an environmentally safe fertilizer or soil extender. In the preferred embodiment the sludge is subject to a pretreatment sterilization step.
In one aspect of my invention synthetic protein can be produced for ruminant consumption such as by the use of any processing plant waste in which a carbohydrate for example lactose is present. Lactose is added to raw or digested sludge and innoculated with lactobacillius and preferably L. plantarum. The lactic acid produced by the L. plantarum can be neutralized continuously with an aqueous ammonia to form ammonium lactate, a synthetic protein for ruminants. The final product of this recycling process will contain a mixture of ammonium lactate and harmless L. plantarum which is naturally found in the intestinal tract of cattle as well as in cattle dung.
The preferred embodiment of my invention uses the specific bacteria L. plantarum and the carbohydrate lactose.
L. plantarum is capable of fermenting all common sugars (except rhamrose) thus having the ability to digest any industrial carbohydrate waste such as potato processing waste, agricultural waste, vegetable pickling waste, cheese manufacturing waste (whey) packing house waste, sugar refinery waste (molasses), corn steep liquor and glucose which may be synthesized from wood chips (cellulose), L. plantarum is homofermentative-non-gas producing. The only significant metabolic product that L. plantarum produces is lactic acid. The only exception is when pentoses are used as the carbohydrate source and equal amounts of acetic acid and lactic acid are produced. The preferred temperature range for L. plantarum is 30°-35° C. Most importantly L. plantarum grows well at a relatively low pH, less than 4.5, which pH is generally unfavaorable for the growth of most contaminant microorganisms.
DESCRIPTION OF PREFERRED EMBODIMENTS
My invention will be described in reference to the treatment of sludge, as defined hereinafter, with a specific bacteria selected from the genus Lactobacillus and a carbohydrate.
More specifically the bacteria used is L. plantarum and carbohydrate used as lactose.
L. plantarum ATCC 14917 was innoculated into 50 milliliters of heat sterilized tomato juice broth (15 minutes, 120° C., 15 psi) and incubated for 18 hours at 30° C. without shaking.
The raw sludge was obtained from Deer Island Treatment Plant of Boston, Mass.
The raw sludge was diluted one to one (1:1) with distilled water and mixed in a Hamilton Beach blender for 5 minutes at high speed.
Digested sludge (secondary sludge from the raw sludge) was mixed by shaking and was not diluted.
Heat sterilized sludge samples were prepared by pouring 100 milliliters of sludge into 500 milliliter Erlenmeyer flasks and were heated for 30 minutes at 121° C.
Irradiated sterilized sludge samples were prepared by pouring 50 milliliter aliquots of sludge into 250 milliliter plastic, capped culture flasks and irradiating with a Van de Graaff machine at a minimum absorbed radiation dose of 4 megrad. After irradiation, the sludge samples were transferred into sterile 500 milliliter Erlenmeyer flasks resulting in 100 milliliters of sludge in each flask.
A 15% lactose solution was prepared by dissolving 15 grams of lactose in 100 milliliters of distilled water at 38° C. using a heating magnetic stirrer. The 15% lactose solution was sterilized by passing it through a filter such as a Millipore filter, 45 millimicrons. 7.1 milliliters of this lactose solution was added to each 100 milliliter sample of sludge resulting in a 1% lactose solution.
After heat sterilization both the raw and digested sludges were checked. The raw sludge had a pH of 5.6 and the digested sludge had a pH of about 8.6. The pH of the digested sludge was lowered by the addition of about 4 milliliters of 10% concentrated hydrochloric acid.
After irradiation the raw sludge had a pH of 5.6 and the digested sludge had a pH of about 9.0. The pH of the digested sludge was lowered by the addition of about 4 milliliters of 10% hydrochloric acid.
The L. plantarum that was grown in the tomato juice broth was harvested in the following manner. The cell culture was poured into a sterile 50 milliliter Serval tube (Serval head type 8834) and centrifuged at 7000 RPM for 10 minutes. The supernatant was decanted and the L. plantarum precipitate was suspended in 18 milliliters of 0.1% Bacto-peptone water. This was centrifuged as above at 7000 RPM for 10 minutes. The supernatant from this step was decanted and the precipitate was suspended in 9 milliliters of 0.1% bacto-peptone water. The L. plantarum concentration was 10 9 /ml. This was diluted to 10 5 /ml and 1 milliliter of this 10 5 /ml. L. plantarum was used as indicated in the following examples.
The sludge samples which were sterilized were confirmed and monitored by plating on TSY (trypticase, soya, yeast extract) agar and incubating for 15 hours at 30° C. The L. plantarum per ml of innoculated sludge was determined by plating 0.1 ml samples on tomato juice agar and incubating at 37° C. for 3 days.
A 5 ml aliquot was removed from each sample each day for pH determination and bacteria counts. In the following examples the sludge samples were 100 milliliters, where lactose was added it was 7.1 milliliters 15% solution, and where the L. plantarum was added it was one milliliter added to 100 ml of sludge sample. Where the designation L. p. is used it refers to the L. plantarum bacteria count/milliliter.
EXAMPLE I
______________________________________Raw sludge heat sterilizedNo L. plantarum addedNo lactose addedDay 0 1 2 3 4 5______________________________________pH 5.6 5.7 5.7 5.7 5.8 5.8______________________________________
EXAMPLE II
______________________________________Raw sludge heat sterilizedNo L. plantarum added1% lactose addedDay 0 1 2 3 4 5______________________________________pH 5.6 5.7 5.8 5.8 5.8 5.8______________________________________
EXAMPLE III
______________________________________Raw sludge heat sterilizedL. plantarum addedNo lactose addedDay 0 1 2 3 4 5______________________________________pH 5.6 5.6 5.6 5.7 5.8 5.8L.p. 1.80 × 1.68 × 2.53 × 3.77 × 1.77 × 1.65 × 10.sup.2 10.sup.7 10.sup.7 10.sup.6 10.sup.6 10.sup.6______________________________________
EXAMPLE IV
______________________________________Raw sludge heat sterilizedL. plantanum added1% lactose addedDay 0 1 2 3 4 5______________________________________pH 5.6 5.6 5.2 4.0 3.7 3.7L.p. 1.93 × 2.35 × 1.73 × 3.71 × 1.12 × 3.20 × 10.sup.2 10.sup.7 10.sup.8 10.sup.8 10.sup.8 10.sup.7______________________________________
EXAMPLE V
______________________________________Raw sludge irradiatedNo L. plantunum addedNo Lactose addedDay 0 1 2 3 4 5______________________________________pH 5.6 5.8 5.7 5.8 5.8 5.7______________________________________
EXAMPLE VI
______________________________________Raw sludge irradiatedNo L. plantunum added1% lactose addedDay 0 1 2 3 4 5______________________________________pH 5.6 5.8 5.7 5.8 5.8 5.8______________________________________
EXAMPLE VII
______________________________________Raw sludge irradiatedL. plantunum addedNo lactose addedDay 0 1 2 3 4 5______________________________________pH 5.4 5.3 5.5 5.5 5.5 5.4L.p. 1.98 × 9.43 × 1.06 × 7.53 × 6.90× 5.55 × 10.sup.2 10.sup.7 10.sup.8 10.sup.7 10.sup.7 10.sup.7______________________________________
EXAMPLE VIII
______________________________________Raw sludge irradiatedL. plantanum added1% lactose addedDay 0 1 2 3 4 5______________________________________pH 5.6 4.6 3.8 3.8 3.7 3.7L.p. 1.96 × 4.14 × 1.03 × 3.21 × 1.39 × 1.82 × 10.sup.2 10.sup.8 10.sup.9 10.sup.8 10.sup.8 10.sup.7______________________________________
EXAMPLE IX
______________________________________Digested sludge heat sterilizedNo L. plantanum addedNo lactose addedDay 0 1 2 3 4 5______________________________________pH 6.2 6.4 6.5 6.6 6.7 6.9______________________________________
EXAMPLE X
______________________________________Digested sludge heat sterilizedNo L. plantanum added1% lactose addedDay 0 1 2 3 4 5______________________________________pH 6.2 6.4 6.5 6.6 6.7 6.9______________________________________
EXAMPLE XI
______________________________________Digested sludge heat sterilizedL. plantanum addedNo lactose addedDay 0 1 2 3 4 5______________________________________L.p. 2.82 × 1.13 × 2.99 × 2.98 × 3.01 × 2.88 × 10.sup.3 10.sup.6 10.sup.6 10.sup.6 10.sup.6 10.sup.6______________________________________
EXAMPLE XII
______________________________________Digested sludge heat sterilizedL. plantarum added1% lactose addedDay 0 1 2 3 4 5______________________________________pH 6.2 6.4 6.4 6.0 5.0 4.4L.p. 2.81 × 1.56 × 6.46 × 4.44 × 2.07 × 4.06 × 10.sup.3 10.sup.6 10.sup.6 10.sup.7 10.sup.8 10.sup.8______________________________________
EXAMPLE XIII
______________________________________Digested sludge irradiatedNo L. plantarum addedNo lactose addedDay 0 1 2 3 4 5______________________________________pH 5.7 5.8 6.0 .1 6.2 6.3______________________________________
______________________________________Digested sludge irradiatedNo L. plantarium added1% lactose added______________________________________Day 0 1 2 3 4 5pH 5.7 5.8 6.0 6.1 6.2 6.3______________________________________
EXAMPLE XIV
______________________________________Digested sludge irradiatedNo L. plantarum added1% lactose addedDay 0 1 2 3 4 5______________________________________pH 5.7 5.8 6.0 6.1 6.2 6.3______________________________________
EXAMPLE XV
______________________________________Digested sludge irradiatedL. plantarum addedNo lactose addedDay 0 1 2 3 4 5______________________________________pH 5.7 5.8 6.0 6.1 6.2 6.3L.p. 2.96 × 4.77 × 8.21 × 7.77 × 1.04 × 9.73 × 10.sup.3 10.sup.6 10.sup.6 10.sup.6 10.sup.7 10.sup.6______________________________________
EXAMPLE XVI
______________________________________Digested sludge irradiatedL. plantarum added1% lactose addedDay 0 1 2 3 4 5______________________________________pH 5.7 4.7 4.4 4.2 4.1 3.7L.p. 3.21 × 1.56 × 2.26 × 1.56× 1.48 × 1.36 × 10.sup.3 10.sup.8 10.sup.8 10.sup.8 10.sup.8 10.sup.8______________________________________
In the above examples, I through XVI the initial pH of the digested sludge was about 7.0. If the pH of the digested sludge is adjusted, before sterilization, to bring it to within the range where L. plantarum is active the pH rises beyond this range after sterilization. Therefore in order to control successfully the pH of the digested sludge, adjustment with hydrochloric acid should take place after the sterilization process.
Based on the above examples whether or not heat sterilized or irradiated, for the raw sludge as long as both L. plantarum and lactose were not added the pH remained about the same i.e. no pH shift.
Where L. plantarum was added to heat sterilized sludge without lactose addition the bacteria count rose from 10 2 /ml to 10 7 /ml.
When L. plantarum is added to irradiated sludge without lactose addition the bacteria count rose from 10 2 /ml to 10 8 /ml. When both L. plantarum and lactose were added to the sterilized sludge unexpectedly the pH decreased and the bacteria count went up. For heat sterilized sludge the pH went from 5.6 to 3.7 and the bacteria count from 10 2 /ml to 10 8 /ml and for the irradiated sludge the pH went from 5.6 to 3.7 and the bacteria count from 10 2 /ml to 10 9 /ml.
For the digested sludge whether heat sterilized or irradiated as long as both L. plantarum and 1% lactose were added as with the raw sludge the pH decreased.
When L. plantarum was added to heat sterilized sludge without lactose addition the bacteria count rose from 10 3 /ml to 10 6 /ml. When L. plantarum was added to irradiated sludge without lactose addition the bacteria count rose from 10 3 /ml to 10 7 /ml.
When both L. plantarum and lactose were added to the sterilized sludge, the pH decreased and the bacteria count went up. For the heat sludge sterilized the pH decreased from 6.2 to 4.4 and the bacteria count rose from 10 3 /ml to 10 8 /ml and for the irradiated sludge the pH decreased from 5.7 to 3.7 and the bacteria count rose from 10 3 /ml to 10 8 /ml.
The following examples are directed to varying the amount of lactose added to the samples as identified above all of which samples have been innoculated with L. plantarum. The preparation of the sludges, lactose solution, harvesting of the L. plantarum etc. was conducted as for the examples I through XVI.
For the examples following XVII through XXII the concentration of the L. plantarum used was 1.0×10 7 /ml.
EXAMPLE XVII
______________________________________Raw Sludge irradiatedIncubation time Percent LactoseDays 5% 3% 1% .5% .25%______________________________________0 5.63 5.63 5.63 5.96 5.951 3.95 4.05 4.58 5.07 5.162 3.82 3.90 4.18 4.15 4.233 3.76 3.80 3.95 3.70 3.974 3.70 3.73 3.80 3.53 3.975 3.70 3.73 3.80 3.46 3.9710 3.68 3.73 3.76 3.49 3.97______________________________________
EXAMPLE XVIII
______________________________________Raw sludge heat sterilized Incubation time Percent LactoseDay 5% 3% 1% .5% .25%______________________________________0 5.63 5.63 5.63 6.28 6.281 4.51 4.57 4.65 6.40 6.402 4.27 4.30 4.45 6.30 6.353 4.11 4.20 4.38 5.60 5.104 4.03 4.10 4.30 4.00 4.135 4.01 4.08 4.29 3.50 3.8010 3.98 4.02 4.10 3.49 3.80______________________________________
EXAMPLE XIX
______________________________________Raw sludge untreated Incubation time Percent LactoseDays 5% 3% 1% 0.5% .25%______________________________________0 5.48 5.50 5.53 5.53 5.531 3.95 3.95 4.04 4.40 5.032 3.70 3.70 3.85 5.00 5.033 3.55 3.58 3.95 5.00 5.034 3.48 3.50 4.33 4.97 5.105 3.40 3.43 5.00 4.98 5.2010 3.33 3.50 5.30 4.58 5.35______________________________________
EXAMPLE XX
______________________________________Digested sludge irradiatedIncubation Time Percent LactoseDay 5% 3% 1% .50% .25%______________________________________0 5.82 5.83 5.80 5.80 5.821 4.90 4.92 5.02 5.15 5.302 4.50 4.60 4.75 4.83 5.053 4.28 4.38 4.55 4.70 4.904 4.20 4.23 4.95 4.70 4.905 4.10 4.15 4.40 4.68 4.9510 3.93 4.00 4.05 4.73 5.13______________________________________
EXAMPLE XXI
______________________________________Digested sludge heat sterilizedIncubation Time Percent LactoseDay 5% 3% 1% .50% .25%______________________________________0 5.40 5.54 5.53 5.67 5.511 4.98 5.10 5.31 5.86 5.772 4.25 4.50 4.55 5.33 5.333 4.03 4.28 4.27 4.70 4.834 3.98 4.26 4.25 4.70 4.865 3.97 4.23 4.23 4.70 4.9310 3.87 4.08 4.15 4.73 5.03______________________________________
EXAMPLE XXII
______________________________________Digested sludge untreated Incubation Time Percent LactoseDay 5% 3% 1% .50% .25%______________________________________0 6.05 5.97 5.93 5.97 6.151 4.80 4.82 4.85 5.03 6.072 4.48 4.55 4.73 5.21 7.003 4.27 4.33 4.78 5.75 7.334 4.15 4.23 4.95 6.20 7.505 4.20 4.22 5.00 6.60 7.7010 3.62 4.80 5.20 7.40 8.05______________________________________
The following tables 1 through 6 summarize the results of Examples XVII through XXII.
Both the digested and raw sludges were lighter in color after digestion. The raw sludge, in particular, was very light appearing light gray. Whenever the pH became lower than 4.0 the protein appeared to have coagulated (this was more clear in the raw sludge than in the digested sludge). When poured through two layers of cheese cloth the raw sludge readily formed a fairly dry cake.
Table 1______________________________________Raw sludge irradiated (4 meg rad) Lactose pH______________________________________ 5% 3.68 3% 3.73 1% 3.76 .50% 3.49 .25% 3.97______________________________________
Table 2______________________________________Raw sludge heat sterilized Lactose pH______________________________________ 5% 3.98 3% 4.02 1% 4.10 .50% 3.49 .25% 3.80______________________________________
Table 3______________________________________Raw sludge not sterilized Lactose pH______________________________________ 5% 3.33 3% 3.50 1% 5.30 .50% 4.58 .25% 5.35______________________________________
Table 4______________________________________Digested sludge irradiated (4 meg rad) Lactose pH______________________________________ 5% 3.93 3% 4.00 1% 4.05 .50% 4.73 .25% 5.13______________________________________
Table 5______________________________________Digested sludge heat sterilized Lactose pH______________________________________ 5% 3.87 3% 4.08 1% 4.15 .50% 4.73 .25% 5.03______________________________________
Table 6______________________________________Digested sludge non sterilized Lactose pH______________________________________ 5% 3.62 3% 4.80 1% 5.20 .50% 7.40 .25% 8.05______________________________________
For the examples following, XXIII through XXVIII the concentration of the L. plantarum used was 1.3×10 3 /ml.
EXAMPLE XXIII
______________________________________Raw sludge irradiated (4 meg rad) Incubation Time Percent LactoseDay 5% 3% 1% .50% .25%______________________________________0 6.15 6.20 6.30 6.25 6.231 5.55 5.70 5.70 5.52 5.572 3.72 3.80 4.10 4.28 4.733 3.53 3.63 3.95 4.20 4.604 3.50 3.60 3.90 4.00 4.285 3.48 3.58 3.83 3.80 3.9510 3.47 3.48 3.25 3.35 3.87______________________________________
EXAMPLE XXIV
______________________________________Raw sludge heat sterilized Incubation Time Percent LactoseDay 5% 3% 1% .50% .25%______________________________________0 6.00 6.00 6.00 6.02 6.071 6.20 6.20 6.25 6.27 6.302 5.20 4.98 5.90 6.13 6.303 4.02 4.05 4.65 5.30 6.254 3.83 3.88 4.15 4.45 5.735 3.72 3.85 3.97 4.05 4.8510 3.60 3.70 3.78 3.80 4.05______________________________________
EXAMPLE XXV
______________________________________Raw sludge untreatedIncubation time Percent LactoseDay 5% 3% 1% .50% .25%______________________________________0 5.70 5.80 5.85 5.85 5.851 4.88 4.90 4.90 4.92 5.352 3.98 4.05 4.15 4.48 5.383 4.02 4.05 4.25 4.72 5.404 4.00 4.07 4.43 4.88 5.455 4.00 4.35 4.65 5.00 5.5010 4.20 4.05 5.45 5.00 5.58______________________________________
EXAMPLE XXVI
______________________________________Digested sludge irradiated (4 meg rad) Incubation Time Percent LactoseDay 5% 3% 1% .50% .25%______________________________________0 6.35 6.35 6.40 6.50 6.521 6.65 6.80 6.92 7.07 7.032 6.20 6.70 6.95 7.30 7.183 4.90 4.80 5.50 7.30 6.454 4.30 4.17 4.83 4.77 5.435 4.08 4.03 4.60 5.07 5.2010 3.80 3.80 3.78 3.95 4.33______________________________________
EXAMPLE XXVII
______________________________________Digested sludge heat sterilized Incubation Time Percent LactoseDay 5% 3% 1% .50% .25%______________________________________0 5.77 5.75 5.75 5.85 5.851 6.23 6.15 6.23 6.30 6.252 5.30 6.03 6.30 6.45 6.383 4.68 5.03 5.90 6.42 6.484 4.07 4.25 4.95 5.83 5.675 3.80 3.97 4.60 5.30 5.4510 3.72 3.77 3.83 3.90 4.80______________________________________
EXAMPLE XXVIII
______________________________________Digested sludge untreated Incubation Time Percent LactoseDay 5% 3% 1% .50% .25%______________________________________0 6.62 6.68 6.60 6.68 6.601 4.08 4.10 4.30 4.45 5.052 3.90 4.02 3.93 5.50 6.333 3.75 3.87 4.08 5.98 6.754 3.63 3.62 4.40 6.43 7.055 3.53 3.45 4.60 6.65 7.1510 3.20 3.20 5.07 6.90 7.15______________________________________
The results of Examples XXIII through XXVIII are summarized below in Tables 7-12. Comparing the results of Examples XVII through XXII with Examples XXIII through XXVIII there appears to be little difference between having an initial L. plantarum concentration of 10 7 /ml or 10 3 /ml.
Table 7______________________________________Raw sludge irradiated (4 meg rad) Lactose pH______________________________________ 5% 3.48 3% 3.58 1% 3.83 .50% 3.80 .25% 3.95______________________________________
Table 8______________________________________Raw sludge heat sterilized Lactose pH______________________________________ 5% 3.72 3% 3.85 1% 3.97 .50% 4.05 .25% 4.85______________________________________
Table 9______________________________________Raw sludge nonsterilized Lactose pH______________________________________ 5% 4.00 3% 4.35 1% 4.65 .50% 5.00 .25% 5.50______________________________________
Table 10______________________________________Digested sludge irradiated (4 meg rad) Lactose pH______________________________________ 5% 4.08 3% 4.03 1% 4.60 .50% 5.07 .25% 5.20______________________________________
Table 11______________________________________Digested slude heat sterilized Lactose pH______________________________________ 5% 3.80 3% 3.97 1% 4.60 .50% 5.30 .25% 5.45______________________________________
Table 12______________________________________Digested slude non-sterilized Lactose pH______________________________________ 5% 3.53 3% 3.45 1% 4.60 .50% 6.65 .25% 7.15______________________________________
In the above examples I through XXVIII the bacterial count of the non-sterilized raw and digested sludges was monitored. Coliforms and gram negative bacteria were plated on MacConkey Agar was incubated at 37° C. for 15 hours. The total bacteria (less L. plantarum) was plated on TSY Agar and was incubated at 30° C. for 15 hours. The L. plantarum was plated on Tomato Juice Agar Special plates containing 0.1 grams per liter bromocresol green.
The following summarizes the bacteriological results.
For raw sludge (non-sterilized) at initial time the coliforms equaled 1.33×10 7 per ml; total gram negative equaled 3.57×10 7 ml; total bacteria (less L. plantarum) equaled 7.2×10 7 ml. And the L. plantarum as added was 1.3×10 3 ml. One day 1 the coliform and total bacteria was approximately 2.0×10 8 and 3.0×10 8 respectively. On day 3 the coliform measurement was negative and total gram negative bacteria was negative, total bacteria present 2.3×10 4 . On day 5 the results were the same as for day 3.
For digested sludge (non sterilized) the initial L. plantarum concentration as added was 1.3×10 3 ml; coliform 2.6×10 4 ; total gram negative bacteria 5.5×10 4 and total bacteria (less L. plantarum) 1.3×10 5 . For day 1 the coliform was approximately 1.0×10 6 ; total gram negative approximately 2.0×10 5 and total bacteria was approximately 1.0×10 7 . On day 3 coliform was 3.1×10 4 ; total gram negative 3.2×10 4 ; and total bacteria 1.6×10 6 . On day 5 coliform was negative, total gram negative was negative and total bacteria was 2.1×10 4 .
It can be seen from the above results that the addition of L. plantarum bacteria and lactose to sludge whether digested or raw and whether or not treated or untreated is sufficient over a predetermined period of time to lower the pH sufficiently such that the undesirable bacteria is reduced to a level wherein the treated sludge in this one step process renders it usable either as a feed stock for animals with the addition of other nutrients if desired) or as a fertilizer or fill.
The above examples and tables were directed to specifically to carbohydrate or the disaccharide lactose and the specific bacteria L. plantarum. The other species of the bacteria lactobaccilli alone or in combination are also suitable. The temperature range for growth is typically 5°-53° C. The Lactobacilli are acidophillic with an optimal initial pH range of 5.5 to 5.8 and clearly grows at a pH of 5.0 or less. The complex nutritional requirements of lactobaccilli for amino acids, peptides, nucleic acid derivatives, vitamins, salts, fatty acids or fatty acid esters appear to be present in typical sewage sludge. It has been found that additional fermentable carbohydrates however must be added to the sewage for the pH to drop below 4.5. Any one of the following bacteria or combinations thereof may be used with my invention: L. acidophilus, L. bulgaricus, L. casei, L. coryniformis, L. delbrucckii, L. helveticus, L. lactis, L. leichmannii, L. plantarum, L. thermophilus, L. xylosus, L. brevis, L. buchneri, L. coprophilus, L. fermentum, L. viridescens.
The carbohydrates used in the scope of my invention may be any carbohydrate such as amygdalin, arabinose, cellobiose, esculin, fructose, glactose, glucose, gluconate, lactose, maltose, mannitol, mannose, melezitose, melibiose, raffinose, rhamnose, ribosse, salicin, sorbitol, sucrose, trehalose, and xylose.
When the carbohydrate is added to the sludge containing the bacteria the pH will drop to below 4.5. Further there is a drastic reduction of all native bacteria normally found in sludge. There was approximately a 10 5 reduction in coliform, total gram negative bacteria and total bacteria (excluding L. plantarum). Thus the innoculation of Lactobaccilli into raw or digested sludge, whether or not presterilized in the presence of additional carbohydrate results in the production of lactic acid. This lactic acid causes the inhibition of growth and death of the vast majority of bacteria normally found in the sludge.
In some of the Examples the sludge was sterilized. As is well known the sterilization step is transitory or temporary, in that within minutes undesirable bacteria growth will likely commence. I have discovered that sterilization followed immediately, within minutes or prior to contamination, by innoculation with lactobacillus and admixing of a carbohydrate allows any carbohydrate to be used successfully. Where there is no sterilization lactose in the preferred carbohydrate.
The following table lists the characteristics of sludge generally.
Table 13______________________________________Parameter Mean Std. Dev.______________________________________TS 38,800 23,700BOD.sub.5 5,000 4,570COD.sub.T 42,850 36,950TOC 9,930 6,990TKN 677 427NH.sub.3 -N 157 120Total P 253 178pH (units) 6.9 (median) --______________________________________
All values in mg/l unless otherwise indicated.
Digested sludge, as is well known in the art, is simply the raw sludge which has been anaerobically digested.
Although my process effects conversion of the sludge in about two days as will be apparent to those skilled in the art, accelerators may be used to enhance the conversion. If desired after the sludge has been stabilized and is removed, a portion of the stabilized sludge may be recycled and used for innoculation and pH adjustment of a new batch of untreated raw or digested sludge.
|
A process for the treatment of sewage wherein the sludge is innoculated with a bacteria, L. plantarum, and a carbohydrate such as lactose is admixed therewith. The addition of the bacteria and the carbohydrate without more, drops the pH of the sludge to below 4.0. This results in the elimination of pathogenic bacteria and renders the sludge suitable for use as a soil extender without any further environmental constraints.
| 2
|
TECHNICAL FIELD
The present invention relates to a rail fastening for points of railway tracks, in which the inner foot of the rail is removed to permit the installation of a movable point which is transversely displaceable relative to the web of the rail.
BACKGROUND OF THE INVENTION
Railway rails are not fastened rigidly to their sleepers, but are fastened in such a way as to retain a certain flexibility in order to better withstand the numerous stresses to which they are subjected, in particular those resulting from expansions and those imposed by the passage of trains. For this purpose, the longitudinal edges of the foot of each rail are fastened to the sleepers by flexible collars the edges of which bear on the foot of the rails under the action of the clamping bolts screwed into the sleepers or into base plates secured to the sleepers.
In view of the fact that these flexible fastenings are located on both sides of the rail, they permit not only a certain vertical elasticity, but also a transverse elasticity in the sense of a compensation for the overturning movements produced in particular when the railway trains change direction.
Unfortunately, until now it has been necessary to interrupt this elastic fastening of the rails in the region of the points, or at least the points which necessitate the removal, over a certain length, of the foot of the rail on the side of the point in order to permit the lateral displacement of the latter relative to the fixed rails. In fact, the absence of the foot of the rail rules out any possibility of fastening the latter on the side of the movable point. Now, it is precisely in the region of the points, where there is necessarily always a change of direction, that this inner fastening would appear to be important, since it is essential to support the rail against the horizontal overturning moment to which it is subjected in the direction opposite the point.
In order to contain these transverse forces on the rail, they are fastened, on the outer side, i.e. the side opposite that where the foot is removed for the installation of the point, by means of a fastening shoe which is bolted to the web of the rail and which opposes the overturning moment of the latter. However, this rigid fastening with the aid of such a show negates the effect of a conventional elastic vertical fastening which, in theory, would always be possible on this outer side, but which is thus rendered superfluous by the rigid fastening of the shoe.
Now, not only does this rigid fastening disrupt the continuity of the flexibility of the track in the region of the points, but, in addition, it leads to other disadvantages such as, for example, acceleration of wear, maintenance difficulties and the risk of the bolts loosening under the action of the vibrations, etc.
SUMMARY OF THE PRESENT INVENTION
The object of the present invention is to provide an elastic fastening of the rails in the region of the points, which eliminates the disadvantages described above.
In order to achieve this objective, the fastening proposed by the present invention is characterized, in its preferred embodiment, by the combination of a fastening with vertical elasticity between the fastening shoe and the base plate and a fastening with lateral elasticity of the rail relative to the base plate.
The fastening with vertical elasticity may be formed, after the fashion of the known elastic fastenings, by a flexible collar provided between the shoe and its adjusting nut.
The fastening with lateral elasticity is formed, according to a preferred embodiment, by a flexible curved plate arranged between the shoe and the web of the rail.
Consequently, the present invention makes it possible to dissociate the vertical support form the horizontal support by virtue of two flexible fastenings which are mutually complementary to the extent that the one is able to exert its effects only by virtue of the presence of the other and vice versa, which allows the rails to retain their natural flexibility when a train passes over the points.
According to a preferred embodiment, the curved plate of the fastening with lateral elasticity has a substantially rectangular shape with cutouts on the two opposite lateral sides so as to exhibit, overall, the shape of an "H", the four arms of which bear on the web of the rail and the center of which bears on the shoe and has passing through it a bolt for fastening the latter to the rail. In order to facilitate the relative movements and allow the elastic fastenings to exert their effects, the edges of the fastening shoe and also the points of contact are rounded.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and characteristics will emerge from the description of an advantageous embodiment presented below, by way of illustration, with reference to the accompanying drawings in which;
FIG. 1 shows a vertical section through a rail and its fastening in the region of the points:
FIG. 2 shows a plan view of the representation of FIG. 1 and
FIG. 3 shows side, front, and plan views of the curved plate which ensures the lateral elasticity.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 show a conventional railway rail comprising a head 12, a vertical web 14 and a foot 16, via which the rail 10 rests, by means of a base-plate pad 17, for example of neoprene, on a sole-plate 18 -which is bolted at 20 to a railway sleeper. As shown in FIG. 1, the inner part of the foot, to the right of the figure, is removed to permit the installation of a point (not shown) which is laterally displaceable relative to the rail 10. In order to oppose the moment exerted on the rail 10 outwards, i.e. towards the left in the figure or on the opposite side, a fastening shoe 22 is provided as shown in FIGS. 1 and 2. This shoe 22 is generally "L"-shaped with a horizontal section 24 and a vertical section 26. The horizontal section 24 of the shoe 22 has a positioning opening 28 which, is association with a corresponding rib 30 of the sole-plate 18, facilitates the correct positioning of the shoe 22. This shoe 22 is fastened vertically to the sole-plate 18 with the aid of a bolt 32 and a nut 34. The bolt 32 is, for example, retained in the sole-plate 18 by an enlarged head 32a capable of penetrating through a keyhole opening in a hollow part of the sole-plate 18, or alternatively is retained therein by virtue of a head in the form of a hammer.
The vertical section 26 of the shoe 22 bears on the web 14 of the rail 10 and is fixed thereto with the aid of a bolt 36.
However, in contrast to the prior art, according to which the fastenings by the two bolts 32 and 36 are rigid, the present invention renders these two fastenings elastic. For this purpose, the vertical fastening in the region of the bolt 32 is formed by means of a collar 38 constructed in the form of a flexible tongue, the outer edge 38a of which is curved down and rests on a supporting base 40, of corresponding shape, which rises from the sole-plate 18 in the opening 28 of the shoe 22 and the opposite edge 38b of which bears elastically on the inner edge of the opening 28 of the shoe 22 under the tightening action of the nut 34. This vertical elastic bearing is transmitted via the shoe 22 to the foot 16 of the rail 10.
This vertical elastic fastening is complemented, according to the present invention, by a lateral elastic fastening which, in the example shown, is located between the shoe 26 and the web 14 of the rail 10. As can be seen in FIGS. 1 and 2 and in greater detail in FIG. 3, the flexible bearing of the shoe 22 on the rail 10 is producted by inserting a flexible curved plate 42 between these two elements. This plate 42 has a substantially rectangular shape with two cutouts 42a, 42b on the two opposite lateral sides so as to define the shape of an "H". This plate is curved so that the central region, which is in contact with the shoe 26, is resilient relative to the four ends which bear on the web 14 of the rail 10. The central region of the plate 42 has an opening 46 to allow the bolt 36 to pass through
The four ends of the plate 42 are arranged and designed as a function of the shape of the web 14 of the rail so as to ensure positioning of the plate 42 against the rail. In order to allow the collar 38 and the plate 42 to exert their effect to the full so as to permit a certain elastic mobility of the rail 10 both in the vertical direction and in the sense of pivoting outwards, it is preferable that, as shown in FIG. 1, the lower edges of the rear bar of the horizontal section 24, via which the latter bears on the sole-plate 18, and also the point of contact between the shoe 22 and the foot 16 are rounded in order to facilitate the relative mobility between these elements, a mobility which is necessary to ensure the flexible freedom of the rail 10.
In order to prevent the plate 42 from breaking, in the event of extreme stresses, the vertical section 26 of the shoe 22 has, on the face adjacent to the rail 12, two lateral stops 26a and 26b, which are able to bear, through the cutouts 42a and 42b, on the web 14 of the rail after a certain amount of bending of the plate 42.
The shape of the shoe 22 is designed to permit its mounting and its mounting and its dismounting without having to move or dismount the rail.
Naturally, the form of the elastic elements 38 and 42, as shown in the figures, is only one exemplary embodiment and it is possible for these elements to be given different forms provided that they perform the same functions. It is even possible to replace the collar 38 by a flexible claw which performs the fastening functions and which thereby makes the presence of the bolts 32 superfluous.
Futhermore, although the position of the plate 42 between the shoe 22 and the rail 10 is a preferred position, it is possible to provide a fixed connection between the shoe 22 and the rail 10 and to provide a flexible support between the shoe 22 and the sole-plate 18, in particular in the region of the rear edge of the opening 28. Such a flexible support would allow, in fact, the same degrees of freedom as those provided by the plate 42.
While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitations.
|
The fastening comprises a fastening shoe having, overall, an "L"-shaped cross-section, one of the branches of which is bolted with vertical elasticity to a sole-plate secured to a railway sleeper and the other branch of which is bolted with lateral elasticity to the web of the rail on the side opposite the movable point.
| 4
|
This is a division of application Ser. No. 852,236, filed Nov. 17, 1977, now U.S. Pat. No. 4,118,212, granted Oct. 3, 1978.
BACKGROUND OF THE INVENTION
The invention relates to a double crucible system for the production of light conducting fibers.
It is already known to draw light conducting fibers from a double crucible. For example, the publicaton by H.G. Unger, "Optische Nachrichtentechnik", 1976 Berlin, describes a device of this type under the key word "double nozzle method" on pages 39 and 40.
Previously, light conducting fibers produced in accordance with the double crucible method possessed a predetermined ratio between the cross-sections of the fiber cores and the fiber casings. This ratio of the cross-sections was determined by the structure of the double crucible. In order to produce fibers having a different ratio of the casing and core cross-sections, it was previously necessary to employ a different double crucible.
As the double crucibles are generally manufactured from highly pure platinum or platinum-rhodium alloys in order to avoid pollution of the glass melts by the crucible material, double crucibles of this type are extremely expensive and this has an unfavorable influence upon fiber cost.
SUMMARY OF THE INVENTION
An object of the invention is to provide a double crucible device with which it is possible to produce light conducting fibers in which the ratio between core and casing cross-sections can be set virtually arbitrarily.
This object is realized by a double crucible system which, in accordance with the invention, provides for an adjustment of the spacing between concentric nozzles on inner and outer crucibles.
Thus, in accordance with the invention, the two crucibles of the double crucible are axially displaceable relative to one another. As a result, the distance between the crucible nozzles of the two crucibles relative to one another changes, and accordingly the ratio of the cross-sections of the fiber core to the fiber casing changes also. The greater the distance between the crucible nozzles, the smaller is the core cross-section relative to the casing cross-section.
Advantageously, monomode and mulitmode fibers can be produced with the double crucible system in accordance with the invention. In monomode fibers, the core has a particularly small cross-section relative to the casing, and furthermore the core possesses only a slightly higher index of refraction than the fiber casing. In multimode fibers, on the other hand, the core has a relatively large cross-section and the difference between the indices of refraction between the core and casing is relatively great.
In an advantageous embodiment of the double crucible system, in addition to a change in the distance between the two crucibles, it is also possible for the inner crucible to rotate about its axis. In this way an agitation effect can advantageously be achieved. As a result it is possible to eliminate gas bubbles which can settle on the crucible walls during the filling of the crucibles.
This agitation effect also has a favorable influence upon the homogenization of the temperature in the glass melt. Temperature fluctuations in the melt can lead to undesirable changes in index of refraction. As these fluctuations can be avoided by the crucible rotation, light conducting fibers exhibiting very low scattering losses can be produced with a double crucible system of this kind.
Advantageously the double crucible system can be designed in such a manner that the crucibles can be continuously loaded, even during the rotation of the crucibles, so that it is possible to produce light conducting fibers having arbitrary lengths.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE illustrates an exemplary embodiment in partial cross-section of a double crucible system in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the invention, the double crucible system possesses an outer crucible 1 and an inner crucible 2. The outer crucible contains a glass melt 3, and the inner crucible a glass melt 4. In order to avoid pollution of the surfaces of the glass melts, and in order to be able to check the atmosphere over the melts, the double crucible is arranged in a capsule 5 consisting of quartz glass. The crucible can be heated with an induction coil 6. The outer crucible 1 is suspended on a water-coded flange 7. The inner crucible 2 is suspended on a tubular shaft 8 which, in accordance with an advantageous embodiment, is rotatable as indicted by corresponding arrows. By means of a shaft suspension 9 which is adjustable in height, the shaft and the inner crucible can be adjusted with respect to their height relative to the outer crucible. In this way it is possible to adjust the distance of the nozzle 10 of the outer crucible relative to the nozzle 20 of the inner crucible. The crucibles can be loaded through glass rods 30, 40. These glass rods which, for example, have a diameter of 4 mm to 10 mm, are slowly inserted into the crucibles. The glass rod 40 is inserted into the inner crucible through the tubular shaft 8.
The crucible nozzles can be closed off by means of a seal (not illustrated). As soon as the glass melts have been brought to the drawing temperature, this seal is removed so that a light conducting fiber 11 can be drawn. A drawing drum 15 is provided for this purpose.
A thickness measuring device 12 can be provided for measuring the thickness of the light conducting fibers.
If it is desired to provide the light conducting fibers with an additional protective casing, a coating bath 13 can be provided. Polyvinyliden chloride (trade name: Kynar) is a suitable material, for example, for a protective casing. A drying furnace 14 can be used to achieve a more rapid hardening of the protective casing.
The crucibles 1 and 2 must consist of a material which does not pollute the glass melts in the crucible. Suitable materials for the crucibles are, for example, platinum and iridium, which metals can also be alloyed with rhodium.
First investigations have indicated that highly pure aluminum oxide is also suitable as a crucible material. As yet no corrosion phenomena have been able to be established in this material and the pollution in the glass melt caused by this crucible material is negligible. Glass types of the system Na 2 O--K 2 O--PbO--SiO 2 have been employed for testing the double crucible system in accordance with the invention.
These glass types possess the desired property of exhibiting no tendency to crystallization within a wide temperature range, as known from the publication by W. Vogel, "Struktur und Kristallisation der Glaser", Lepzig 1965. Furthermore, these glass types can be drawn at relatively low temperatures, this being advantageous as it is thus possible to maintain pollution due to the crucible material at a particularly low level. Furthermore, with these types of glass, it is possible to change the index of refraction within a wide range by altering the PbO concentration. Thus it is easily possible, with these types of glass, to achieve a wide difference in index of refraction between the casing and the core of the later formed light conducting fiber. Furthermore these glass types have a good chemical and thermal stability and furthermore good mechanical properties.
The glass rods 30 and 40 provided for the loading of the crucibles can be manufactured in the following manner. The highly pure raw materials of the glass system are fused in the desired mixture ratio in platinum crucibles or in highly pure ceramic crucibles. This fusion process is carried out in an argon-oxygen atmosphere, keeping the melt times as short as possible in order to ensure that the melt is polluted by the crucible material to the least extent possible. The glass melt is homogenized by agitation with a platinum rod or ceramic rod. Now glass rods can be directly drawn out of a crucible opening. During testing, glass rods having a thickness of between 4 and 10 mm and a length of up to 1 m were used. The fluctuation in thickness of the rods was in the region of ±3%.
Absorption measurements carried out on the drawn light conducting fibers have indicated that the absorption losses of the light conducting fibers are dependent both upon the purity of the raw materials and upon the crucible material and the atmosphere employed during the melting process.
It has been shown that glasses melted in platinum crucibles may assume a yellow color. However, the glass melts can be rendered transparent again by blowing oxygen through the melt. The yellow color is probably due to platinum dissolved in colloidal form, which is oxidized by the oxygen, thus rendering the melt transparent again.
Obviously the platinum is extremely homogeneously distributed in the melt, which means that the platinum does not produce any scattering centers within the drawn light conducting fiber.
When crucibles consisting of iridium and a protective atmosphere consisting of argon were used to which were added a few percent of oxygen, a colorless glass melt was always achieved. However, inclusions of iridium or iridium oxides in the glass melt result in a relatively high number of scattering centers which led to relatively high losses in the later formed light conducting fiber, although these losses can be disregarded in the case of transmission paths of not too great a length.
The glass rods which have been produced in this way are now introduced into the double crucible system and are fused. A protection from pollution is provided by a protective atmosphere, e.g. argon or nitrogen in the capsule 5. As soon as the glass melts have been brought to drawing temperature, a light conducting fiber can be drawn off.
The double crucible system in accordance with the invention can advantageously also be used to produce gradient index profile light conducting fibers. For this purpose melts in which a sufficiently strong diffusion occurs at a common boundary surface are used for the fiber core and the fiber casing. In particular, between the nozzles of the double crucible, in a high temperature range, the melts partially diffuse into one another at their common boundary surface. By adjusting the spacing between the nozzles--this fundamentally governs the period of time in which diffusion takes place--the index of refraction profile can be caused to become parabolic, for example.
The double crucible system in accordance with the invention and the aforementioned types of glass are particularly suitable for the production of light conducting fibers whose absorption loss lies at a few dB/km, and the numerical aperture of which is 0.2 or higher. Light conducting fibers having lower absorption losses are in fact important for optical long distance traffic communications systems, although in many applications the degree of the absorption losses is less important than a high numerical aperture. Such applications consist, for example, of data processing, close range traffic communications systems, and air traffic applications. For a range of, for example 100 m, a light conducting fiber possessing an absorption of 50 dB/km and a numerical aperture of 0.47, in combination with a luminescence diode, permits the transmission of a considerably higher light power than when a light conducting fiber with 5 dB/km and a numerical aperture of 0.2 are used. Furthermore, light conducting fibers having a large, numerical aperture have the particular advantage that microbending in the light conducting fiber lead to only low additional losses.
The double crucible system in accordance with the invention is also suitable for the production of fibers from synthetic materials. In this case the crucibles can also consist of glass.
Although various minor modifications may be suggested by those versed in the art, it should be understood that I wish to embody within the scope of the patent warranted hereon, all such embodiments as reasonably and properly come within the scope of my contribution to the art.
|
A double crucible system is disclosed for the production of light conducting fibers. The system has an interior crucible which can be axially displaced in relation to the exterior crucible which is concentric thereto. The spacing of the crucible jets in the exterior and interior crucible in relation to one another is thereby altered so that the proportion of the cross-sections of the fiber core and the fiber casing is continuously altered.
| 2
|
RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent application Ser. No. 14/454,056 filed Aug. 7, 2014, which is a continuation of U.S. patent application Ser. No. 12/409, 941 filed Mar. 24, 2009 which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/142,184, filed Dec. 31, 2008 titled “METHODS AND APPARATUS FOR CONTROLLING CONTENT DISTRIBUTION”, each of the above listed applications is hereby expressly incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to methods and apparatus for controlling delivery of program content, and, more particularly, to methods and apparatus that support controlled blocking of program content delivery in some regions, e.g., certain geographic regions on a selective basis.
BACKGROUND OF THE INVENTION
[0003] Content distribution, e.g., distribution of video programs and/or other content over large geographic regions is often performed using satellites to transmit the program content to be distributed to multiple locations at the same time. Thus, through the use of satellites, the need to transmit the same content to multiple locations though land based connections can be avoided. Satellite distribution of content has commercial advantages in that content delivery to multiple locations dispersed over large geographic regions can be achieved without the need for land based connections between the dispersed locations. Satellite distribution often allows for the distribution of valuable program content such as sporting event programs in real time or near real time. Some such programs may be subject to geographic region based program content distribution restrictions.
[0004] Generally, the cost of having multiple satellite receiver stations has been less costly than the cost of bandwidth which would be needed to distribute large amounts of content via land based links to multiple local distribution centers serving various geographic regions throughout the country. In addition, the use of satellite distribution in combination with satellite receivers at local distribution centers has offered a relatively high degree of control since the satellite receivers at different distribution centers could be controlled so as not to decode and distribute content on a per satellite receiver basis thereby preventing content delivery to the region served by a particular receiver satellite.
[0005] FIG. 1 illustrates a known distribution system 100 used for program content delivery and distribution. Satellite 102 has links, e.g., satellite communication links 103 , 105 , with a plurality of different local distribution centers 108 , 118 located in different geographic regions 104 , 106 , respectively. Local distribution center 108 includes a satellite receiver 110 while local distribution center 118 includes a satellite receiver 120 , for receiving content from the distribution network 102 . The distribution system 100 distributes, via satellite 102 , the program content to a plurality of N local distribution centers 108 , 118 , located in different geographic regions 104 , 106 . For example, as shown in FIG. 1 the distribution system 100 includes local distribution centers 108 , 118 corresponding to geographic regions 1 104 and N 106 , respectively.
[0006] Each of the geographic regions 1 104 , and N 106 , serviced by one of the local distribution centers 108 , 118 has a corresponding set of customer premises, e.g., customer premise 1 112 , customer premise 2 114 , . . . , customer premise N 116 in region 1 104 and customer premise 1 122 , customer premise 2 124 , . . . , customer premise N 126 in region N 106 . The local distribution centers, e.g., local distribution center 108 , 118 , included in geographic region 104 , 106 , each serve a plurality of customers.
[0007] While the known approach to content distribution using satellites allows for content distribution restrictions to be implemented at a geographic region level which is relatively localized, this is due to the presence of satellite receivers at a relatively local level. Maintaining large numbers of satellite receivers at numerous locations can be costly. As the cost of land based distribution networks continues to decrease, it would be desirable if the number of satellite receiver stations could be decreased without limiting the ability to control program distribution blackouts on a relatively localized geographic region basis using the same satellite communications link used to provide program content for distribution.
SUMMARY OF THE INVENTION
[0008] Methods and apparatus for distributing content via satellite while enabling blackout of program content delivery to individual geographic regions are described.
[0009] In accordance with the invention, rather than providing an individual satellite receiver for each individual geographic region which may be subject to a program blackout, a satellite receiver is located at a network head end which supplies content to multiple local content distribution systems, e.g., local cable office or headend, via a delivery network, e.g., a ring network used in some embodiments for content delivery.
[0010] While a single copy of program content may be received via satellite at the network distribution headend, the headend delivers individual copies of the content via the delivery network to each local content distribution system, e.g., using output ports and/or IP addresses corresponding to the individual local content distribution systems. While this approach results in greater network loading as compared to using a broadcast address to deliver the content over the delivery network, it allows for program content to be blocked in the network headend serving multiple geographic regions based on regional blackout information and/or commands.
[0011] In accordance with one feature of the invention, program blackout commands specifying that program content should be restricted from delivery to specific geographic regions may be transmitted via satellite to the distribution network headend. In this manner, content sources, e.g., providers of satellite content feeds, can control blackout implementation through use of the same satellite link used to distribute the content. In this manner, the content provider can control content distribution directly without having to rely on operators at regional or local distribution sites, e.g., local cable offices.
[0012] Furthermore, by having content distribution implemented in the distribution network headend rather than individual local distribution centers, the content distribution and substitution remains somewhat centralized with content substitution being performed at relatively few locations nationwide even though the blackout restrictions may be specified as corresponding to relatively small geographic regions which maybe only a small subset of the geographic regions served by an individual regional distribution center.
[0013] While in some embodiments, the region subject to a content distribution blackout is indicated in a blackout command by specifying the name of a geographic region, in some embodiments the region is identified by supplying a port and/or IP address used by the distribution network headend to distribute content via the distribution network to the region subject to the blackout. Providing such information identifying the region subject to the blackout can facilitate implementation of the blackout and/or content substitution operation at the distribution network headend eliminating or avoiding the need for the distribution network headend to map geographic region names to port and/or IP addresses affected by a regional blackout restriction.
[0014] Alternative content may optionally be specified for delivery in place of program content which is prohibited from delivery to a geographic region subject to a blackout command.
[0015] Numerous additional methods, features, apparatus and benefits of the present invention are discussed in the detailed description which follows.
[0016] It should be appreciated that all features need not be used or included in all embodiments and that a wide variety of content distribution methods are possible.
[0017] Various additional features and advantages of the present invention are discussed in the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 illustrates a known content distribution system.
[0019] FIG. 2 illustrates an exemplary distribution system implemented in accordance with the invention.
[0020] FIG. 3 illustrates an exemplary distribution network headend which can be used in the system of FIG. 2 .
[0021] FIG. 4 is a flowchart of an exemplary method of operating a distributor network headend in accordance with an exemplary embodiment.
[0022] FIGS. 5, 6 and 7 illustrate formats of various commands which can be used in the exemplary system of FIG. 2 to block delivery of program content to one or more geographic regions.
DETAILED DESCRIPTION
[0023] The present invention relates to methods and apparatus for controlling delivery of program content to a region, and, more particularly, to methods and apparatus that support controlled blocking of program content delivery in some regions, e.g., one or more geographic regions. In accordance with the invention port and/or IP address information can be used to control which geographic region is blocked with regard to the distribution of particular program content.
[0024] FIG. 2 illustrates an exemplary distribution system 200 implemented in accordance with an exemplary embodiment of the invention.
[0025] The distribution system 200 includes a satellite 201 for transmitting, e.g., relaying, program content and commands from one or more content sources, e.g., program content providers. In addition to satellite 201 the system 200 includes a distribution network headend 202 including a satellite receiver 204 , a distribution network 212 , and a plurality of local geographic regions 214 , . . . , 224 , each including one or more local distribution centers 216 , 226 which are coupled to the distribution network 212 . The distribution network may be implemented as a ring network and is used to provide content from the regional network headend to the various distribution centers coupled to the network ring. In various embodiments distribution network headend 202 is implemented as a land based network implemented using, e.g., fiber optic cable. It should be appreciated that a local geographic region may, and sometimes does, include more than one local distribution center. Also shown in FIG. 2 , are customer locations served by each local distribution center, e.g., customer premise 218 , customer premise 220 etc. served by local distribution center 216 and customer premise 228 , customer premise 230 , etc., served by local distribution center 226 .
[0026] The distribution network headend 202 receives content from, e.g., a content source, e.g., a content provider which transmits to satellite 201 for distribution. Received content may include a variety of programs, movies, T.V shows, on-demand content etc. The distribution network headend includes a satellite receiver 204 via which the content communicated by a remote content provider is received via a satellite link by the distribution network headend 202 . The distribution network headend includes an output interface that supports a plurality of ports, e.g., port 1 206 , port 2 206 , . . . , port N 210 which can be used to distribute content. It should be appreciated that the ports of an interface used for outputting data, commonly referred to as output ports, can have a set relationship to an application type, e.g., a content distribution application, IP address, and/or region depending on how a system designer or an administrator has configured the distribution system. In some embodiments, the distribution network headend 202 may deliver program content for, e.g., a local distribution center 216 , 226 using a port number designated for use in distributing content to a specific local distribution center. However, in some other embodiments the distribution network headend 202 is configured to deliver program content for, e.g., a regional distribution center, based on a port number and IP address combination where the IP address is normally a non-broadcast address corresponding to a local distribution center.
[0027] A satellite receiver 204 at the distribution network headend 202 receives content and supplies it to the distribution network 212 for delivery to the individual local distribution centers 224 . In accordance with the invention while a single satellite feed may be received at network headend 202 , multiple discrete copies of the received content may be sent over the distribution network 212 , e.g., with a separate copy in the form of one or more packets being sent to each local distribution center authorized to distribute the particular program content. Local distribution centers which are not to receive particular content are not sent and are thus blocked from receiving the satellite content, or are supplied with alternative content. While the sending of multiple individual content streams which often contain the same program content over distribution network 212 may increase network loading as compared to a broadcast distribution approach, the individual stream approach has the advantage of placing control over content distribution and geographic based program blackouts at the distribution network headend as opposed to at the individual local distribution centers 216 , 226 .
[0028] The distribution network 212 receives content streams, e.g., program content, output by the distribution network headend 202 and distributes the received content streams to the distribution centers which are serviced by the distribution network headend 202 . For example, in some embodiments the distribution network 212 receives various data packets including the program content.
[0029] Local distribution centers, e.g., distribution center 216 , 226 monitors for data packets which have their destination address , e.g., an IP address corresponding to that particular geographic region/distribution center. In accordance with the present invention, in some embodiments when a program content distribution is blocked at the distributor headend output interface, then local distribution centers will not receive data packets including the blocked program content. In some embodiments, the distributor headend is configured to output alternative program content to regions where particular program content is to be blocked. In some such embodiments, the local distribution centers for which program content is blocked, receive the alternative program content through the distribution network 212 .
[0030] FIG. 3 is a drawing of an exemplary distribution network headend 300 which can be used as the distributor network headend 202 . The distribution network head end 300 support selective duplication and delivery of program content to various local distribution centers in accordance with the various embodiments of the present invention. The distribution network head end 300 includes a receiver 302 , an I/O interface 304 , a processor 306 , an IP address look-up module 307 , a codec 308 , a storage device 326 , a program recovery module 310 and a command recovery module 314 coupled together by a bus 309 . The receiver 302 is coupled to a satellite dish, e.g., antenna 303 , for receiving content to be distributed from a satellite, e.g., satellite 201 .
[0031] The various elements of the distributor network headend 300 can exchange data and information over the bus 309 . Via the I/O interface 304 , the distributor network headend 300 can exchange signals and/or information with other devices/ servers/networks, e.g., a national content storage server which stores additional programs, movies etc., via, e.g., distribution network 212 . For example, the I/O interface 304 may support the receipt and/or transmission of content to/from a national content server as represented by arrow 340 . The I/O interface 304 further supports the communication of application and/or control signals between the distributor network headend 300 and other servers, distribution centers and sub-systems, e.g. local/regional distribution centers 104 and 106 .
[0032] The satellite receiver 302 receives signals including, for example, content and command signals. The received content may include content subject to geographic based distribution restrictions while the command signals may include commands used to restrict or control content distribution, e.g., to enforce region based program blackouts. The commands may be supplied by the provider of the content being distributed and can be used to block out distribution to individual regions and/or control the supply of alternative content to particular local geographic regions. Received content may include, e.g., program content from a content provider, alternative program content to be delivered in place of a blocked program etc.
[0033] The processor 306 , e.g., a CPU, executes routines 340 stored in the memory 326 and, under direction of the routines 340 , controls the distributor network headend 300 to operate in accordance with the invention. To control the headend 300 , the processor 306 uses information and/or routines including instructions stored in memory 326 . The processor 306 may control codec 308 which is a combined coder/decoder to perform various decoding and/or re-encoding operations on received content prior to distribution via distribution network 212 . Thus, codec 308 can be used to support transcoding so that content will be received by individual local distribution centers in formats and at rates best suited for the particular local distribution center to which a content stream is sent even though it may be received from satellite 201 in a different format or having a different data rate.
[0034] In addition to the above described elements, the headend 300 also includes a content replication module 312 coupled to the program recovery module 310 , a program content distribution control module 316 , a content substitution module 318 and a plurality of selection/packetization modules 320 , 322 , 324 , each corresponding to a different local distribution center which can be an output port number and/or port/IP address pair used by the distribution network headend 300 to stream packets including program content to an individual local distribution center. Each of the selection/packetization module, i.e., selection/packetization module 320 , 322 , . . . , and 324 has two selection inputs S 1 and S 2 which are either open for supplying content or closed depending on a control signal from the content distribution control module 316 , e.g., control signal C 1 , C 2 , . . . , CN as shown in FIG. 3 . In addition to the controllable inputs, each selection module also has an output, which feeds the content output from the selection module to a distribution network, e.g., distribution network 212 of FIG. 2 . Input S 1 of each of the selection modules 320 , 322 , . . . , 324 is coupled to the content substitution module 318 . Each of the selection inputs S 2 of each of the selection modules 320 , 322 , . . . , 324 is coupled to the content replication module 312 . The program recovery module 310 is responsible for processing the received program content and recovering the program to be distributed to various local/regional distribution centers, e.g., local distribution center 216 and 226 . In some embodiments, the program recovery module 310 is also responsible for putting the recovered program content in a suitable format for distribution to various local distribution centers. The program recovery module 310 may use codec 308 for transcoding functions and/or when a reduction in data rate is to be achieved through the use of decoding/re-encoding prior to distribution to one or more local distribution centers. As noted above, received program content may and in many embodiments is, duplicated and distributed to local distribution centers via separate and independent packet streams, e.g., non-multicast packet streams.
[0035] The content replication module 312 is coupled to the program recovery module 310 , and is configured to replicate the received program content for delivery to a plurality of different regional distribution centers. The distribution of the duplicated content is achieved using at least one of i) different ports and ii) different IP addresses to indicate which of the different regional distribution centers particular content is directed to. In this manner, packets containing duplicated content can be distributed using individual packet streams directed to individual local distribution centers
[0036] The blackout of individual geographic regions and distribution of content is controlled under the direction of commands received, e.g., along with content to be distributed via the satellite downlink. Command recovery module 314 is responsible for processing commands received from a remote location, e.g., via satellite from a content provider at a remote location, to determine if the distribution of a program included in the received content is to be blocked from delivery to a particular local region. The command recovery module 312 recovers commands from received satellite signals and then supplies the commands to program content distribution control module 316 which is responsible for controlling distribution in accordance with the received commands. In accordance with the commands, content may be distributed to specific local regions, blocked from distribution to specific regions and/or alternative content may be distributed to a local distribution center in place of blocked content. The alternative content may be specified by a received command or determined by the local distribution center or distribution network headend. The alternative content in some embodiments is an alternative content stream received via the satellite link. In other embodiments the alternative content is obtained from content stored at the distribution network headend .
[0037] In some embodiments the recovered commands supplied to the control module 316 indicate the region for which the content delivery is to be blocked by specifying at least one of: i) a port number and ii) an IP address corresponding to the region to which content delivery is to be blocked. In some embodiments the command includes information identifying a geographic region from which program content is to be blocked. For example the command may indicate or specify a geographic region identifier corresponding to a region for which the program content delivery is to be blocked. In some embodiments, the information identifying a geographic region is a name of the geographic region. In such embodiments the distributor headend 300 may use the IP address lookup module 342 for determining, from the information identifying the geographic region, an IP address of a distribution center, e.g., a regional distribution center, serving the identified geographic region. In some other embodiments, the command may include port number and/or IP address information corresponding to a region to which content delivery is to be blocked.
[0038] In order to implement a received content distribution control command, program distribution control module 316 controls one or more of selection/packetization modules 320 , 322 , 324 to select between outputting content corresponding to a received program or alternate content. As can be seen in FIG. 3 , the selection/packetization modules 320 , 322 , 324 can output substitute programming content by packetizing and streaming the content supplied to substitute content input S 1 or output the regular program content, e.g., when it is not subject to blackout restrictions, by packetizing and streaming the content supplied to the second input S 2 . While the use of separate switching devices 320 , 322 , 324 under the control of control module 316 is shown with each switching module corresponding to a different local distribution center, it should be appreciated that the switching between regular program content and alternative program content in response to a received command may be implemented in a plurality of ways.
[0039] It should be appreciated that routers and/or other content distribution systems can be configured so that a port maps to a particular application, combination of application and IP address and/or some other identifier, e.g., a region identifier, that can be configured by a system administrator. Thus, ports of an interface used for outputting data, commonly referred to as output ports, can have a set relationship to an application type, IP address, and/or region depending on the system configuration. Therefore it should be appreciated that the distribution control module 316 may control the headend to, in some embodiments, disable a port at the distributor network headend 300 that outputs the content to the distribution ring, e.g., distribution network 212 of FIG. 2 .
[0040] Content substitution module 318 , among other things, is responsible for outputting alternative program content to be supplied in place of content which is being blocked with regard to a specific geographic region for which a command indicates program content is to be blocked. The alternative content is selected and output on a per region basis, e.g., based on information included in a received command.
[0041] Having described various elements which are used to distribute content, block content for particular regions and/or supply alternative content, the various data, routines and other elements stored in memory used to implement the methods of the invention will now be discussed further. The memory 326 includes various stored information and storage modules, e.g. such as the recovered program content 328 which stores the program content recovered by the program recovery module 310 . Prior to supplying the program content to a plurality of regional distribution centers, the content replication module 312 uses the recovered program content 328 to replicate received content. The memory further includes a port to region mapping information 330 , recovered alternative program content 332 , locally stored content 334 , scheduling information 336 , information regarding distribution centers 338 , routines 340 , IP address look-up module 342 , received command 344 and specific alternative program content information 346 . The port to region mapping information 330 stores information regarding different ports corresponding to different application, e.g., video, audio etc., in different regions. For example, in one embodiment port to region mapping information 330 includes information as to what port(s) in a geographic region, e.g., geographic region 1 214 of FIG. 2 , support the video and audio applications. In some embodiments, the headend 300 uses this port to region mapping information 330 to disable the corresponding port(s) at the output interface e.g., port/IP address pair 1 321 .
[0042] Recovered alternate program content 332 stores alternate program content communicated by the content provider in the event a specific alternate program is indicated for distribution in place of the blocked program content. For example, in some embodiments it may be desired by the content provider that a specific program targeted specially for a region and/or the customers in that region, be distributed in place of the blocked program content. In such an event, the content provider may send specific alternate program content for use in replacing the blocked program in the regions. Alternatively, in some other embodiments, alternative program content may be locally stored in the locally stored content 334 .
[0043] Scheduling information 336 stores the timing and scheduling information, communicated by the content provider, about the time and/or the period of time for which the program content delivery is to be blocked for a region or regions. Scheduling information 336 may and in some embodiments is, used by program content distribution module 316 in combination with received commands to determine what content to deliver at a particular point in time. For example, if a pay per view program is to be broadcasted, e.g., from 9:00 PM to 11:00 PM, then, in some embodiments, the content provider would communicate this timing/scheduling information to the headend 300 so that the headend 300 can schedule and block the delivery of program content in a specified region accordingly. In some embodiments scheduling information 336 also includes information regarding the time when one or more alternative program content should be distributed.
[0044] Information regarding distribution centers 338 includes, e.g., information mapping different distribution centers to different geographic areas that the distribution center is serving. For example, in one embodiment information regarding distribution centers 338 includes information that geographic area 1 214 is being served by local distribution center 216 , geographic area N 224 is being served by local distribution center 226 and so on. Routines 340 include communications routines and/or distributor network headend control routines.
[0045] IP address look-up information 342 includes information, e.g., a look-up table, that maps a local distribution center serving a geographic region, to an IP address associated with that distribution center. In some embodiments, the look-up information 342 is dynamically updated when a dynamic IP address associated with a distribution center changes. In some other embodiments it is also possible that a static IP address may be associated with a distribution center and in such cases an entry associated with such a distribution center in the look-up information 342 remains unchanged. The IP address look-up module 307 uses IP address look-up information 342 for determining from the information identifying a geographic region, an IP address of a distribution center serving the identified geographic region.
[0046] Received command 344 is a received command which is temporarily stored after it is recovered by the command recovery module 314 prior to use by the distribution control module 316 .
[0047] FIG. 4 is a flowchart 400 of an exemplary content delivery method where a distributor network headend, e.g., distribution network headend 300 of FIG. 3 , may block the delivery of program content to a particular region in accordance with an exemplary embodiment. The distribution network headend 300 is configured to receive program content via satellite from a content source, e.g., a content provider and distribute the program content to a plurality of local distribution centers, e.g., local distribution center 216 , etc. Operation of the exemplary method starts in step 402 where the distribution network headend 300 is initialized. Operation proceeds from start step 402 to step 404 .
[0048] In step 404 the distribution network headend 300 receives program content via a satellite communications link. Operation proceeds from step 404 to step 406 .
[0049] In step 406 the distribution network headend 300 replicates the received program content for delivery to a plurality of local distribution centers, e.g., local distribution centers 216 , 226 , etc. The network headend 300 uses at least one of i) different ports and ii) different IP addresses for distribution of content to different regional distribution centers. As discussed earlier in the example of FIG. 3 , the distribution network headend 300 includes a content replication module 312 which is configured to carry out the process of replicating the received program content. Operation proceeds from step 406 to step 408 .
[0050] In step 408 , the distribution network headend 300 receives a command from a remote location to block the delivery of the received program content to a particular region or regions. In some embodiments the command is received via the satellite communications link. Operation proceeds from step 408 to step 410 .
[0051] In step 410 the distribution network headend 300 processes the received command to determine if distribution of a program included in received program content is to be blocked from delivery to a region, e.g., a region subject to a blackout of the particular program content. In some embodiments the received program content includes multiple programs that may, and sometimes are identified by, e.g., different program IDs. The multiple programs may include movies, soap operas, pay-per-view programs, on-demand programs etc. In order to control the selective blocking of content distribution, a command received by the distributor headend may, and sometime does, include, e.g., a program ID identifying a program included in said received content to be blocked from delivery to a particular region identified in the command. In some embodiments the received command indicates the region to which the content delivery is to be blocked by specifying at least one of: i) a port number and ii) an IP address corresponding to the region to which content delivery is to be blocked. In some embodiments, received command includes information identifying both the port number and IP address. In other embodiments, the command indicates the region to be blocked by one or more other identifiers, e.g., by the name of the region. Operation proceeds from step 410 to step 412 .
[0052] In step 412 the distribution network headend 300 determines and makes a decision whether or not program delivery is to be blocked for a region, based on the processing performed by the distributor headend in step 410 . When the received command does not indicate that a program delivery be blocked for any region, operation proceeds from step 412 to 416 .
[0053] Where the program content is distributed to a plurality of regional/local distribution centers. The operation then proceeds from step 416 back to step 404 .
[0054] In step 412 , if the command indicates program delivery for a region is to be blocked, operation proceeds to step 414 rather than 416 . In step 414 the distributor headend recovers from the received command, information identifying a geographic region subject to a program blackout. The information may be a port number and IP address corresponding to a local content distribution center serving the region from which program delivery is to be blocked. Operation proceeds from step 414 to step 418 .
[0055] In optional step 418 the distribution network headend 300 receives, via the satellite communications link, information indicating specific alternative program content to be distributed in place of the program to be blocked. For example in some embodiments where it is desired to block delivery of a program to a region, a content provider may send information to the distribution network headend 300 regarding the alternative program that should be distributed in place of the blocked program. In some such embodiments, the distribution network headend 300 may already have the alternative program content in a storage device, e.g., locally stored content 334 of FIG. 3 . However in some other embodiments, the alternative program content may not be locally stored in the distribution network headend 300 in which case the distributor headend may, and sometimes does request the alternative program from an outside server, e.g., a national content server. Alternatively in some other embodiments, the content provider communicates the alternative program content to the distribution network headend 300 for distribution. In some embodiments, the information indicating specific alternative program content is included in the received command. In cases where alternative program content is not specified, the distribution network headend 300 may select content to be distributed in place of the blacked out content. Operation proceeds from step 418 when implemented to optional step 420 .
[0056] In step 420 , the distribution network headend 300 receives, via the satellite communication link, alternative program content to be distributed in place of the program to be blocked. It should be appreciated that step 420 is an optional step in some embodiments, i.e., in some embodiments the content provider does not communicate the alternative program content to the distribution headend via the satellite link. In some embodiments, a received command specifies the alternative program content to be displayed but the content is not supplied by the satellite link. The alternative content may and sometimes is identified by, e.g., an alternative program/substitute program ID, which helps a program recovery module 310 in the distribution network headend 300 to identify and retrieve the alternative program content. In some embodiments, the alternative program is stored in the distribution headend 300 memory as, e.g., locally stored content 334 . The operation proceeds from optional step 420 to step 422 . In some embodiments where the optional steps 418 and 420 are not used, operation proceeds directly from step 414 to step 422 .
[0057] In step 422 , using the information recovered from the received command, the distribution network headend 300 blocks the program from being output using a port and/or an IP address corresponding to a local distribution center corresponding to the geographic region subject to the program blackout. In some embodiments, step 422 includes sub-step 424 which may, and sometimes is, performed. In sub-step 424 the distribution network headend 300 outputs the alternative program content in place of the program content to be blocked using the port and/or IP address information corresponding to the geographic region subject to the program blackout.
[0058] FIGS. 5, 6 and 7 illustrate different exemplary command formats for commands to block delivery of program content which may be used in various exemplary embodiments.
[0059] FIG. 5 , illustrates the format of an exemplary command 500 , to block delivery of program content in accordance with a first exemplary embodiment. As shown in FIG. 5 , the exemplary command 500 include fields 502 , 504 , 506 and optionally 508 .
[0060] Field 502 is a command type indicator field which indicates that command 500 is a block command used to block program content from being delivered to a particular geographic region, e.g., a region subject to a program blackout. Field 504 is a program ID field which includes information identifying the specific program, which is to be blocked from being delivered to a geographic region or regions indicated in the message. In some embodiments, field 504 includes a program identifier number. Field 506 is a geographic region identifier field. The geographic region identifier field 506 identifies the geographic region subject to a program blackout. The region subject to the blackout may be identified by a name or IP address, and/or port number corresponding to a geographic region and/or local content distribution center serving the region. In some embodiments, the distributor is able to identify a geographic region even if only the name of that region is provided in the command. In some such embodiments, the distribution network headend uses the stored information 338 regarding different geographic regions served by different local/regional distribution centers. In such embodiments the distributor headend may, and sometimes does, further include means for determining, from the geographic region identifier, e.g., information in field 506 , an IP address of a distribution center serving the identified geographic region. For example in some embodiments the distributor headend includes an IP address look-up module, e.g., look-up module 307 , configured to determine, from the geographic region identifier, an IP address of a distribution center serving the identified geographic region
[0061] Field 508 is an optional substitute program ID field. Accordingly it may be, and sometimes is, present in some embodiments while not present in some other embodiments. The substitute program ID field 508 includes information identifying a substitute program content, e.g., an alternative program to be distributed to the region subject to the program blackout in place of the program to be blocked. Thus, the substitute program ID field 508 enables the distributor headend to identify substitute/alternative program content to be output in place of the program content being blocked.
[0062] FIG. 6 , illustrates format of another exemplary command 600 , to block delivery of program content in accordance with another exemplary embodiment. In accordance with the present invention, in some embodiments, a command received by the distributor headend indicates the region to which content delivery is to be blocked by specifying at least one of: i) port number and ii) an IP address corresponding to the region to which content delivery is to be blocked. As shown in FIG. 6 , the exemplary command 600 include different fields 602 , 604 , 606 and 608 , each including different information and/or instruction for performing a function. As can be seen from FIG. 6 , the three fields in the exemplary command 600 , i.e., field 602 , 604 and 608 are similar to the fields 502 , 504 and 508 , even though these fields have been identified using different numerals.
[0063] Field 602 indicates that command 600 is a command for blocking program content from being delivered to a region indicated in the message.
[0064] Program ID field 604 indicates the program to be blocked while field 606 specify at least one of i) port number and ii) an IP address corresponding to the region to which content delivery is to be blocked. Providing the region information in this manner eliminates the need for the distribution network headend to determine this information based on the name of a region and can simplify the implementation of the blocking and program substitution operation. In some embodiments field 606 includes either a port number or an IP address corresponding to the region to which content delivery is to be blocked.
[0065] Optional substitute program ID field 608 when present indicates the program to be output in plae of the blocked program content.
[0066] FIG. 7 illustrates a format of another exemplary command 700 , to block delivery of program content in accordance with yet another exemplary embodiment. The command 700 includes command identifier 702 , program identifier 704 , optional substitute program ID 710 and both a port number and IP address field 706 , 708 used to indicate the region subject to the indicated program blackout. The port number field 706 indicates the output port at the distribution network headend 300 corresponding to the local region subject to the blackout while the IP address field 708 is an address of the local distribution center in the geographic region subject to the blackout. Using the port and/or IP address, distribution of the blacked out program content to the geographic region subject to the blackout, can be achieved and alternative content can optionally be delivered in place of the blacked out program content.
[0067] While described in the context of a video delivery system, it should be appreciated that the methods and apparatus of the present invention are not limited to the delivery of video content and can be used to support delivery of audio content and/or other types of information content which may be subject to regional blackouts and/or other delivery restrictions.
[0068] In various embodiments system elements described herein are implemented using one or more modules which are used to perform the steps corresponding to one or more methods of the present invention. Each step may be performed by one or more different software instructions executed by a computer processor, e.g., a central processing unit (CPU) such as processor 306 .
[0069] At least one system implemented in accordance with the present invention includes individual means for implementing each of the various steps which are part of the methods of the present invention. Each means may be, e.g., an instruction, processor, hardware circuit and/or combination of such elements used to implement a described step.
[0070] The commands described herein are often buffered and/or stored in memory. Accordingly some embodiments are directed to a machine readable medium including the commands discussed herein being stored on the machine readable medium. Many of the above described methods or method steps can be implemented using machine, e.g., computer, executable instructions, such as software, included in a machine, e.g., computer, readable medium used to control a machine, e.g., general purpose computer with or without additional hardware, to implement all or portions of the above described methods, e.g., in one or more nodes.. The machine readable medium may be, e.g., a memory device, e.g., RAM, floppy disk, etc. Accordingly, among other things, the present invention is directed to a machine-readable medium including machine executable instructions for causing a machine, e.g., processor and associated hardware, to perform one or more of the steps of the above-described method(s).
[0071] Numerous additional embodiments, within the scope of the present invention, will be apparent to those of ordinary skill in the art in view of the above description and the claims which follow.
|
Methods and apparatus for controlled distribution of program content are described where program content for certain regions may be selectively blocked. The described methods and apparatus allow content distribution to authorized regions while providing control to the content provider to effectively block program content delivery to regions not entitled to receive the program content.
| 7
|
BACKGROUND OF THE INVENTION
1. Field of the invention:
The present invention relates to a drive coupling device for use in optical instruments which are detachably combined together. The drive coupling device of the present invention is used, for example, for transmitting a drive force from a camera body as one optical instrument to a lens shifting mechanism in an interchangeable lens as another optical instrument for automatic focusing, when the interchangeable lens is mounted on the camera body.
2. Description of the Prior Art:
Drive coupling devices for optical instruments are required to be connected or disconnected automatically and reliably at the same time that the optical instruments incorporating such drive coupling devices are coupled to or detached from each other. Such drive coupling devices are disclosed in Japanese Laid-Open Utility Model Publication No. 57-9914 (hereinafter referred to as Publication (1)), Japanese Laid-Open Patent Publications Nos. 57-173809, 57-177105, and 57-195224 (hereinafter referred to as Publications (2), (3), (4), respectively), for example. In these disclosed drive coupling devices, generally, the drive coupling member in one optical instrument extends parallel to the optical axis thereof, and the driven coupling member in another optical instrument also extends parallel to the optical axis thereof. These drive and driven coupling members are connected through a male-and-female interfitting connection to each other to couple the optical instruments together.
The drive coupling device shown in Publication (1) has a male engaging portion in the form of a cross screwdriver tip, and a female engaging portion in the form of a cross-recessed screw head, the male and female engaging portions being interfittingly engageable with each other. The drive coupling device shown in the Publications (2), (3), (4) includes a flat male engaging portion and a slotted female engaging portion which can be brought into mesh with each other. The flat male and slotted female engaging portions illustrated in Publication (2) also have central female and male centering engaging portions, respectively.
The drive coupling device shown in Publication (1) is advantageous in that the male and female engaging portions can easily be interfitted and disengaged, and when in mesh with each other, they can center the drive and driven coupling members coaxially with each other. The drive coupling device is also advantageous in that the male and female engaging portions are automatically engaged and disengaged smoothly with and from each other by relative movement of the two optical instruments in a direction perpendicular to the axes of the drive and driven coupling members. These advantages are achieved by the male and female engaging portions held in contact with each other through slanted surfaces. However, when a rotative drive force is to be transmitted between the drive and driven coupling members, the male and female engaging portions are subject to a force tending to disengage them out of meshing relation due to the contact at their slanted surfaces. Thus, no stable torque transmission is achieved, and high torques cannot be transmitted by the drive and driven coupling device
With the drive coupling device shown in Publications (3), (4), the male and female engaging portions are not subject to a force which would tend to disengage them in transmitting the rotative drive force. As a consequence, the disclosed drive coupling device can essentially stably transmit torques and can transmit high torques. However, the drive coupling device of this type has a disadvantage described below.
FIGS. 10 and 11 of the accompanying drawings illustrate such drive coupling device composed of a driven coupling member B in an optical instrument A and a drive coupling member D in an optical instrument C. The optical instruments A, C as combined together may not be positionally aligned or may have the driven and drive coupling members B, D disposed out of alignment. Therefore, when the optical instruments A,C are coupled together, the flat male engaging portion d and the slotted female engaging potion b may be in mesh with each other with their axes E, F out of alignment, as shown in FIGS. 10 and 11. The illustrated drive coupling device has no ability to correct such an axial misalignment. The rotative drive force is transmitted while the flat male engaging portion d and the slotted female engaging portion b are out of axial alignment, with the result that the male and female engaging portions d, b are liable to get distorted or twisted. Further, the male engaging portion d tends to rub against the inner peripheral surface of an axial receiving bore G, damaging the inner peripheral surface thereof and allowing chips from the damaged inner peripheral surface to enter between the inner peripheral surface and the outer peripheral surface of the driven coupling member B. The illustrated prior drive coupling device is therefore of a low torque transmission efficiency, has low durability, and is apt to produce noises, actually. When the drive force is transmitted from the flat male engaging portion d to the slotted female engaging portion b, the flat male engaging portion d contacts an edge b' of the slotted female engaging portion b as shown in FIG. 11. The edge b' is subject to a concentrated shock-induced stress and may be damaged thereby as when the drive coupling member D is abruptly stopped. For the above reason, the drive coupling device is less durable, and the damages make the drive coupling device poor in appearance. To eliminate the above shortcomings, the slotted female engaging portion b would have to be formed in a relatively large size.
The drive coupling device of Publication (2) transmits torques in the same manner as those of Publications (3) and (4), and has central male and female engaging portions for preventing the male and female coupling members from being misaligned during a rotation. Therefore, it is free from the disadvantages which would arise from the torque transmission by the misaligned drive and driven coupling members. However, the construction is more complex due to the "double-engaging" structure and costly to manufacture. Moreover, the male and female engaging portions have no ability to guide the male and female coupling members for centering their axes when the axes are misaligned beyond a certain degree so as not to allow engagement of the central male engaging portion into the central female engaging portion.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a drive coupling device having drive and driven coupling members which can easily be connected and disconnected, remain stably in mesh with each other, can stably transmit torques, and can transmit high torques.
Another object of the present invention is to provide a drive coupling device composed of drive and driven coupling members which can be brought into mesh with each other without being misaligned.
Still another object of the present invention is to provide a drive coupling device which is highly durable, and will not produce noises and not be damaged during operation.
To achieve the object, a drive coupling device of the present invention includes one of driving and driven coupling members on a first optical instrument and the other of the driving and driven coupling members on a second optical instrument detachably attached on the first optical instrument. The rotational axes of the driving and driven coupling members extend parallelly to the optical axes of the first and second optical instruments. A pair of connecting portions extending perpendicularly to the rotational direction of the driving and driven coupling members are formed on the driving and driven coupling members, respectively, to connect the two coupling members for rotation. A first surface is formed at a tip end of one of the coupling members and at a tip end of the other coupling member is formed a second surface which is brought into contact with the first surface under a biasing force of a biasing means biasing at least one of the coupling members in the direction parallel to their rotational axes. The second surface has a centerlizing guide slope for guiding the first surface therealong so that the rotational axes of the coupling members come into alignment with each other.
With the above construction, when the driving coupling member is rotated by a driving means, the rotation is transmitted to the driven shaft through the pair of connecting portions. A stable connection is established during the rotation since no force disconnecting the driving and driven coupling members from each other is produced because of the pair of connecting portions extending perpendicularly to the rotational direction of the coupling members. Moreover, as the centerlizing guide slope of the second surface guides the first surface therealong so that the rotational axes of the coupling members come into alignment with each other, there occurs no misalignment of the rotational axes. Accordingly, the drive coupling device of the present invention is capable of high torque transmission, highly durable, and will not produce noises and will not be damaged during operation.
The above and other objects, features and advantages of the present invention will become more apparent from the following description when taken in conjunction with the accompanying drawings in which a preferred embodiment of the present invention is shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary cross-sectional view of a drive coupling device according to an embodiment of the present invention;
FIG. 2 is a fragmentary cross-sectional view taken along a different cross-sectional plane, showing the drive coupling device of the invention;
FIG. 3 is an exploded perspective view of the drive coupling device;
FIG. 4 is a cross-sectional view of the drive coupling device as incorporated in an optical device or camera;
FIGS. 5 through 9 are fragmentary cross-sectional views showing the manner in which the drive coupling device in connected;
FIG. 10 is a fragmentary cross-sectional view of a conventional drive coupling device; and
FIG. 11 is a front elevational view, partly in cross section, of the drive coupling device of FIG. 10.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 through 9 show a drive coupling device according to the present invention. An interchangeable lens 1 as one or interchangeable optical instrument is detachably mounted on a camera body as another or base optical instrument. As shown in FIGS. 1 through 4, the drive coupling device has a driven coupling member 4 mounted in the interchangeable lens 1 and drive coupling member 5 mounted in the camera body 2, the driven and drive coupling members 4, 5 being interfittingly engageable for transmitting an automatic focusing force from the camera body 2 to a lens moving mechanism 3 in the interchangeable lens 1.
The interchaneable lens 1 and the camera body 2 have mounts 6, 7, respectively, for detachably coupling them. The mounts 6, 7 have annular mount surfaces 6a, 7a held in intimate contact with each other in a direction parallel to an optical axis of the interchangeable lens 1, the driven and drive coupling members 4, 5 being connectably disposed adjacent to the mount surfaces 6a, 7a.
The driven coupling member 4 in the interchangeable lens 1 is disposed parallel to the optical axis 8 and within an outer barrel 9. The driven coupling member 4 is rotatably fitted in and supported by a bearing 10 mounted in the mount 6 and a bearing 11 mounted on the inner surface of the outer barrel 9. The lens moving mechanism 3 (FIG. 4) is of a double-helicoidal construction having an intermediate helicoidal member 15 held in mesh through helicoidal teeth 13, 14 with the inner circumferential surface of the outer barrel 9 and the outer circumferential surface of a lens holder 12. The lens holder 12 is movable only in directions parallel to the optical axis 8 through engagement between a groove 16 defined in the lens holder 12 parallel to the optical axis 8 and a key 17 fixed to the inner surface of the outer barrel 9. To the front end of the intermediate helicoidal member 15, there is fixed a manual control ring 18 by means of a screw 19. The intermediate helicoidal member 15 has on its rear end a driven gear 20 meshing with a gear 21 mounted on the rear end of the driven coupling member 4. In response to rotation of the manual control ring 18 or the driven coupling member 4, the intermediate helicoidal member 15 moves the lens holder 12 parallel to the optical axis for focusing the lens 1.
The drive coupling member 5 in the camera body 2 extends parallel to the optical axis 8. The drive coupling member 5 has on a rear end thereof a flat shank 5a of a rectangular cross section fitted in a rectangular hole 23a in a driven gear 23 rotatably supported by a bearing 22 in the camera body 2. The drive coupling member 5 is retained in position by a snap ring 24 mounted on the rear end thereof and is normally urged by a biasing menas defining spring 25 toward the interchangeable lens 1. Therefore, the drive coupling member 5 is cantilevered which is slidable axially toward the interchangeable lens 1. The drive coupling member 5 is normally kept under the spring force in the position in which the tip end thereof projects toward the driven coupling member 4 by an interval x (FIG. 1) beyond accumulated positional errors in the axial direction at the time the driven and drive coupling members 4, 5 are mounted respectively in the interchangeable lens 1 and the camera body 1.
The mating end of the driven coupling member 4 has a slotted female engaging portion 26 and the mating end of the drive coupling member 5 has a flat male engaging portion 27. The drive coupling 5 is a axially retractable by abutment of the tip end of the male engaging portion 27 against the bottom of the female engaging portion 26 for the above interval x when they are interfitted. When the female and male engaging portions 26, 27 are held in meshing engagement with each other, they are coupled for co-rotation.
The female engaging portion 26 of the driven coupling member 4 is slightly retracted from the mount surface 6a. With the female and male engaging portions 26, 27 are interfitted, the male engaging portion 27 of the drive coupling member 4 projects beyond the mount surfaces 7a, 6a into meshing engagement with the female engaging portion 26.
The drive coupling member 5 in the camera body 2 has a smaller-diameter portion 5b to which there is connected an interlinking member 28 for coaction with an interchangeable lens locking member (not shown). When the mount surfaces 6a, 7a mate with each other for mounting the interchangeable lens 1 on the camera body 2, the interchangeable lens locking member is retracted until the mount surfaces 6a, 7a reach their normal mount positions. As the locking member is thus retracted, the drive coupling member 5 is resiliently retracted slightly behind the mount surface 7a against the resilient force of the spring 25 so that the drive coupling member 5 will not interfere with the lens mounting operation and will prevent the mount surface 7a and the male engaging portion 27 from being damaged. When the mount surfaces 6a, 7a have reached their normal mount positions and the locking member is moved back to lock the interchangeable lens 1 in a normal mount position with respect to the camera body 2, the drive coupling member 5 projects beyond the mount surface 7a under the resilient force of the spring 25 until the male engaging portion 27 is held against the female engaging portion 26 of the driven coupling member 4. If the female and male engaging portions 26, 27 are properly aligned with each other, then they are brought into mesh with each other as they are. If the female and male engaging portions 26, 27 are not oriented in different directions, then they will be brought into mesh with each other when they are turned into aligned orientation by the rotation of the drive coupling member 5.
The drive coupling member 5 can be rotated through a drive gear 31 and the driven gear 23 meshing therewith by a motor 30 mounted on a baseboard 29 on which the bearing 22 is mounted. The motor 30 is energized by a driver circuit 32 to which there is connected an operating circuit 34 supplied with an output signal from a focus condition detecting element 33, so that the motor 30 can be controlled by the output signal from the operating circuit 34. The operating circuit 34 issues a normal-rotation signal to drive the motor 30 in a normal direction when the operating circuit 34 is supplied with a signal indicating that the lens 1 is in a rear focused condition. When the operating circuit 34 is supplied with a signal indicating that the lens is in a front focused condition, the operating circuit 34 issues a reverse-rotation signal to drive the motor 30 in a reverse direction. The operating circuit 34 stops the generation of the motor drive signal to de-energize the motor 30 when it is supplied with a focusing signal indicating that the lens 1 is properly focused.
The rotation of the drive coupling member 5 dependent on the control mode of the motor 30 is transmitted from the driven coupling member 4 to the lens moving mechanism 3 for moving the interchangeable lens 1 toward the properly focused position from the defocused postion thereof. Upon arrival at the properly focused position, the lens 1 is stopped and now automatically focused.
The female engaging portion 26 of the driven coupling member 4 is formed as a slot defined in a smaller-diameter portion 4a diametrically across the same, and has a bottom formed as a centering guide surface 35 against which the male engaging portion 27 of the drive coupling member 5 is pressed under the resilient force of the spring 25 while being retracted by the interval x, and which serves to move the female and male engaging portions 26, 27 relatively to each other into the axially aligned position. The centering guide surface 35 comprises an arcuate concave surface curved in the longitudinal direction of the slotted female engaging portion 26. The centering guide surface 35 is effective in centering the female and male engaging portions 26, 27 out of axial misalignment in the longitudinal direction of the slotted female engaging portion 26. The slotted female engaging portion 26 also has on its mating end a conical concave surface 36 for guiding the male engaging portion 27 into proper mesh with the female engaging portion 26. The male engaging portion 27 is in the form of a rectangular tongue projecting from the tip end of the drive coupling member 5 and extending diametrically thereacross. The male engaging portion 27 has a polygonal end surface 27a bevelled at its opposite corners at an angle equal to the angle at which the conical concave surface 36 is slanted to thereby form outwardly converging side faces.
The female and male engaging portions 26, 27 of the driven and drive coupling members 4, 5 may be formed by cutting, forging, die-casting, or other suitable processes.
Meshing and centering of the female and male engaging portions 26, 27 will be described in greater detail. When the interchangeable lens 1 is mounted on the camera body 2 and if the axes of the driven and drive coupling members 4, 5 are aligned, then the female and male engaging portions 26, 27 are pressed against each other in axial alignment. If the female and male engaging portions 26, 27 are not oriented axially in one direction at this time, then the polygonal end surface 27a of the male engaging portion 27 is and remains pressed against the conical concave surface 36 of the female engaging portion 26, as shown in FIG. 5. The drive coupling member 5 is then rotated to bring the male engaging portion 27 into the same orientation as that of the female engaging portion 26, whereupon the male engaging portion 27 is immediately moved into mesh with the female engaging portion 26 in coaxial alignment as shown in FIGS. 1 and 2. If the female and male engaging portions 26, 27 are initially oriented in the same direction, then the male engaging portion 27 meshes with the female engaging portion 26 in coaxial alignment as shown in FIGS. 1 and 2 at the same time that the interchangeable lens 1 is mounted on the camera body 2.
If the driven and drive coupling members 4, 5 are not coaxially aligned with each other, then the female and male engaging portions 26, 27 are pressed against each other in axial misalignment with each other. In the event that the female and male engaging portions 26, 27 are not oriented in the same direction at this time, the polygonal end surface 27a of the male engaging portion 27 is pressed against the conical concave surface 36 of the female engaging portion 26 out of coaxial alignment as shown in FIG. 6. The male engaging portion 27 is now subject to a force component F 1 tending to shift the male engaging portion 27 laterally in a clearance or play into axial alignment with the female engaging portion 26. The above play is provided for the following reason: The driven and drive coupling members 4, 5 tend to be forced out of coaxial alignment due to respective positional errors of the driven and/or drive coupling members 4, 5 and also due to relative positional errors induced when the interchangeable lens 1 is mounted on the camera body 2. The above play can absorb such positional errors since the tip end of the drive coupling member 5 can be laterally shifted in the play. The drive coupling member 5 is flexibly cantilevered since its rear end is supported by the driven gear 23 and the front end thereof extends through a hole 37 defined in the mount 7. Therefore, the tip end of the male engaging portion 27 can be laterally displaced under the force component F 1 into axial alignment with the female engaging portion 26 until the male and female engaging portions 27, 26 can automatically centered with respect to each other as shown in FIG. 7. When in the position of FIG. 7, the drive coupling member 5 is rotated to orient the female and male engaging portions 26, 27 in one direction, thereby allowing the male engaging portion 27 into mesh with the female engaging portion 26 in coaxial alignment as illustrated in FIGS. 8 and 9.
In the case where the driven and drive coupling members 4, 5 are out of axial alignment even if the female and male engaging portions 26, 27 are oriented in the same direction, and also where the male engaging portion 27 is in mesh with the female engaging portion 26 because the driven and drive coupling members 4, 5 are not axially aligned in the longitudinal direction of the slotted female engaging portion 26, as indicated by the imaginary lines in FIG. 9, then the polygonal end surface 27a of the male engaging portion 27 is pressed against the centering guide surface 35 at the bottom of the female engaging portion 26 and is subject to a force component F 2 tending to move the male engaging portion 27 laterally into axial alignment with the female engaging portion 26. Therefore, the drive coupling member 5 is moved so that the male engaging portion 27 thereof will be brought into axial alignment with the female engaging portion 26 as indicated by the solid lines in FIG. 9.
The female and male engaging portions 26, 27 as coaxially aligned as indicated by the solid lines in FIGS. 8 and 9 can stably held in mesh with each other under the meshing force and the centering action caused by the force component acting on the polygonal end surface 27a to displace the same along the centering guide surface 35 into the axial aligned position. The rotative drive force can now be transmitted from the drive coupling member 5 to the driven coupling member 4 smoothly and efficiently without twisting or distorting the driven and drive coupling members 4, 5.
The female and male engaging portions 26, 27 as meshing with each other are positioned within the given play in the transverse direction of the slotted female engaging portion 26, and are also positioned in coaxial alignment in the longitudinal direction of the slotted female engaging portion 26 by the centering action between the centering guide surface 35 and the polygonal end surface 27a. Therefore, the conical concave surface 36 may be dispensed with since it is not dispensable for positioning the female and male engaging portions 26, 27 in the above fashion. A guide portion for the sole purpose of facilitating the male engaging portion 27 to mesh with the female engaging portion 26 would simply be formed by bevelling the entrance of the slotted female engaging portion 26. Alternatively, the male engaging portion 27 would be bevelled to reduce the width of the tip end thereof for the same purpose.
Although not shown, the interchangeable optical instrument to be mounted on the camera body may be an intermediate optical instrument to be disposed between the interchangeable lens and the camera body e.g. an extention ring, a rear converter. The coupling member mounted in such an intermediate optical instrument may be the drive coupling member or the driven coupling member as described above. The drive coupling device of the present invention may be employed to transmit various drive forces other than the force for automatically focusing the lens, such as a force for automatically adjusting a diaphragm in an exchangeable lens.
Although a certain preferred embodiment has been shown and described, it should be understood that many changes and modifications may be made therein without departing from the scope of the appended claims.
|
A drive coupling device for transmitting a rotational drive force from an optical instrument such as a camera body to another optical instrument such as an exchangeable lens has a construction which couples driving and driven coupling members steadily while centerizing the center axes of the driving and driven coupling members for efficient drive force transmission. A flat male engaging portion having a top surface and parallel side walls is formed on the driving coupling member while a slotted female engaging portion having a concave bottom wall and parallel side walls is formed on the driven coupling member. With the optical instruments connected to each other, the male engaging portion is brought into engagement with the female engaging portion under a force of a spring.
| 5
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a first-in-first-out random access memory (FIFO RAM), and more particularly to an apparatus and method for controlling the access of an asynchronous dual port FIFO memory.
[0003] 2. Description of Related Art
[0004] Metastability, e.g. unstable transient state, is a major problem of controlling an asynchronous dual port FIFO. Different access frequencies in read and write may result in uncertainty of operating addresses specified by a read pointer and a write pointer. For instance, the FIFO control on the write part needs to sample the value of the read pointer for checking the signal FIFO_FULL status with a write clock that is asynchronous to a read clock. Similarly, the FIFO control on the read part needs to sample the value of the write pointer for checking the signal FIFO_EMPTY status with the read clock that is asynchronous to the write clock. However, this may lead to a situation where each bit of the read pointer is changing state from “1” to “0” or “0” to “1”, and every signal bit goes metastable.
[0005] The Gray code method is one of the most common approaches to overcome the problem of metastability. Gray code is a unit of distance code; that is, no more than one bit is changed between two adjacent codes. FIG. 1 shows an example of a 3-bit Gray code counter. Gray code method can reduce the metastable bits to the minimum while the pointers are being sampled. The sampled value will at most have one bit error each time. This means that the Gray-coded pointer only changes one bit between two adjacent values. The previous and current values in the counter will be sampled, and the two are corrected for checking FIFO pointers. FIG. 2 illustrates an asynchronous dual port FIFO containing 8 depth of words (not shown). Two 3-bit Gray code pointers 21 , 22 (the aforementioned read pointer and write pointer), the different read and write frequencies RCLK, WCLK and their respective synchronizing circuits 210 , 220 are used to implement the FIFO. The FIFO is deemed empty (FIFO_EMPTY) when the read point and the write pointer are equal. When the next write pointer value is equal to the current read pointer value through presentations of read and write FIFO status indicators 23 , 24 , it means the FIFO is full (FIFO_FULL). As such, the read pointer 21 and the write pointer 22 need to be converted to read and write binary counters 25 , 26 , for indicating read and write addresses of the FIFO, and a subtraction is then performed on the read and write binary counters 27 , 28 in order to determine the available space in the FIFO.
[0006] Although the Gray code method solves the problem of metastability, it has three disadvantages. First, it is difficult to code the counter in the form of a state machine with the states encoded with Gray code when a long asynchronous FIFO is being implemented. Second, complex detection of FIFO_FULL signal and complicated Gray code arrangement incur problems of timing slacks and large circuit areas. For example, 8 conditions need to be compared to determine whether or not the FIFO is almost full if a 3-bits Gray code counter is implemented. The 8 conditions includes, for example: when the pseudo code in write pointer is “100” and the pseudo code in read_pointer is “000”, the pseudo code in FIFO_FULL is the value “1”; when the pseudo code in write_pointer is “000” and the pseudo code in read_pointer is “001”, the pseudo code in FIFO FULL is the value “1”, . . . , etc. Finally, the Gray code method requires Gray-to-binary converters and subtractors to indicate the status of the FIFO. This leads to increased costs. The circuit and equation of an n-bit Gray-to-Binary conversion are shown in FIG. 3, wherein n is any integer more than one. In this example, if the addresses are n-bit wide so the input 31 includes one input line for each of the n bits, wherein n is any integer more than one. The output 32 also includes n individual output lines 34 . The n-bit Gray-to-Binary conversion is accomplished using the exclusive OR (XOR) gates 35 and the equations Bn, Bi as shown, wherein n is any integer more than one.
SUMMARY OF THE INVENTION
[0007] Accordingly, an object of the invention is to provide a method and apparatus for controlling the access of an asynchronous dual port FIFO efficiently.
[0008] Another object of the invention is to provide an asynchronous dual port FIFO having n-bit Gray code counters for handshaking between the read part and write part of the FIFO.
[0009] According to the invention, circular Gray code counters are used for handshaking between the FIFO read part and write part. Additional binary counters are used to accumulate the read and write overflows for the circular Gray code counters. When any circular Gray code counter is overflow, the read or write count is transferred to the respective binary counter for recording the FIFO accesses.
[0010] An FIFO status indicator uses one of the binary counters for indicating used space of the FIFO. Also, the level of the memory used in the FIFO can state the FIFO status with FIFO_FULL and FIFO_EMPTY in the write part and read part respectively.
[0011] The invention provides an application of an asynchronous FIFO control without any limitation on the read and write frequencies. Also, the binary counters and few n-bit Gray counters have better timing slack and smaller area than the typical Gray code implementation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention will become apparent by referring to the following detailed description of a preferred embodiment with reference to the accompanying drawings, wherein:
[0013] [0013]FIG. 1 shows an example of 3-bit Gray code counter;
[0014] [0014]FIG. 2 illustrates a block diagram of an asynchronous dual port FIFO using the Gray code method;
[0015] [0015]FIG. 3 is an example of an n-bit Gray-to-binary converter;
[0016] [0016]FIG. 4 shows an example of the action of the counters according to the invention;
[0017] [0017]FIG. 5 illustrates an asynchronous dual port FIFO in accordance with the invention;
[0018] [0018]FIG. 6 is a block diagram of the handshaking unit in the write part of FIG. 5 according to the invention;
[0019] [0019]FIG. 7 is a block diagram of the overflow control circuit in the write part of FIG. 5 according to the invention; and
[0020] [0020]FIG. 8 is a block diagram of the FIFO status indicator in the write part of FIG. 3 according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The Gray code counter can minimum the metastable bits while the read and write counters are being sampled. When an FIFO has the depth of 2 n , a Gray code counter with at least n bits will be implemented in each read and write pointers. The Gray code counter can express the depth of the FIFO such that the Gray code read pointer will never overstep the write pointer. Similarly, the Gray code write pointer will never overstep the read pointer. For example, when the FIFO is empty, the read pointer is equal to the write pointer and the subsequent read request will be disabled and the read pointer is not counted.
[0022] Two circular Gray code counters with n bits are used in handshaking read and write parts, wherein n is any integer greater than one. Because the circular Gray code counters are not sufficient for indicating the values of the read and write pointers; additional binary counters are used for accumulating overflows of the read and write Gray code counters. For instance, a two-bit gray-coded write pointer can indicate four write requests with 00, 01, 11, 10. If the FIFO contains more than four elements, in the write part, the count is transferred to the binary counter for recording the write operation when the FIFO is not full and the gray-coded write counter is overflow. The action of the read part is the same as the write part does.
[0023] [0023]FIG. 4 shows an example of the action of the counters according to the invention. The asynchronous dual port FIFO contains 16 elements and each of the read part and the write part contains two Gray code counters, namely, Wmaster and Rslave or Rmaster and Wslave. In the write part, Wmaster is a 2-bit Gray code counter for recording actions of write requests. Rslave is another 2-bit Gray code counter for synchronizing with the read part. A binary counter Wacc that cooperates with Wmaster is used for recording the overflow of Wmaster. The write pointer Wptr is a binary counter. In this example, the write frequency is faster than the read frequency. The initial status is shown in step 0 . From steps 0 to 4 , five write requests are serviced. In step 3 , Wslave of the read part is sampled by the write part and the sampled result is compared with Wmaster for detecting the overflow. When the overflow is detected, Wmaster stops counting and the counter Wacc increases one. In step 5 , Wmaster is sampled by the read part and the sampled result is compared with the Wslave. Because Wmaster and the Wslave are different in comparison, Wslave increases by one. Meanwhile, Rmaster increases by one since an FIFO read request is performed. In step 6 , the overflow state is cancelled such Wmaster increases by one and Wacc reduces by one. In step 7 , the same step is performed as in step 5 . Step 8 is the same as step 6 except that Wacc is not decreased because an FIFO write request is input. The read part symmetrical to the write part (see FIG. 5) has the same performance identical to the write part. As such, under the overflow control in respective write and read binary counters, Wmaster will never overstep Wslave and Rmaster will never overstep Rslave. With the cooperation of the Gray code counters and the binary counters, the bit numbers of each Gray code counter can be reduced. Thus, the binary counters and Gray code counters of the present invention have better timing slack and smaller area than the typical gray code implementation that needs the same size in conventional FIFO.
[0024] [0024]FIG. 5 illustrates the asynchronous dual port FIFO 500 in accordance with the invention. The asynchronous dual port FIFO 500 comprises a dual port random access memory (RAM) 510 . Input data are written into the RAM 510 through an input port (not shown) and a write pointer Wptr indicates a write address. Output data are read from the RAM 510 through an output port (not shown) and a read pointer Rptr indicates a read address. The FIFO 500 further comprises a pair of read and write parts with symmetrical implementation. Each part contains an FIFO status indicator ( 501 , 502 ), a handshaking unit ( 503 , 504 ), and an overflow controller ( 505 , 506 ). The FIFO status indicator ( 501 , 502 ) indicates the levels of the RAM 510 use in an FIFO pointer and the read or write pointer (see FIG. 8). The level of the RAM 510 use in the FIFO pointer can state the FIFO full with FULL (see FIG. 8) in the write part and the FIFO empty with EMPTY in the read part. Each pointer is a binary counter. The handshaking unit ( 503 , 504 ) contains two n-bit Gray code counters and a synchronizing circuit (see FIG. 6), wherein n is any integer more than one. The synchronizing circuit can be an Flip/Flop. The overflow controller ( 505 , 506 ) cooperates with the handshaking unit to obtain the performance of FIG. 4. As cited, the performance is identical to both read and write parts. For simplicity, the further description only gives to the write part as shown in FIGS. 6 to 8 .
[0025] [0025]FIG. 6 is a block diagram of the handshaking unit 503 in the write part of FIG. 5 according to the invention. In the handshaking unit, one n-bit gray counter is Wmaster and the other is Rslave, wherein n is any integer more than one. If the write request Write is enabled and the overflow Wacc does not occur, Wmaster increases by one as shown in step 9 of FIG. 5. Also, Wmaster increases by one if the conditions no overflow, no servicing FIFO write request and Wacc not equal to zero are met. Rslave increases by one if the comparison Cpr (not shown) of Rslave and sampled Rmaster is not equal. The handshaking unit 504 in the read part is the same as that in the write part, except that the read and write elements and signals are exchanged.
[0026] [0026]FIG. 7 is a block diagram of the overflow controller 505 in the write part of FIG. 5 according to the invention. The overflow controller is a binary counter Wacc. Wacc increases by one if the write request is enabled and the overflow is detected, as shown in the step between steps 4 and 5 of FIG. 5. Wacc reduces by one if Wmaster has no overflow, Wacc is not zero and no FIFO write request Write is serviced, as shown in the step between steps 6 and 7 of FIG. 5. The overflow controller 506 in the read part is the same as that in the write part, except that the read and write elements and signals are exchanged.
[0027] [0027]FIG. 8 is a block diagram of the FIFO status indicator in the write part of FIG. 3 according to the invention. The status indicator contains a circular binary counter Waddr for indicating a write address by the write pointer Wptr and a binary counter Wlevel for indicating used size of the FIFO. Waddr increases by one if the write request Write is serviced. Wlevel increases by one if the comparison Cpr of the Rslave and sampled Rmaster is equal and the write request Write is enabled. Wlevel reduces by one if the comparison Cpr is not equal and no FIFO write request Write is serviced. Also, the status indicator 502 in the read part is the same as that in the write part, except that the read and write elements and signals are exchanged.
[0028] Although the present invention has been described in its preferred embodiment, it is not intended to limit the invention to the precise embodiment disclosed herein. Those who are skilled in this technology can still make various alterations and modifications without departing from the scope and spirit of this invention. Therefore, the scope of the present invention shall be defined and protected by the following claims and their equivalents.
|
An apparatus and method for controlling an asynchronous First-In-First-Out (FIFO) memory. The asynchronous FIFO has separate, free running read and write clocks. A number of n-bit circular Gray code counters are used to handshake the operation between read and write parts of the FIFO, wherein n is any integer more than one. Additional binary counters are used to accumulate the read and write overflows for the circular Gray code counters. When any circular Gray code counter is overflow, the read or write count is transferred to the respective binary counter for recording the FIFO accesses.
| 7
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to shingles, and more particularly, to a pair of coordinated roofing shingles of the solid type, usually made from either felt or fiberglass covered with asphalt and ceramic granules, and each with at least two vertical adhesive strips to hold down both shingles and to seal the overlap between two adjoining shingles in the same row of shingles so as to prevent the horizontal flow of water at the overlaps. Both of the shingles have a rectangular shape. One of the shingles is of full size with its major edges substantially three times the length of its minor edges. The other shingle is one-half the length of the full-size shingle so that the major edges are only one and one-half times the length of the minor edges. The shingles are placed on a roof with two of the full-size shingles overlapping and above the half-size shingle fitted between them.
2. Description of the Prior Art
In an earlier filed application of the same inventor, Ser. No. 442,597, now U.S. Pat. No. 4,466,226, filed Nov. 18, 1982, a shingle is shown with a series of marks for convenience in cutting the shingle. In the earlier application, a series of methods are taught for installing a roofing shingle with overlapped joints rather than butt joints to assist in avoiding leaks. However, even with two adjoining shingles having an overlapped joint, it is possible, during a heavy rain, or when accumulated ice melts on a roof, that water will flow sideways under the overlap. Even in the absence of these conditions, problems of water flowing sideways occurs on roofs having a low pitch.
In the earlier application, Ser. No. 442,597, a method described as the first method of three is the method most suitable for use with the pair of coordinated shingles according to this invention.
It has been known in the art to provide a strip of adhesive material on shingles so that when the shingles are applied, less nailing is required to secure the shingles to the roof and, after installation, as the heat of the sun warms the roof, the adhesive strip or band on the shingle causes each adjacent higher course or row of shingles to adher to the next lower course or row of shingles thereby preventing shingles from blowing up on end in a high wind. However, in the past, such adhesive bands have been either in a horizontal solid horizontal line or in a series of dots along a horizontal line parallel with the major edges of the shingle and also parallel with the lower edge of the roof. Without doubt, such horizontally oriented adhesive bands do assist in holding down the shingles but, as has been pointed out, water still can flow sideways at the overlapped joints. Unfortunately, with a solid horizontal adhesive strip, the adhesive strip or band itself holds the water in the joint causing it to continue to flow horizontally resulting in a leak.
The novel features which are considered as characteristics of the invention are set forth with particularity in the appending claims. The invention itself, however, as to its construction and obvious advantages will be best understood from the following description of the specific embodiment when read with the accompanying drawings.
SUMMARY OF THE INVENTION
The present invention overcomes the disadvantages of the self-sealing horizontal strip by providing a roofing shingle in the form of a flat sheet of weather resistant material with vertical adhesive bands each having a width of at least one-quarter inch.
DESCRIPTION OF THE DRAWINGS
The present invention may be better understood and its numerous advantages will become apparent to those skilled in the art by reference to the accompanying drawings wherein like reference numerals refer to like elements in the various figures in which:
FIG. 1 is a plan view of a full-size shingle showing the adhesive bands in the upper portion of the shingle with a total of five adhesive bands being shown.
FIG. 2 is a plan view of the half shingle with one pair of adhesive bands substantially the same length as the minor edges of the shingle and located adjacent the minor edges.
FIG. 3 is an exploded view of both the full-size and half-size shingles according to this invention shown apart but arranged as they would overlap one another on a roof.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, there is shown a standard size shingle 11 which, in the British system of measurements, has a width of twelve inches and a length of thirty-six inches. A metric size shingle is also available and is just slightly larger than the shingle with British system measurements. The shingle, which has a rectangular shape, has two major edges 13 and two minor edges 15. The major edges 13 are placed substantially horizontally along the horizontal edge of the roof 13 (not shown), and the minor edges 15, which are shorter than the major edges 13, are placed vertically on the roof substantially parallel with the vertical edges of the roof. It is common practice to place shingles side by side, either abutting one another but it is preferable to use an overlap 17 wherein each shingle either overlaps or is overlapped by its adjacent shingle by approximately two or three inches. The larger overlap of three inches has been used on lower courses of shingles in colder climates where a buildup of snow or ice can occur. Two inches is otherwise adequate in the upper portions of the roof and on the entire roof in areas where ice and snow would not accumulate along the lower edge of the roof. With the benefit of this invention, only two inches of overlap 17 is satisfactory at any point on the roof.
The shingles are applied in a series of horizontal rows with each adjacent higher row also overlapping an upper portion 19 of the shingle below it. In the past, more than half of the lower shingle would be covered by the next higher row of shingles but with the advantages of this invention, only one-half of the lower shingle need by covered by the course or row of shingles directly above it.
The major edges 13 of the full-size shingle 11 shown in FIG. 1, whether in the metric or in the British system are substantially three times the length of the minor edges 15. Each full-size shingle 11 has both the upper portion 19 and a lower portion 21. The upper portion 19, as has been pointed out, is covered by the next higher shingle. The lower portion 21 is exposed to the weather. The full-size shingle 11, as shown in FIG. 1, includes five adhesive bands 23. Each of the adhesive bands 23 is a sticky, tar-like material which when heated by the sun will adher to whatever shingle is placed upon it. The length of the five adhesive bands 23 is substantially one-half the length of the minor edges 15 since, as has been pointed out, the upper portion 19 covered the next higher row of course, can be limited to one-half the length of the minor edges 15 but it can be increased if desired. The five adhesive bands 23 are all located in the upper portion 19 of the full-size shingle 11. All of the five adhesive bands 23 are substantially parallel to one another and to the minor edges 15 of the full-size shingle 11 shown in FIG. 1. Each has a width of at least one-quarter of an inch. Preferable, the adhesive bands 23 would have a width of three-eighths of an inch and may even be as wide as one-half inch.
Included within the five adhesive bands 23 are an outside pair of adhesive bands 25 which are located along the minor edges 15 of the full-size shingle 11 and just slightly removed from the minor edges 15. An intermediate pair of adhesive bands 27 are located at the one-third and two-third points as measured along the major edges 13 of the full-size shingle 11. One edge of the intermediate pair of adhesive bands 27 is at the one-third and two-thirds point line with each of the intermediate adhesive bands 27 within the one-third part of the full-size shingle closest to the nearest minor edge 15.
A middle adhesive band 29 is located substantially along the centerline between the two minor edges 15.
Referring now to FIG. 2, the smaller or half-size shingle 30 is shown. The half-size shingle 30, like the full-size shingle 11, includes the upper portion 19 and the lower portion 21. This shingle also has a pair of major edges 31 and a pair of minor edges 33. The major edges 31 are approximately one and one-half times the length of the minor edges 33. The minor edges 33 of the half-size shingle 30 are substantially the same length as the minor edges 15 of the full-size shingle 11. With the half-size shingle 30, only one pair of adhesive bands 35 are on the shingle 30. Again, each of the adhesive bands 35 should be at least one-quarter inch in width as with the larger or full-size shinge 11. However, with the half-size shingle 30, shown in FIG. 2, each of the adhesive bands 35 is substantially as long as the minor edge 33 and located adjacent each of the minor edges 33 of the half-size shingle 30 in a similar manner to the pair of outside bands 25 of the full-size shingles 11.
Referring now to FIG. 3, a method is shown, which is taught in applicant's earlier patent application, previously referred to herein. The first or lowest course of shingles shown in FIG. 3 is a base course 37 which is the first or runner set of shingles placed across the roof before laying a first course 39 which is the first course that is exposed. The first shingle 41 which starts the base course 37 is a full-length shingle 11 cut to a one-third length. Since the intermediate pair of adhesive bands 27 are located within the one-third part of the full-size shingle 11 adjacent its nearest minor edge 15 one of the intermediate adhesive bands 27 is on the one-third shingle to assist in securing the next course. The third shingle 43 in the base course 37 is a full-length, full-size shingle 11. Placed between the first shingle 41 in the base course 37 and the third shingle 43 in the base course 37 is a second shingle 45 which is a one half-size shingle 30. Both minor edges 33 of the half-size shingle 30 are placed beneath the ends of the first shingle 41 and the third shingle 43. The space between the first shingle 41 and the third shingle 43 is one-third the length of a full-size shingle 11. Since the second shingle 45 is a one-half shingle 30, there is the overlap 17 between both the first shingle 41 and second shingle 45 and the second shingle 45 and third shingle 43 is adequate. The adhesive bands 35 of the half-size shingle 30 are shown as dotted lines in the base course 37 in FIG. 3. A fourth shingle 47 is again a half-size shingle 30 and a fifth shingle 49 is a full-size shingle 11 and a sixth shingle 51 is a half-size shingle 30 with the same spacing and the same overlap as described for the first shingle 41, the second shingle 45 and the third shingle 43 of the base course 37. It should be noted that a second course 53 follows the same procedure and sequence as the base course 37.
Referring now to the first course 39, the first shingle 57 is a full-size shingle 11. Had a full-size shingle 11 been used as the first shingle in the base course 37, a one-third shingle would have been used in the first course 39 with the same resultant changes in successive courses. A third shingle 59 is also a full-size shingle 11 spaced from the first shingle 57 along the first course 39 a distance of one-third the length of a full-size shingle 11. A fifth shingle 61, also a full-size shingle 11 is placed the same one-third distance from the third shingle 59. A second shingle 63 and the fourth shingle 65 of the second course 53 are half shingles 30 and the second shingle 63 is placed between the first shingle 57 and the third shingle 59 and the fourth shingle 65 is placed between the third shingle 59 and fifth shingle 61 in the same manner as was done in the base course 37. It should be noted that the first course 55 is directly and completely over the base course 37 so that none of the base course 37 is exposed.
The second course 53 follows the same description as the base course 37. The second course 53, however, only partially overlaps the first course 39 covering only the upper portion 19 of the full-size shingles 11 and the half-size shingles 30. However, looking at the first course 39 and the second course 53, it can be seen that the full-size shingle 11 will touch and be sealed down by one of the intermediate pairs of adhesive bands 27 and middle bands 29 located on the shingles directly below it and the pair of adhesive bands 35 of the half-size shingle 30 will completely seal the entire course to prevent leakage from the horizontal flow of water. Both the intermediate pair of adhesive bands 27 and the middle adhesive band 29 serve to hold the higher row of shingles down securely.
The third row 67 of shingles follows the same description as the first row 39 of shingles. In each of the rows 37, 39, 53, 67, a half-size shingle 30 is alternated with a full-size shingle 11 and each full-size shingle 11 has a half-size shingle 30 centrally aligned with it in the next higher row.
The use of nails 69 would be limited and preferable would be placed toward the lower ends of the outside pair of adhesive bands 25 and the intermediate pair of adhesive bands 27.
While a preferred embodiment has been shown and described, various modifications and substitutions may be made without departing from the spirit and scope of this invention. Accordingly, it is understood that this invention has been described by way of illustration rather than limitation.
|
A pair of coordinated roofing shingles of the solid variety both with vertical adhesive strips to provide sealing of the shingles with limited nailing and to provide a complete vertical seal at the overlap between adjoining shingles in the same course to prevent water leakage from the horizontal flow of water.
| 4
|
This application is a division of application Ser. No. 269,976, filed June 3, 1981, now U.S. Pat. No. 4,368,688.
BACKGROUND OF THE INVENTION
The present invention relates to a method of treating a tow of filamentary filter material, especially a tow which is about to be converted into the filler of a filter rod adapted to be subdivided into filter rod sections of desired length. Such filter rod sections are used in filter tipping machines for the mass production of filter cigarettes, cigars or cigarillos.
It is well known to apply a liquid plasticizing agent, such as triacetin and hereinafter called plasticizer, to a running tow of filamentary filter material. The plasticizer is atomized so that it forms a myraid of minute droplets which are propelled against the running tow and cause portions of neighboring filaments to become soft and adhere to each other so that the filaments of the filler form a maze of passages for the flow of tobacco smoke into the mouth. As a rule, the tow is first converted into a relatively wide but thin layer wherein all or nearly all of the filaments are exposed during application of plasticizer (note the commonly owned U.S. Pat. No. 3,971,695 granted July 27, 1976 to Block); this ensures more uniform distribution of droplets of plasticizer on the filaments of the tow. The thin layer of filamentary material is at least slightly permeable to liquids, i.e., a certain percentage of minute droplets of plasticizer penetrates through the interstices or gaps between neighboring filaments of the tow and must be gathered for renewed use or for delivery to a location where the thus gathered liquid does not interfere with the application of atomized plasticizer to freshly arriving increments of the running tow. In most instances, the liquid plasticizer is atomized and applied to the running tow at a predetermined rate, namely, in such a way that the quantity of liquid plasticizer which is applied to successive unit lengths of the running tow remains unchanged even if the speed of the tow is increased or reduced. This can be readily accomplished by utilizing a pump which supplies plasticizer to the plasticizer-atomizing and plasticizer-applying station at a speed which changes proportionally with variations in velocity of the running tow. The latter is withdrawn from a bale and is caused to pass along, through or past and beyond one or more so-called banding devices which facilitate conversion of the tow into a layer whose filaments are adjacent to each other and are adequately exposed for proper application of atomized plasticizer. The tow is thereupon gathered into a rod-like filler which is draped into a web of cigarette paper or the like to form therewith a continuous filter rod. The rod is severed at regular intervals to yield filter rod sections of desired length, and such sections are ready to enter the magazine of a filter tipping machine, the storage or a reservoir system wherein the curing of plasticizer is completed and which discharges filter rod sections at a rate at which the sections are processed in one or more associated filter tipping machines.
The filaments of the tow often consist of cellulose, and the plasticizer is selected with a view to soften the contacted portions of such filaments and to cause the softened portions to adhere to each other. This leads to formation of the aforementioned maze of minute passages or paths for the flow of tobacco smoke into the mouth. Many smokers are quite particular as regards the so-called draw of a filter cigarette or another smokers' product having a filter plug at one end thereof. Excessive resistance to the flow of smoke is not desirable because each drag entails the exercise of a substantial effort and the smoker fails to draw sufficient quantities of smoke into his or her mouth. On the other hand, insufficient resistance to the flow of smoke is equally (or perhaps even more) unsatisfactory because the quantity or inhaled smoke is excessive and/or because the smoke is too hot and the filter fails to remove or intercept a requisite percentage of nicotine, condensate and/or other deleterious or presumably deleterious ingredients.
Predictable resistance to the flow of tobacco smoke through a filter involves the application of liquid plasticizer in accurately metered quantities. Such predictable (and evidently acceptable or optimum) resistance is desirable and advantageous on the the additional ground that it is least likely to interfere with proper operation of apparatus, mechanisms and/or machines for further treatment of filter plugs. Thus, filter plugs of excessive hardness would be likely to damage (e.g., puncture) the uniting band material which is used to connect filter plugs with rod-shaped tobacco-containing articles, such as plain cigarettes of unit length or multiple unit length. Excessive application of plasticizer (i.e., the application of excessive quantities of plasticizer per unit length of the two) is undesirable on still another ground, namely, because the plasticizer is expensive and excessive application results in waste of such material as well as in excessive number of rejects, i.e., of finished filter rod sections which are not acceptable for further processing in a filter tipping or like machine.
It is well known to confine the station where the atomized plasticizer is applied to successive increments of the running tow in a housing designed to gather the plasticizer which has penetrated through the interstices between the filaments of the running tow. The droplets of plasticizer which have penetrated through the tow are caused to impinge upon the internal surface of the housing, and such internal surface is configured to direct the gathered liquid into the range of one or more atomizing instrumentalities, e.g., rotary brushes whose bristles convert the liquid into minute droplets while simultaneously propelling the droplets against one or both sides of the running tow. The just described mode of gathering or intercepting atomized plasticizer which has penetrated through or across the running tow is quite satisfactory when the machine for making filter rod sections operates normally, i.e., when the tow is driven at a normal or average speed, when the plasticizer is delivered at a rate which is proportional to the speed of lengthwise movement of the tow, and when the nature of the tow is such that the latter can accept optimum quantities of finely atomized plasticizer. The preferably smooth internal surface of the housing can direct the surplus of plasticizer (and more accurately the plasticizer which has penetrated through the running tow) into the range of a rotary brush in the lower portion of the housing, and such liquid plasticizer returns or flows into the lower portion of the housing by trickling along walls which flank one or both sides of the path for lengthwise movement of the running tow through the housing. After elapse of a certain interval following starting of the machine, the machine establishes in the housing a so-called internal equilibrium which simply means that the quantity of admitted plasticizer machines or very closely approximates that quantity of atomized plasticizer which is evacuated by successive increments of the running tow. The internal equilibrium can be established (or its establishment promoted) by varying the rate of delivery of plasticizer to the atomizing station while the tow is transported at a constant speed.
A drawback of presently known methods and apparatus for applying liquid plasticizer is that the aforediscussed internal equilibrium is invariably destroyed when the filter rod making machine is arrested, and also that it takes a relatively long interval of time to reestablish such equilibrium after renewed starting of one or more prime movers which drive the rotary and/or otherwise movable constituents of the machine. The internal equilibrium is also destroyed or rendered unsatisfactory if the feed of one of two constituents (filter tow and plasticizer) to the atomizing station is changed while the rate of delivery of the other constituent remains unchanged. Since a modern high-speed filter rod making machine turns out very large quantities of rod-shaped articles per unit of time, and since the filter rod sections which contain unsatisfactory quantities of plasticizer must be segregated because they would contribute to the making of unsatisfactory smokers' products, it is evidently desirable to reduce the period of absence of the internal equilibrium to a minimum.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the invention is to provide a novel and improved method of applying atomized plasticizer to a running tow of filamentary filter material in such a way that the periods of improper application of plasticizer are reduced to a fraction of the time which elapses when the application of plasticizer takes place in accordance with conventional methods.
Another object of the invention is to provide a novel and improved method of applying liquid plasticizer to a running tow of filamentary filter material immediately after the tow is set in motion.
A further object of the invention is to provide a method which reduces the likelihood of excessive wetting of a running tow of filamentary filter material while the tow is in the process of acceleration to its normal speed.
An additional object of the invention is to provide a method of the above outlined character which reduces the likelihood of breakage or tearing of a filamentary filter material during certain stages of operation of the machine wherein the tow is converted into the filler of a filter rod.
Still another object of the invention is to provide a method of the above outlined character which reduces the likelihood of excessive hardening of filter rod sections produced immediately after initial or renewed starting of the machine which turns out filter rod sections for the making of filter tipped smokers' products.
One feature of the invention resides in the provision of a method of applying liquid plasticizer (e.g., triacetin) to a foraminous running tow of filamentary filter material (such as cellulose acetate fibers). The method comprises the steps of establishing and maintaining a treating zone, conveying a tow into, through and beyond the treating zone at a variable speed (one of the several speeds at which the tow is or can be conveyed is zero), conveying into the treating zone atomized liquid plasticizer at a first rate such that successive increments of the tow which leave the treating zone entrain the admitted plasticizer as soon as the treating zone accumulates a quantity of residual plasticizer (e.g., in the form of droplets which are suspended in air in the region of the treating zone and/or which accumulate and flow along the internal surface of a housing or casing which is preferably provided to confine the treating zone, some of the residual plasticizer forming part of liquid which has penetrated through the interstices of the foraminous tow), interrupting the conveying of the tow and/or the conveying of the plasticizer (e.g., in response to the generation of a defect signal which is indicative of unsatisfactory rate of conveying of liquid plasticizer, unsatisfactory conveying of the tow toward, through or beyond the treating zone, unsatisfactory characteristics of the product which embodies the treated tow, and/or a combination of such factors), withdrawing at least some residual plasticizer from the treating zone on interruption of conveying of the tow and/or plasticizer resuming the conveying steps (e.g., after the cause of malfunction which has initiated the generation of a defect signal has been eliminated) including resuming the conveying of liquid plasticizer but at a higher second rate as to restore the quantity of residual plasticizer in the treating zone, and thereupon again proceeding with the conveying of liquid plasticizer at the first rate (i.e., at a rate such that the quantity of residual plasticizer which dwells in the treating zone remains substantially unchanged because the running tow removes from the treating zone a given quantity per unit of time or unit length of the tow, namely, a quantity which matches the quantity of liquid plasticizer that is admitted into the treating zone during the same interval of time or per unit length of the running tow).
The method preferably further comprises the step of establishing and maintaining a main source of supply of liquid plasticizer (e.g., in a suitable vessel whose contents are preferably agitated in order to enhance the homogeneousness of liquid which is being drawn from such source). The plasticizer conveying step then includes drawing plasticizer from the main source (e.g., by resorting to a variable-delivery pump, such as a gear pump), and the withdrawing step then preferably includes accumulating the withdrawn portion of residual plasticizer independently of the main source. The step of resuming the conveying of plasticizer then preferably includes admitting the plasticizer from the main source at the first rate as well as simultaneously reintroducing the withdrawn portion of residual plasticizer into the treating zone. The just mentioned accumulating step preferably includes causing at least some residual plasticizer to leave the treating zone by gravity flow or under the action of suction.
The plasticizer conveying step preferably includes supplying to the treating zone at least one continuous stream of liquid plasticizer and atomizing successive increments of the stream on entry into the treating zone.
The step of establishing and maintaining the treating zone may comprise confining the treating zone in a housing which defines an elongated path for the transport of the tow therethrough, and the plasticizer conveying step then comprises spraying atomized plasticizer against one side of the tow in the aforementioned path whereby at least some of the plasticizer penetrates through the foraminous tow and the plasticizer which has penetrated through the tow forms part of residual plasticizer in the treating zone. The withdrawing step then comprises (or such withdrawing step may comprise) allowing residual plasticizer to flow along the interior of the housing and to issue from the housing by gravity flow. The method then preferably further comprises the step of storing the issuing plasticizer in the proximity of the treating zone during interruption of transport of the tow along the aforementioned path (for example, the issuing plasticizer can be stored in the chamber of a container whose bottom constitutes a membrane which is displaceable in a direction to return the accumulated residual plasticizer into the treating zone during the initial stage of renewed conveying of the tow through the housing, namely, during that stage which normally involves acceleration of the tow from a lower speed (e.g., zero speed) to the normal or average speed). In fact, the readmission of withdrawn residual plasticizer can be completed with a fraction of the interval which is needed to accelerate the tow from zero speed to the normal or average speed.
The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The apparatus itself, however, both as to its construction and its mode of operation, together with additional features and advantages of the method, will be best understood upon perusal of the following detailed description of certain specific embodiments with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic partly elevational and partly sectional view of an apparatus which can be used for the practice of the novel method and is incorporated in a filter rod making machine;
FIG. 2 is a diagrammatic view of a detail in the apparatus of FIG. 1; and
FIG. 3 illustrates a portion of a modified apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1, there is shown a filter rod making machine which is designed to produce a file of discrete filter rod sections 56 of desired length, e.g., of six or eight time sunit length. The machine comprises a first section or unit 1 which serves to prepare a continuous tow 4 of filamentary filter material for draping into a continuous web 48 of cigarette paper, imitation cork or other suitable wrapping material. The tow 4 is stored in the form of a bale 6 which is confined in a receptacle 5 and stores a substantial supply of compacted filamentary filter material. The means for withdrawing tow 4 from the bale 6 comprises a first pair of advancing rolls 3 which cause the tow to travel over a deflecting roller 103 and past two so-called banding devices 7 and 8 respectively located upstream and downstream of the roller 103. The banding devices comprise pipes (see the pipe 7a) which are connected to a source of compressed gaseous fluid (e.g., air), nozzles (see the nozzle 7b) whose orifices direct a plurality of small streams of compressed gaseous fluid against successive increments of the moving tow whereby the streams penetrate through the tow and rebound upon suitable plates (see the plate 7c). The purpose of the banding devices 7 and 8 is to loosen the tow 4 so that the latter can be converted into a thin but wide layer whose filaments are adjacent to each other and are exposed for satisfactory contact with finely atomized liquid plasticizer, such as triacetin.
The banded tow 4 is thereupon caused to enter the nip of two additional advancing rolls 9 whose peripheral speed preferably exceeds the peripheral speed of the first advancing rolls 3 so that the filaments of the tow are stretched during travel between the rolls 3 and 9. This renders it possible to reduce the customary crimp of the filamentary filter material, e.g., to stretch the filaments to their elastic limit and to thereby ensure that all of the filaments (or practically all of the filaments) are straight during transport toward and through a plasticizer applying station 12 which is disposed between the advancing rolls 9 and a third pair of advancing rolls 11.
The tow 4' which advances beyond the nip of the advancing rolls 11 is converted into a cylindrical filler during travel through a gathering horn 44 forming part of a second section or unit 2 of the filter rod making machine shown in FIG. 1. The second section or unit 2 comprises a frame F which supports a spindle 45 for a reel 46 of wrapping material. The web 48 is drawn off the reel 46 by a pair of advancing rolls 50, and one side of the running web is coated with adhesive by a paster 47 which is installed upstream of a wrapping mechanism 51 disposed above an endless transporting belt conveyor 49 known as garniture. The conveyor 49 cooperates with the mechanism 51 to drape successive increments of the web 48 around successive increments of the filler issuing from the gathering horn 44 so that the web 48 is converted into a tubular envelope whose marginal portions overlap each other to form a seam which extends in the longitudinal direction of the resulting continuous filter rod 52. The seam is heated or cooled (depending on the nature of adhesive which is applied by the paster 47) by a sealer 53 and the rod 52 thereupon enters a cutoff 54 which severs it at regular intervals so that the rod yields a single file of discrete filter rod sections 56 of desired length. Successive filter rod sections 56 are accelerated by a rotary cam 57 which propels the sections 56 into successive axially parallel peripheral flutes of a rotary drum-shaped row-forming conveyor 58 serving to convert the single file of sections 56 into one or more rows wherein the sections travel sideways. The row or rows of filter rod sectins 56 are deposited on the upper reach of a belt conveyor 59 which delivers the filter rod sections into storage, into a reservoir system (such as that known as Resy and manufactured by the assignee of the present application) or directly into the magazine of a filter tipping machine for cigarettes or other rod-shaped smokers' products. A filter tipping machine of the type known as MAX S and capable of processing the filter rod sections 56 is manufactured by the assignee of the present application.
Referring again to the first section or unit 1 of the machine shown in FIG. 1, the lower rolls of the three pairs of advancing rolls 3, 9 and 11 receive torque from the main prime mover 13 (e.g., a variable-speed electric motor) of the filter rod making machine. The output element of the main prime mover 13 drives a first endless belt of chain 13a which rotates the lower roll of the pair of rolls 9 and which further drives a second endless belt or chain 13b serving to rotate the input element of a variable-speed transmission 14 whose output element drives the lower roll 3. The ratio of the transmission 14 can be changed by a servomotor 16, e.g., in response to signals which are generated by the operator or in response to signals from one or more devices which monitor the condition of the filter rod 52 and/or the condition of filter rod sections 56 in a manner not forming part of the present invention. As mentioned above, the peripheral speed of the rolls 3 is less than that of the rolls 9 so that the filaments of the tow 4 are stretched during travel from the nip of the rolls 3 toward the nip of the rolls 9.
A third endless belt or chain 13c drives the lower advancing roll 11, and a further endless chain or belt 13d transmits motion to a pulley 49a for the garniture 49. The manner in which the advancing rolls 50 for the web 48 are driven is not specifically shown in the drawing.
The plasticizer conveying and applying mechanism at the station 12 comprises a housing 18 having a slot-like inlet immediately or closely downstream of the nip of the advancing rolls 9 and a similar outlet immediately or closely upstream of the apex of the upper advancing roll 11. Such slot-like inlets and outlets are shown in greater detail in the commonly owned copending application Ser. No. 143,184 filed Apr. 24, 1980 by Heinz Greve et al. The horizontal path along which the flattened and stretched tow 4 advances through the housing 18 is denoted by the reference character 17. The housing 18 contains an atomizing device in the form of a brush 21 drive by a discrete prime mover 19, e.g., a constant-speed electric motor. The bristles of the rapidly rotating brush 21 propel minute droplets of liquid plasticizer against the underside of the tow 4 which advances along the path 17 whereby some droplets adhere to the tow and the remaining droplets penetrate through the interstices or gaps between the filaments of the tow and enter the upper portion of the housing 18 above the path 17. Such droplets deposit on the internal surface of the upper portion of the housing 18 and trickle or flow downwardly into the lower portion below the path 17 for renewed atomizing and propulsion against the running tow.
A supply of liquid pasticizer (e.g., triacetin) is stored in a main source here shown as a vessel 22. A continuous stream of plasticizer is drawn from the vessel 22 by a pump 24 (e.g., a gear pump which can be said to constitute a means for conveying to the housing 18 metered quantities of liquid plasticizer per unit length of the tow 4) which is installed in a conduit 23. The rotary parts of the pump 24 are driven by the output element of the main prime mover 13 by way of a further belt or chain 13e which drives the input element of a variable-speed transmission 26. The output element of the transmission 26 drives the pump 24 by way of a belt or chain 26a. A second pump 27 in the vessel 22 serves to agitate and circulate the supply of liquid plasticizer and to thus ensure that the intake end of the conduit 23 invariably receives such quantities of plasticizer as are required in the housing 18 in view of the momentary speed of the prime mover 13. Since the prime mover 13 drives the tow 4 as well as the pump 24, the quantity of liquid plasticizer which is conveyed into the housing 18 per unit of time is always proportional to the quantity of filter material which is conveyed through the station 12 during the same unit of time. The surplus of plasticizer which is drawn from the vessel 22 via conduit 23 is returned into the vessel by a return line 28.
The housing 18 further contains means for uniformly distributing the admitted liquid plasticizer along the full length of the brush 21. Such distributing means comprises an elongated manifold 29 which is installed in the lower portion of the housing 18 and has one or more elongated channels 31 extending in parallelism with the axis of the brush 21 and receiving plasticizer from the discharge end of the conduit 23. The latter contains a suitable flow metering or monitoring device 32 which is also shown in FIG. 2.
The housing 18 further contains or is connected with a second monitoring device 33 (e.g., a hydroelectronic transducer or any known design) which ascertains the quantity of plasticizer in the lower portion of the housing 18 and generates corresponding electric signals for transmission to a control unit 70 shown in FIG. 2. The flow metering device 32 generates signals which denote whether or not the pump 24 supplies a requisite quantity of plasticizer into the manifold 29, and the monitoring device 33 generates signals denoting whether or not the lower portion of the housing 18 contains an excessive quantity of liquid plasticizer. The monitoring device 33 may also constitute a pressure-responsive switch which simply closes when the static pressure of residual plasticizer which accumulates in the lower portion of the housing 18 exceeds a permissible value, namely, a value which indicates that the rate of conveying of plasticizer into the housing 18 is too high and/or that the tow 4 cannot accept requisite quantities of plasticizer per unit length of its filamentary material. The monitoring device 33 can also be said to detect the quality of the atomizing action of bristles on the core of the rotating brush 21. If the motor 19 is arrested or does not drive the brush 21 at a satisfactory speed, the quantity of residual plasticizer in the housing 18 will increase and the device 33 will transmit an appropriate signal to effect a correction or to stop the main prime mover 13.
In accordance with a feature of the present invention, the housing 18 is further connected with an evacuating pipe or conduit 34 whose left-hand end communicates with the lower portion of the housing and whose discharge end is connected to a chamber 38a at a level about a deformable membrane 38 in a container or reservoir 37 serving to store a predetermined quantity of liquid plasticizer in response to stoppage of the prime movers 13 and 19. The conduit 34 is further connected with or comprises a branch line 34 containing a shutoff valve 36 and discharging into the vessel 22 for the main supply of liquid plasticizer.
The membrane 38 is normally held in a lower end or retracted position by a resilient element such as a coil spring 40 acting upon the piston 39 of a single-acting pneumatic cylinder 41. A similar cylinder 42 is or can be provided to actuate the shutoff valve 36. The cylinders 41 and 42 can receive compressed air or another suitable gaseous fluid by way of a conduit 75 containing a shutoff valve 43. The source of compressed gas for admission into the conduit 75 when the valve 43 is open is shown in FIG. 2, as at 71. FIG. 2 also shows a master switch 72 which can be manipulated by hand or by remote control to arrest the prime movers 13, 19 and to simultaneously transmit a signal to the control unit 70 instead of or in addition to a signal from the monitoring device 32 and/or 33.
The operation is as follows:
When the machine is in use, the prime mover 13 drives the pairs of advancing rolls 3, 9, 11, the pump 24 (by way of the variable-speed transmission 26) and the moving parts of the section or unit 2 (the cutoff 54 is or may be provided with a discrete motor) whereby the rolls 3 draw the tow 4 from the bale 6 and such tow is loosened during travel past the banding devices 7, 8 prior to being stretched during travel between the rolls 9 and 11. The bristles of the rotating brush 21 propel droplets of atomized plasticizer against the tow 4 during travel through the housing 18, and the quantity of plasticizer which is sprayed onto successive unit lengths of the tow 4 is uniform because the prime mover 13 drives not only the rolls 3, 9 and 11 but also the pump 24. In other words, when the speed of the prime mover 13 (and hence the speed of lengthwise movement of the running tow 4) increases, the rate at which the pump 24 supplies liquid plasticizer to the manifold 29 also increases or vice versa. The brush 21 is driven at a constant speed and cooperates with the manifold 29 to atomize successive increments of the stream of liquid plasticizer supplied to its bristles by the channel or channels 31. Those droplets of atomized plasticizer which penetrate through the layer of filamentary material in the path 17 are intercepted by the upper portion of the housing 18 and drip or flow back into the lower portion to be thereby returned into the range of orbiting bristles of the brush 21 which bristles propel the returning liquid against the tow 4 in the path 17. After a relatively short interval of operation of the machine subsequent to starting of the prime movers 13 and 19, the mechanism at the station 12 establishes a state of equilibrium between the quantity of plasticizer which is conveyed into the housing 18 and the quantity of atomized plasticizer which is removed by the running tow 4, i.e., in normal operation the quantity of plasticizer supplied via conduit 23 per unit of time is identical with the quantity of plasticizer removed by the tow 4 from the housing 18. At such time (in normal operation), the control unit 70 maintains the shutoff valve 43 in open position so that the cylinders 41 and 42 receive compressed air from the source 71. Consequently, the branch 35 of the conduit 34 is sealed and the spring 40 in the cylinder 41 is compressed so that the membrane 38 is held in its upper end position and provides little if any room for gravity flow of a certain (predetermined) quantity of liquid plasticizer from the housing 18 into the chamber 38a of the cylinder 41.
If the monitoring device 32 and/or the monitoring device 33 (and/or the master switch 72 which is actuatable by the attendants) transmits a signal denoting that the rate of delivery of at least one component of the filter rod 52 (i.e., of the tow 4 and/or the web 48 and/or the plasticizer) is unsatisfactory, the control unit 70 transmits a signal which causes the valve 43 to connect the cylinders 41 and 42 with the atmosphere (via venting orifice of a nozzle 43a) and to simultaneously seal the two cylinders from the source 71 of compressed gaseous fluid. The spring (not shown) in the cylinder 42 then causes or allows the valve 36 to open and the spring 40 retracts the deformable piston or membrane 38 to its lower end position so that the chamber 38a in the upper part of the container 37 can receive and store a predetermined quantity of liquid plasticizer which flows into the lower part of the housing 18 when the brush 21 is idle. The liquid plasticizer which has penetrated through the filamentary filter material in the path 17 and has accumulated at the inner side of the upper portion of the housing 18 continues to flow toward and into the lower portion of the housing and thence into the intake end of the conduit 34. The liquid flowing in the conduit 34 fills the chamber 38a in the upper portion of the container 37 above the membrane 38 and the remnant of accumulated liquid plasticizer flows through the branch conduit 35, open valve 36 and back into the vessel 22. The quantity of liquid plasticizer which flows through the branch 35 and back into the vessel 22 depends on the duration of interruption, i.e., on the length of the interval during which the bristles of the brush 21 fail to propel finely dispersed droplets of liquid plasticizer against the running tow 4 in the path 17.
The evacuation of residual liquid plasticizer from the lower portion of the housing 18 in response to actuation of the valve 43 by the control unit 70 ensures that the liquid contents of the housing 18 are evacuated to the extent which is necessary to prevent soaking of the tow 4 with liquid plasticizer once the brush 21 is again set in rotary motion. Such soaking could unduly weaken the tow 4 so that the tow would break on renewed starting of the main prime mover 13 and resulting rotation of the advancing rolls 3, 9 and 11. It will be recalled that the tow 4 is stretched downstream of the rolls 3 so that the danger of breakage is quite pronounced provided that the bristles of the brush 21 are permitted to propel excessive quantities (e.g., a veritable flood) of liquid plasticizer against the oncoming increments of the tow 4 in the path 17. The atomizing action is satisfactory when the bristles of the brush 21 receive liquid plasticizer only by way of the channel or channels 31 in the manifold 20 as well as the relatively small quantities of liquid plasticizer which descend into the lower portion of the housing 18 after having penetrated across the path 17 to flow back into the lower portion by trickling along the internal surface of the housing 18 in the regions at both sides of the path 17. However, such atomizing action (if any) may be utterly unsatisfactory if the lower portion of the housing 18 can accumulate a rather large pool of residual liquid plasticizer which has trickled down the internal surface of the housing while the brush 21 was driven at less than satisfactory speed, while the conduit 23 was in the process of delivering an excessive quantity of liquid plasticizer per unit of time, while the filamentary filter material in the path 17 was incapable of accepting and entraining a desired quantity of atomized plasticizer and/or for any other reason which leads to accumulation of excessive quantities of residual plasticizer in the housing 18 while the valve 36 is closed and the capacity of the chamber 38a above the membrane 38 of the container 37 is small or negligible. Under such circumstances, the bristles of the brush 21 propel veritable streams or large drops of liquid plasticizer which thoroughly soaks the tow 4 in the path 17 and can lead to the aforediscussed breakage or, at the very least, to the making of unsatisfactory filter plugs. Thus, once the applied plasticizer sets, it imparts to the filter plugs a certain hardness which might be too pronounced if the respective filter plugs contain excessive quantities of plasticizer. The plasticizer softens the contacted portions of the filaments while it is still in a liquid state and causes such portions to adhere to each other so that the filaments of the filler in a finished filter rod section 56 form a maze of minute paths for the flow of tobacco smoke. If the quantity of applied plasticizer is excessive, the filler of the filter rod section 56 can constitute a solid plug which is devoid of any paths for the flow of tobacco smoke or which offers excessive resistance to such flow. The smoker is annoyed because he or she expects that the resistance to the flow of smoke will be within certain acceptable limits.
As a rule, or at least in many filter rod making machines, the filter rod sections which are produced during acceleration of the machine to normal operating speed are discarded because they are potentially or actually defective, i.e., the tension of the filamentary filter material might not be satisfactory, the ratio of plasticizer to filamentary material per unit length of the filter rod 52 may be excessive or insufficient, the condition of adhesive in the paster 47 might have changed so that the adhesive cannot properly bond the web 48 to the filler (trated and converted tow 4') and/or for other reasons. On the other hand, it is evidently desirable to ensure that the number of rejects during restarting of the machine should be as low as possible, especially in a modern high-speed filter rod making machine which can turn out many thousands of filter plugs per minute. Thus, it is desirable that the aforementioned internal equilibrium in the housing 18 be established shortly or practically immediately after starting of the prime movers 13 and 19. This is accomplished by the control unit 60 which actuates the valve 43 as soon as the motors 13 and 19 are started (the motor 19 can be started in automatic response to starting of the motor 13 or vice versa). The valve 43 then seals the nozzle 43a from the atmosphere and connects the chambers of the cylinders 41, 42 with the source 71 of compressed gaseous fluid. The valve 36 is closed and compressed fluid which flows into the lower portion of the cylinder 41 comprises the spring 40 via piston 39 so that the membrane 38 is moved upwardly and expels the accumulated discrete supply of liquid plasticizer into the conduit 34 and thence into the lower portion of the housing 18, i.e., into the range of the tips of bristles on the rotating brush 21. This ensures that the brush 21 atomizes the liquid plasticizer which is supplied by the pump 24 via conduit 23 and manifold 29 as well as the additional liquid plasticizer which is supplied by the membrane 38 which acts not unlike a plunger or piston and forces the stored quantity of residual liquid plasticizer to return into the lower portion of the housing 18. The marginal portion of the membrane 38 can be sealingly held between two separable (upper and lower) portions or halves of the cylinder 41. It has been found that the admission of liquid plasticizer from the container 37 into the lower portion of the housing 18 ensures the establishment of the aforementioned internal equilibrium even before the prime mover 13 completes the acceleration of advancing rolls 3, 9, 11 and certain moving parts of the unit or section 2 to their normal or average speed.
Once the internal equilibrium is established, the running tow 4 again removes all of the plasticizer which is supplied by the conduit 23 so that the quantity of plasticizer which enters the housing 18 equals the quantity of plasticizer leaving the housing with the properly sprayed tow 4. The aforedescribed operation is repeated again when the prime mover 13 and/or 19 is arrested for any one of a variety of reasons each of which is normally an indicator of improper conveying of filamentary filter material, or improper operation of the unit 2, of improper conveyor of plasticizer via conduit 23, of improper spraying action of the brush 21 or of the inability of filamentary filter material in the housing 18 to accept and retain requisite quantities of atomized plasticizer.
The properly treated tow 4' is then converted into a rod-like filler during travel through the gathering horn 44 and is draped into the web 48 to form therewith the aforementioned continuous rod 52. The rod 52 is severed by the cutoff 54 and the resulting filter rod sections 56 are propelled by the accelerating cam 57 to form one or more rows in the drum-shaped conveyor 58 which delivers the row or rows to the upper reach of the belt conveyor 59 for transport to storage or to the next processing station. The curing of plasticizer in the fillers of the filter rod sections 56 can continue during travel in the peripheral flutes of the conveyor 58, during travel with the belt conveyor 59 or even during storage in the aforementioned reservoir system (such as Resy).
It will be noted that the improved method must satisfy certain contradictory requirements, namely, rapid reestablishment of the supply or quantity of residual plasticizer in the treating zone within the housing 18 but without excessive soaking or wetting of filamentary filter material during acceleration of the tow from zero speed to normal or average speed. The solution is that, when the conveying of tow 4 through the housing 18 (i.e., along the path 17) is interrupted, at least some of the quantity of residual plasticizer in the housing 18 is removed from the treating zone by the simple expedient of providing for such residual plasticizer a storage place or container 37 in close or immediate proximity of the housing 18, and of returning the thus accumulated or withdrawn residual plasticizer into the housing 18 when the conveying of the tow by the rolls 3, 9, 11 is resumed. This means that, when the prime mover 13 is set in motion again, the treating zone in the housing 18 receives liquid plasticizer in quantities exceeding those which are removed by the treated tow 4' but less than would be the case if the residual plasticizer were retained, in its entirety, in the interior of the housing 18 on interruption of conveying of the tow 4 along the path 17. Consequently, the quantity of residual plasticizer in the housing 18 is rapidly restored to its normal value at which an internal equilibrium exists in the treating zone because the quantity of liquid plasticizer admitted via conduit 23 matches the quantity which is removed by the tow 4 on its way from the housing 18 toward the upper roll 11. Such rapid restoration of internal equilibrium takes place without risking excessive soaking or wetting of filamentary filter material with liquid plasticizer because the rate at which the contents of the container 37 are returned into the housing 18 can be regulated practically at will, the same as the quantity of residual plasticizer which is stored in the container 37 rather than being permitted to flow into the branch 35 and back into the main source of plasticizer in the vessel 22.
The improved method can be modified in a number of ways without departing from the spirit of the invention. For example, the container 37 can be omitted and the entire residual plasticizer returned into the vessel 22 as soon as the transport of the tow 4 through the housing 18 is interrupted if the pump 24 is designed or operated in such a way that the rate at which it supplies liquid plasticizer into the housing 18 increases automatically during acceleration of the tow 4, i.e., during that interval which immediately follows first starting or renewed starting of the prime mover 13. Alternatively, the apparatus could include a further pump which would be started and which would remain in operation only during a certain interval following starting of the prime mover 13. The solution which is shown in FIGS. 1 and 2 is preferred at the present time because the container 37 can accumulate an accurately metered quantity of residual plasticizer which has been evacuated from the housing 18 on interruption of transport of the tow 4, and such accurately metered quantity can be returned into the housing 18 during the initial stage of acceleration of the tow 4 on starting of the prime mover 13 following an interruption. When the prime mover 13 is started gain, the pump 24 delivers a stream of liquid plasticizer into the range of bristles of the brush 21 at the rate which is proportional to the speed of the tow 4, and the membrane 38 admits the accumulated residual plasticizer from the chamber 38a of the container 37 into the lowermost part of the housing 18 where the returned plasticizer is entrained and atomized by the bristles of the brush 21 to ensure that the treating zone in the housing 18 can rapidly accumulate the requisite quantity of residual plasticizer which thereupon remains therein while the pump 23 supplies liquid plasticizer via conduit 24 at the same rate at which the tow 4 withdraws atomized plasticizer from the housing 18.
If the container 37 is omitted and the apparatus of the present invention does not employ an additional pump, the pump 24 must be designed and controlled to ensure that, when the prime mover 13 is started, the conduit 23 delivers into the range of the brush 21 liquid plasticizer at a rate which is higher than the normal rate because the pump 24 then constitutes the means for admitting plasticizer that is needed for proper application to successive increments of the running tow 4 plus the plasticizer which is needed to restore the internal equilibrium, i.e., the plasticizer which is needed to accumulate in the housing 18 a predetermined quantity of residual plasticizer which remains in the housing during normal operation of the apparatus, namely, while the rate of admission of plasticizer via conduit 23 matches the rate of evacuation of plasticizer via outlet of the housing 18. The controls for a pump which would increase its output at a lower speed and reduce its output at an elevated speed of the associated motor are rather complex and expensive. Therefore, the provision of the container 37 which allows for utilization of a commercially available gear pump (i.e., a pump whose output or rate of delivery increases with increasing speed of its motor) is preferred at this time. The supply of liquid plasticizer which accumulates in the container 37 constitutes a relatively small reserve which is preferably close to the housing 18 and is available for reintroduction into the housing 18 as soon as the prime mover 13 is started. If desired, the conduit 34 can discharge into the conduit 23 so that only one of these conduits admits liquid plasticizer directly into the housing 18, i.e., into the range of bristles on the rotating brush 21. This brush can be replaced with other atomizing means, e.g., with a nozzle of the type disclosed in commonly owned U.S. Pat. No. 4,132,189 granted Jan. 2, 1979 to Heinz Greve et al.
A separate pump, which is used in addition to the pump 24 and is active only after starting of the prime mover 13, i.e., during acceleration of the tow 4 from zero speed to normal operating speed, is desirable or advantageous when the prime mover 13 is arrested for longer periods of time, e.g., for periods exceeding 60 seconds. Such additional pump is shown at 124 in FIG. 3 of the drawing; it is installed in a conduit 123 which receives liquid plasticizer from the vessel 22. The reference character 124a denotes a timer which is started simultaneously with starting of the prime mover 13 and causes the pump 124 to draw liquid plasticizer from the vessel 22 for a certain interval of time following starting of the prime mover 13. If the apparatus comprises the pump 124, the container 37 may but need not be omitted. If the container 37 is omitted, the conduit 34 merely serves to return all of the residual plasticizer into the vessel 22 if the interval of idleness of the prime mover 13 is sufficiently long to allow for return flow of the entire quantity of residual plasticizer. The pump 124 is adjusted to rapidly restore the requisite quantity of residual plasticizer but without permitting undue wetting of filamentary filter material during acceleration of the tow 4 to normal or average speed. The valve 36 then remains open as long as the prime mover 13 is idle.
It has been found that the improved method invariably ensures rapid restoration of internal equilibrium in the treating zone which is defined and confined by the housing 18, and that such method ensures rapid establishment of internal equilibrium without risking excessive moisturizing of filaments forming the tow 4, even during a very short portion of that interval which is required to accelerate the tow to its normal or average speed. In fact, and as already mentioned above, restoration of the internal equilibrium can be completed well ahead of completion of acceleration of the tow 4 to such normal or average speed. This is due to the fact that, even though the membrane 38 or the pump 124 causes a second stream of liquid plasticizer to enter the housing 18 immediately after starting of the prime mover 13, the rate at which such second stream is supplied can be readily regulated in such a way that the brush 21 or another suitable atomizing device is incapable of propelling excessive quantities (i.e., a flood) of liquid plasticizer against the adjacent increments of the tow 4 while the tow is transported through the housing 18 at less than normal speed because the prime mover 13 is still in the process of accelerating its output element.
Another advantage of the improved method is that the number of rejects is reduced to a bare minimum because there is no need to segregate, due to lack of quality, any filter rod sections which are produced after acceleration of the tow 4 to normal or average speed. In other words, the machine of FIG. 1 can be associated with a mechanism which automatically ejects only those filter rod sections which are produced during acceleration of the tow 4 but none of the sections which are produced when the acceleration of the tow is completed. Preferably automatic ejection or segregation of filter rod sections which are produced during acceleration stage of the tow following a period of idleness of the main prime mover of the filter rod making machine is considered advisable and necessary in order to prevent entry of unsatisfactory filter rod sections into storage, into a reservoir (curing) system, or directly into the magazine of a filter tipping machine. Such filter rod sections are normally unsatisfactory or less than entirely satisfactory because some of the adhesive which is applied by the paster 47 to the web 48 is permitted to become dry or cold (depending on the nature of adhesive) in the region between the paster 47 and the garniture 49 when the prime mover 13 is idle, because the sealer 53 is deactivated (e.g., lifted above the seam of the filter rod 52 therebelow) when the prime mover 13 is idle, because the plasticizer on the flat tow 4' has set in the zone between the rolls 11 and the gathering horn 44 prior to conversion into a rod-like filler, and/or for other reasons. In other words, the plasticizer applying apparatus of the present invention does not contribute to the number of rejects because all of the rejects are caused by phenomena or factors other than the presence of residual plasticizer in the housing 18 in normal operation of the machine and/or the need to prevent excessive wetting of filamentary filter material or renewed starting of the prime mover.
The container 37 will be retained and used even if the apparatus employs the second pump 124 if neither the pump 124 nor the container (when used alone) can guarantee rapid restoration or establishment of a state of equilibrium in the housing 18 after renewed or initial starting of the prime mover 13.
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 and specific aspects of our contribution to the art and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the appended claims.
|
A filter rod making machine wherein a rotary brush which is installed in a housing normally atomizes successive increments of a stream of liquid plasticizer which is supplied thereto by a varibale-delivery pump at a rate matching the speed of transport of a permeable tow of filamentary filter material through the housing so that the housing confines a quantity of residual plasticizer and the tow thereafter continuously withdraws atomized plasticizer from the housing at the rate at which the pump supplies liquid plasticizer into the range of the brush. When the tow is arrested, at least some of the residul plasticizer is evacuated from the housing and, on renewed starting of the prime mover which drives the tow, the plasticizer is admitted at a rate higher than normal rate, either by resorting to a separate pump or by gathering the evacuted residual plasticizer during the interval of idleness of the prime mover and readmitting the gathered residual plasticizer into the housing during acceleration of the tow to normal speed so as to rapidly reestablish the quantity of residual plasticizer which is necessary to ensure that a state of internal equilibrium prevails in the housing, namely, that the rate of admission of liquid plasticizer into the range of the brush again equals the rate at which the running tow removes atomized plasticizer from the housing.
| 8
|
This is a continuation of Ser. No. 07/643,023 filed Jan. 18, 1991, now abandoned; which is a continuation-in-part of Ser. No. 06/787,692 filed Oct. 15, 1985; which is a continuation of Ser. No. 06/644,155 filed Aug. 27, 1984, now abandoned; which is a continuation of Ser. No. 06/555,426 filed Nov. 23, 1983, now abandoned; which is a continuation of Ser. No. 06/178,107 filed Aug. 14, 1980, now abandoned; which Ser. No. 06/555,426 is also a continuation-in-part of Ser. No. 06 6/330,159 filed Dec. 14, 1981, now U.S. Pat. No. 4,430,628; which is a division of Ser. No. 05/973,741 filed Dec. 28, 1978, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to ballasting means for gas discharge lighting means.
2. Description of Prior Art
For a description of pertinent prior art, reference is made to U.S. Pat. No. 4,677,345 to Nilssen; which patent issued from a Division of application Ser. No. 06/178,107 filed Aug. 14, 1980; which application is the original in-part progenitor of instant application.
Otherwise, reference is made to the following U.S. Pat. No. 3,263,122 to Genuit; No. 3,320,510 to Locklair; No. 3,996,493 to Davenport et el.; No. 4,100,476 to Ghiringhelli; No. 4,262,327 to Kovacik et al.; No. 4,370,600 to Zansky; No. 4,634,932 to Nilssen; and No. 4,857,806 to Nilssen.
SUMMARY OF THE INVENTION
Objects of the Invention
A main object of the present invention is that of providing a cost-effective ballasting means for gas discharge lamps.
This as well as other objects, features and advantages of the present invention will become apparent from the following description and claims.
BRIEF DESCRIPTION OF THE INVENTION
In an electronic inverter-type ballast for a gas discharge lamp, a basic and significant problem associated with powering the lamp by way of a current-limiting inductance means more-or-less directly from the inverter's high-frequency (e.g. 30 kHz) squarewave voltage (as opposed to first shaping this squarewave voltage into a sinusoidal voltage by way of a tuned circuit) is that of spurious resonances occurring due to resonant interactions (at harmonic components of the squarewave voltage) between the effective output inductance represented by the current-limiting inductance means and the unavoidable stray capacitance associated with the output wiring means used for connecting between the ballast's output and the lamp. This problem is mainly significant during periods of open circuit operation (such as prior to lamp ignition); but during those periods, the spurious resonances are apt to cause excessive power dissipations within the ballast, thereby potentially causing damage to the ballast. Since the particular capacitance value associated with the output wiring means is an unknown--being dependent on some unknown end-use situation--it is not feasible in a straight forward manner simply to tune the ballast output inductance and/or the inverter's operating frequency such as to avoid these spurious resonances.
Of course, the reason these spurious resonances occur in the first place is that the inverter's squarewave voltage contains a substantial amount of odd harmonic components. In particular, it contains one third (i.e. 33.3%) third harmonics, one fifth (i.e., 20.0%) fifth harmonics, etc.
The usual approach to avoiding the above-mentioned problem of uncontrollable spurious resonances is that of powering the lamp by way of a tuned circuit resonantly tuned to the fundamental component of the inverter's squarewave voltage; and, as a result of this tuning, the problems associated with the harmonic components are substantially eliminated.
In an initial preferred embodiment of the present invention, a half-bridge inverter is powered from a constant DC voltage and provides an AC output voltage that is--in contrast with the usual squarewave voltage--describable as being a sinusoidal waveform with the tops clipped off at some fixed magnitude; or, described differently, a waveform composed of truncated sinusoidal waves; or, described still differently, a waveform having trapezoidally shaped half-cycles. This AC voltage is applied across the primary winding of a so-called reactance transformer, whose loosely coupled secondary winding is connected across a gas discharge lamp. The internal inductive reactance of the secondary winding constitutes a lamp ballasting means by way of limiting the magnitude of the resulting lamp current to a pre-established desired level. Potentially damaging spurious or parasitic resonances--which are very likely to occur under actual operational circumstances with an unloaded secondary winding when the primary winding is supplied with a squarewave voltage--are avoided because of the truncated sinusoidal waveshape of the AC voltage; which truncated sinusoidal shape is efficiently attained by a combination of three factors: (i) using rapidly switching transistors in the inverter; (ii) having the transformer's primary winding exhibit a substantial shunt inductance; and (iii) providing for a slow-down capacitor coupled directly across the primary winding, thereby to substantially slow down the rise time of the inverter's output voltage as compared with what it would have been if it were to have been determined solely by the high switching speed of the transistors.
Otherwise and more generally, the present invention is directed to providing improved gas discharge lighting means and inverter circuits for powering and controlling gas discharge lamps. The inverter circuits according to the present invention are highly efficient, can be compactly constructed and are ideally suited for energizing gas discharge lamps, particularly compact folded "instant-start" "self-ballasted" fluorescent lamps.
According to one feature of the present invention, a series-connected combination of an inductor and a capacitor is provided in circuit with the inverter transistors to be energized upon periodic transistor conduction. Transistor drive current is preferably provided through the use of at least one saturable inductor to control the transistor inversion frequency to be equal to or greater than the natural resonant frequency of the inductor and capacitor combination. The high voltages efficiently developed by loading the inverter with the inductor and capacitor are ideally suited for energizing external loads such as gas discharge lamps. In such an application, the use of an adjustable inductor permits control of the inverter output as a means of adjusting the level of lamp illumination.
According to another feature of the present invention, reliable and highly efficient half-bridge inverters include a saturable inductor in a current feedback circuit to drive the transistors for alternate conduction. The inverters also include a load having an inductance sufficient to effect periodic energy storage for self-sustained transistor inversion. Importantly, improved reliability is achieved because of the relatively low and transient-free voltages across the transistors in these half-bridge inverters.
Further, according to another feature of the present invention, novel and economical power supplies particularly useful with the disclosed inverter circuits convert conventional AC input voltages to DC for supplying to the inverters.
Yet, further, according to still another feature of the invention, a rapid-start fluorescent lamp is powered by way of a series-resonant LC circuit; while heating power for the lamp's cathodes is provided via loosely-coupled auxiliary windings on the tank inductor of the LC circuit. Alternatively, cathode heating power is provided from tightly-coupled windings on the tank inductor; in which case output current-limiting is provided via a non-linear resistance means, such as an incandescent filament in a light bulb, connected in series with the output of each winding.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation of a folded fluorescent lamp unit adapted for screw-in insertion into a standard Edison incandescent socket;
FIG. 2 is a schematic diagram illustrating the essential features of a push-pull inverter circuit particularly suitable for energizing the lamp unit of FIG. 1;
FIG. 3A-3D is a set of waveform diagrams of certain significant voltages and currents occurring in the circuit of FIG. 2;
FIG. 4 is a schematic diagram of a DC power supply connectable to both 120 and 240 volt AC inputs;
FIG. 5 is a schematic diagram which illustrates the connection of a non-self-ballasted gas discharge lamp unit to the FIG. 2 inverter circuit;
FIG. 6 is a schematic diagram which illustrates the use of a toroid heater for regulation of the inverter output;
FIG. 7 is an alternate form of push-pull inverter circuit according to the present invention;
FIG. 8 is a schematic diagram showing the connection of a gas discharge lamp of the "rapid-start" type to an inductor-capacitor-loaded inverter according to the present invention;
FIG. 9 is a schematic diagram illustrating an inverter ballast circuit arrangement wherein a pair of series-connected fluorescent lamps is powered, by way of a reactance transformer, from an inverter output voltage having a trapezoidal (i.e. truncated sinewave) waveform like that of FIG. 3A.
FIG. 10 is a schematic illustration of the reactance transformer used in the circuit arrangement of FIG. 9.
FIG. 11A-11H show various voltage and current waveforms associated with the circuit arrangement of FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a screw-in gas discharge lamp unit 10 comprising a folded fluorescent lamp 11 suitably secured to an integral base 12. The lamp comprises two cathodes 13, 14 which are supplied with the requisite high operating voltage from a frequency-converting power supply and ballasting circuit 16; which, because of its compact size, conveniently fits within the base 12.
The inverter circuit 16 is connected by leads 17, 18 to a screw-type plug 19 adapted for screw-in insertion into a standard Edison-type incandescent lamp socket at which ordinary 120 Volt/60 Hz power line voltage is available. A ground plane comprising a wire or metallic strip 21 is disposed adjacent a portion of the fluorescent lamp 11 as a starting aid. Finally, a manually rotatable external knob 22 is connected to a shaft for mechanical adjustment of the air gap of a ferrite core inductor to vary the inductance value thereof in order to effect adjustment of the inverter voltage output connected to electrodes 13, 14 for controlled variation of the lamp illumination intensity.
With reference to FIG. 2, a power supply 23, connected to a conventional AC input, provides a DC output for supplying a high-efficiency inverter circuit 24. The inverter is operable to provide a high voltage to an external load 26, which may comprise a gas discharge device such as the fluorescent lamp 11 of FIG. 1.
The power supply 23 comprises bridge rectifier having four diodes 27, 28, 29 and 31 connectable to a 240 volt AC supply at terminals 32, 33. Capacitors 34, 36 are connected between a ground line 37 (in turn directly connected to the inverter 24) and to a B+ line 38 and a B- line 39, respectively. The power supply 23 also comprises a voltage doubler and rectifier optionally connectable to a 120 volt AC input taken between the ground line 37 and terminal 33 Or 32. The voltage doubler and rectifier means provides a direct electrical connection by way of line 37 between one of the 120 volt AC power input lines and the inverter 24, as shown in FIG. 2. The bridge rectifier and the voltage doubler and rectifier provide substantially the same DC output voltage to the inverter 24 whether the AC input is 120 or 240 volts. Typical voltages are +160 volts on the B+ line 38 and -160 volts on the B- line 39.
With additional reference to FIG. 4, which shows an alternate power supply 23', the AC input, whether 120 or 240 volts, is provided at terminals 32' and 39. Terminal 39 is in turn connected through a single-pole double-throw selector switch 41 to terminal 37' (for 120 volt operation) or terminal 33' (for 240 volt operation). In all other respects, power supplies 23 and 23' are identical.
The inverter circuit 24 of FIG. 2 is a half-bridge inverter comprising transistors 42, 43 connected in series across the DC voltage output of the power supply 23 on B+ and B- lines 38 and 39, respectively. The collector of transistor 42 is connected to the B+ line 38, the emitter of transistor 42 and the collector of transistor 43 are connected to a midpoint line 44 (designated "M") and the emitter of transistor 43 is connected to the B- line 39. The midpoint line 44 is in turn connected to the ground line 37 through primary winding 46 of a toroidal saturable core transformer 47, a primary winding 48 on an identical transformer 49, an inductor 51 and a series-connected capacitor 52. The inductor 51 and capacitor 52 are energized upon alternate transistor conduction in a manner to be described later.
An external load 26 is preferably taken off capacitor 52, as shown in FIG. 2. The inductor 51, preferably a known ferrite core inductor, has an inductance variable by mechanical adjustment of the air gap in order to effect variation in the level of the inductor and capacitor voltage and hence the power available to the load, as will be described. When the load is a gas discharge lamp such as lamp 11 in FIG. 1, variation in this inductance upon rotation of knob 22 accomplishes a lamp dimming effect.
Drive current to the base terminals of transistors 42 and 43 is provided by secondary windings 53, 54 of transformers 49, 47, respectively. Winding 53 is also connected to midpoint lead 44 through a bias capacitor 56, while winding 54 is connected to the B- lead 39 through an identical bias capacitor 57. The base terminals of transistors 42 and 43 are also connected to lines 38 and 44 through bias resistors 58 and 59, respectively. For a purpose to be described later, the base of transistor 42 can be optionally connected to a diode 61 and a series Zener diode 62 in turn connected to the midpoint line 44; similarly, a diode 63 and series Zener diode 64 in turn connected to the B- line 39 can be connected to the base of transistor 43. Shunt diodes 66 and 67 are connected across the collector-emitter terminals of transistors 42 and 43, respectively. Finally, a capacitor 68 is connected across the collector-emitter terminals of transistor 43 to restrain the rate of voltage rise across those terminals, as will be seen presently.
The operation of the circuit of FIG. 2 can best be understood with additional reference to FIG. 3, which illustrates significant portions of the waveforms of the voltage at midpoint M (FIG. 3A), the base-emitter voltage on transistor 42 (FIG. 3B), the current through transistor 42 (FIG. 3C), and the capacitor 52 voltage and the inductor 51 current (FIG. 3D).
Assuming that transistor 42 is first to be triggered into conduction, current flows from the B+ line 38 through windings 46 and 48 and the inductor 51 to charge capacitor 52 and returns through capacitor 34 (refer to the time period designated I in FIG. 3). When the saturable inductor 49 saturates at the end of period I, drive current to the base of transistor 42 will terminate, causing voltage on the base of the transistor to drop to the negative voltage stored on the bias capacitor 56 in a manner to be described, causing this transistor to become non-conductive. As shown in FIG. 3c, current-flow in transistor 43 terminates at the end of period I.
Because the current through inductor 51 cannot change instantaneously, current will flow from the B- bus 39 through capacitor 68, causing the voltage at midpoint line 44 to drop to -160 volts (period II in FIG. 3). The capacitor 68 restrains the rate of voltage change across the collector and emitter terminals of transistor 42. The current through the inductor 51 reaches its maximum value when the voltage at the midpoint line 44 is zero. During period III, the current will continue to flow through inductor 51 but will be supplied from the B- bus through the shunt diode 67. It will be appreciated that during the latter half of period II and all of period III, positive current is being drawn from a negative voltage; which, in reality, means that energy is being returned to the power supply through a path of relatively low impedance.
When the inductor current reaches zero at the start of period IV, the current through the primary winding 46 of the saturable inductor 47 will cause a current to flow out of its secondary winding 54 to cause transistor 43 to become conductive, thereby causing a reversal in the direction of current through inductor 51 and capacitor 52. When transformer 47 saturates at the end of period IV, the drive current to the base of transistor 43 terminates and the current through inductor 51 will be supplied through capacitor 68, causing the voltage at midpoint line 44 to rise (period V). When the voltage at the midpoint line M reaches 160 volts, the current will then flow through shunt diode 66 (period VI). The cycle is then repeated.
As seen in FIG. 3, saturable transformers 47, 49 provide transistor drive current only after the current through inductor 51 has diminished to zero. Further, the transistor drive current is terminated before the current through inductor 51 has reached its maximum amplitude. This coordination of base drive current and inductor current is achieved because of the series-connection between the inductor 51 and the primary windings 46, 48 of saturable transformers 47, 49, respectively.
The series-connected combination of the inductor 51 and the capacitor 52 is energized upon the alternate conduction of transistors 42 and 43. With a large value of capacitance of capacitor 52, very little voltage will be developed across its terminals. As the value of this capacitance is decreased, however, the voltage across this capacitor will increase. As the value of the capacitor 52 is reduced to achieve resonance with the inductor 51, the voltage on the capacitor will rise and become infinite in a loss-free circuit operating under ideal conditions.
It has been found desirable to regulate the transistor inversion frequency, determined mainly by the saturation time of the saturable inductors 47, 49, to be equal to or higher than the natural resonance frequency of the inductor and capacitor combination in order to provide a high voltage output to external load 26. A high voltage across capacitor 52 is efficiently developed as the transistor inversion frequency approaches the natural resonant frequency of the inductor 51 and capacitor 52 combination. Stated another way, the conduction period of each transistor is desirably shorter in duration than one quarter of the full period corresponding to the natural resonant frequency of the inductor and capacitor combination. When the inverter 24 is used with a self-ballasted gas discharge lamp unit, it has been found that the inversion frequency can be at least equal to the natural resonant frequency of the tank circuit. If the capacitance value of capacitor 52 is reduced still further beyond the resonance point, unacceptably high transistor currents will be experienced during transistor switching and transistor burn-out will occur.
It will be appreciated that the sizing of capacitor 52 is determined by the application of the inverter circuit 24. Variation in the values of the capacitor 52 and the inductor 51 will determine the voltages developed in the inductor-capacitor tank circuit. The external load 26 may be connected in circuit with the inductor 51 (by a winding on the inductor, for example) and the capacitor may be omitted entirely. If the combined circuit loading of the inductor 51 and the external load 26 has an effective inductance of value sufficient to effect periodic energy storage for self-sustained transistor inversion, the current feedback provided by the saturable inductors 47,49 will effect alternate transistor conduction without the need for additional voltage feedback. When the capacitor 52 is omitted, the power supply 23 provides a direct electrical connection between one of the AC power input lines and the inverter load circuit.
Because the voltages across transistors 42, 43 are relatively low (due to the effect of capacitors 34, 36), the half-bridge inverter 24 is very reliable. The absence of switching transients minimizes the possibility of transistor burn-out.
The inverter circuit 24 comprises means for supplying reverse bias to the conducting transistor upon saturation of its associated saturable inductor. For this purpose, the capacitors 56 and 57 are charged to negative voltages as a result of reset current flowing into secondary windings 53, 54 from the bases of transistors 42, 43, respectively. This reverse current rapidly turns off a conducting transistor to increase its switching speed and to achieve inverter circuit efficiency in a manner described more fully in my co-pending U.S. patent application Ser. No. 103,624 filed Dec. 14, 1979 and entitled "Bias Control for High Efficiency Inverter Circuit" (now U.S. Pat. No. 4,307,353). The more negative the voltage on the bias capacitors 56 and 57, the more rapidly charges are swept out of the bases of their associated transistors upon transistor turn-off.
When a transistor base-emitter junction is reversely biased, it exhibits the characteristics of a Zener diode having a reverse breakdown voltage on the order of 8 to 14 Volt for transistors typically used in high-voltage inverters. As an alternative, to provide a negative voltage smaller in magnitude on the base lead of typical transistor 42 during reset operation, the optional diode 61 and Zener diode 62 combination can be used. For large values of the bias capacitor 56, the base voltage will be substantially constant.
If the load 26 comprises a gas discharge lamp, the voltage across the capacitor 52 will be reduced once the lamp is ignited to prevent voltages on the inductor 51 and the capacitor 52 from reaching destructive levels. Such a lamp provides an initial time delay during which a high voltage, suitable for instant starting, is available.
FIG. 5 illustrates the use of an alternate load 26' adapted for plug-in connection to an inverter circuit such as shown in FIG. 2. The load 26' consists of a gas discharge lamp 71 having electrodes 72, 73 and connected in series with a capacitor 74. The combination of lamp 71 and capacitor 74 is connected in parallel with a capacitor 52' which serves the same purpose as capacitor 52 in the FIG. 2 circuit. However, when the load 26' is unplugged from the circuit, the inverter stops oscillating and the development of high voltages in the inverter is prevented. The fact that no high voltages are generated by the circuit if the lamp is disconnected while the circuit is oscillating is important for safety reasons.
FIG. 6 illustrates a capacitor 52" connected in series with an inductor 51" through a heater 81 suitable for heating the toroidal inductors 47, 49 in accordance with the level of output. The load 26" is connected across the series combination of the capacitor 52" and the toroid heater. The heater 81 is preferably designed to controllably heat the toroidal saturable inductors in order to decrease their saturation flux limit and hence their saturation time. The result to decrease the periodic transistor conduction time and thereby increase the transistor inversion frequency. When a frequency-dependent impedance means, that is, an inductor or a capacitor, is connected in circuit with the AC voltage output of the inverter, change in the transistor inversion frequency will modify the impedance of the frequency-dependent impedance means and correspondingly modify the inverter output. Thus as the level of the output increases, the toroid heater 81 is correspondingly energized to effect feedback regulation of the output. Further, transistors 42, 43 of the type used in high voltage inverters dissipate heat during periodic transistor conduction. As an alternative, the toroid heater 81 can use this heat for feedback regulation of the output or control of the temperature of transistors 42, 43.
The frequency dependent impedance means may also be used in a circuit to energize a gas discharge lamp at adjustable illumination levels. Adjustment in the inversion frequency of transistors 42, 43 results in control of the magnitude of the AC current supplied to the lamp. This is preferably accomplished where saturable inductors 47, 49 have adjustable flux densities for control of their saturation time.
FIG. 7 schematically illustrates an alternate form of inverter circuit, shown without the AC to DC power supply connections for simplification. In this Figure, the transistors are connected in parallel rather than in series but the operation is essentially the same as previously described.
In particular, this circuit comprises a pair of alternately conducting transistors 91, 92. The emitter terminals of the transistors are connected to a B- line 93. A B+ lead 94 is connected to the center-tap of a transformer 96. In order to provide drive current to the transistors 91, 92 for control of their conduction frequency, saturable inductors 97, 98 have secondary windings 99, 101, respectively, each secondary winding having one end connected to the base of its associated transistor; the other ends are connected to a common terminal 102. One end of transformer 96 is connected to the collector of transistor 91 through a winding 103 on inductor 98 in turn connected in series with a winding 104 on inductor 97. Likewise, the other end of transformer 96 is connected to the collector of transistor 92 through a winding 106 on inductor 97 in series with another winding 107 on inductor 98.
The B+ terminal is connected to terminal 102 through a bias resistor 108. A bias capacitor 109 connects terminal 102 to the B- lead 93. This resistor and capacitor serve the same function as resistors 58, 59 and capacitors 56, 57 in the FIG. 2 circuit.
The bases of transistors 91, 92 are connected by diodes 111, 112, respectively, to a common Zener diode 113 in turn connected to the B- lead 93. The common Zener diode 113 serves the same function as individual Zener diodes 62, 64 in FIG. 2.
Shunt diodes 114, 116 are connected across the collector-emitter terminals of transistors 91, 92, respectively.
A capacitor 117 connecting the collectors of transistors 91, 92 restrains the rate of voltage rise on the collectors in a manner similar to the collector-emitter capacitor 68 in FIG. 2.
Inductive-capacitive loading of the FIG. 7 inverter is accomplished by a capacitor 118 connected in series with with an inductor 119, the combination being connected across the collectors of the transistors 91, 92. A load 121 is connected across the capacitor 118.
FIG. 8 illustrates how an inverter loaded with a series capacitor 122 and inductor 123 can be used to energize a "rapid-start" fluorescent lamp 124 (the details of the inverter circuit being omitted for simplication). The lamp 124 has a pair of cathodes 126, 127 connected across the capacitor 122 for supply of operating voltage in a manner identical to that previously described. In addition, the inductor 123 comprises a pair of magnetically-coupled auxiliary windings 128, 129 for electrically heating the cathodes 126, 127, respectively. A small capacitor 131 is connected in series with lamp 124.
FIG. 9 shows an embodiment of the present invention that is expressly aimed at an alternative way of taking advantage of the fact that the inverter output voltage of the inverter circuit arrangement of FIG. 2 has the particular trapezoidal waveshape illustrated by FIG. 3A.
In FIG. 9, a DC supply voltage of about 320 Volt is assumed to be provided between a B- bus and a B+ bus.
A first high-frequency bypass capacitor BPC1 is connected between the B- bus and a junction Jc; and a second high-frequency bypass capacitor BPC2 is connected between junction Jc and the B+ bus. The source of a first field effect transistor FET1 is connected with the B- bus, while the drain of this same transistor is connected with a junction Jf. The source of a second field effect transistor FET2 is connected with junction Jf, while the drain of this same transistor is connected with the B+ bus. As shown in dashed outline, each field effect transistor has a commutating diode built-in between its drain and source. A slow-down capacitor SDC is connected between junction Jf and the B- bus.
The primary winding PW of a leakage transformer LT is connected between junction Jc and a junction Jx; the primary winding PW1 of a first saturable current transformer SCT1 is series-connected with the primary winding PW2 of a second saturable current transformer SCT2 between junctions Jf and Jx.
A secondary winding SW1 of transformer SCT1 is connected between the source and gate terminals of FET1; and a secondary winding SW2 of transformer SCT2 is connected between the source and gate terminals of FET2. A resistor R1 is connected across secondary winding SW1; and a resistor R2 is connected across secondary winding SW2. A Zener diode Z1a is connected with its cathode to the source of FET1 and with its anode to the anode of a Zener diode Z1b, whose cathode is connected with the gate of FET1. A Zener diode Z2a is connected with its cathode to the source of FET2 and with its anode to the anode of a Zener diode Z2b, whose cathode is connected with the gate of FET2.
A secondary winding SW of leakage transformer LT is connected between ballast output terminals BOT1 and BOT2.
A first fluorescent lamp FL1 is series-connected with a second fluorescent lamp FL2 to form a series-combination; which series-combination is connected between ballasts output terminals BOT1 and BOT2. Lamp FL1 has a first cathode C1a and a second cathode C1b; while lamp FL2 has a first cathode C2a and a second cathode C2b. Each cathode has two cathode terminals. Each of the terminals of cathode C1b is connected with one of the terminals of cathode C2a. Each cathode's terminals are connected with the terminals of one of three separate cathode heater windings CHW.
The leakage transformer of FIG. 9 is illustrated in further detail in FIG. 10. In particular and by way of example, leakage transformer LT includes a first and a second ferrite core element FC1 and FC2, each of which is an extra long so-called E-core; which E-cores abut each other across an air gap AG. Primary winding PW is wound on a first bobbin B1; and secondary winding SW is wound on a second bobbin B2. Cathode heating windings CHW are wound on a small third bobbin B3; which bobbin B3 is adjustably positioned between bobbins B1 and B2.
The operation of the circuit arrangement of FIG. 9 may best be understood by referring to the voltage and current waveforms of FIGS. 11A to 11F.
FIG. 11A shows the waveform of the voltage provided at the output of the half-bridge inverter of FIG. 9 during a situation where lamps FL1 and FL2 are being fully powered. In particular, FIG. 11A shows the waveform of the voltage provided at junction Jf as measured with reference to junction Jc. (The voltage at Jx is substantially equal to the voltage at Jf).
This waveform is substantially equal to that of FIG. 3A.
FIG. 11B shows the corresponding waveform of the gate-to-source voltage (i.e. the control voltage) of FET2.
FIG. 11C shows the corresponding drain current flowing through FET2; which is the current drawn by the upper half of the half-bridge inverter from the DC supply voltage (i.e., from the B+ bus).
FIG. 11D shows the corresponding current flowing through fluorescent lamps FL1 and FL2.
FIG. 11E shows the waveform of the voltage provided at the output of the half-bridge inverter of FIG. 9 for a situation where ballast output terminals BOT1/BOT2 are unloaded except for stray (or parasitic) capacitance associated with the wiring extending between ballast output terminals BOT1/BOT2 and lamp cathodes C1a and C2b.
The waveform of FIG. 11E is substantially equal to that of FIG. 11A except for an increase in the duration of each cycle period.
FIG. 11F shows the corresponding open circuit output voltage present across ballast output terminals BOT1 and BOT2.
FIG. 11G shows the waveform of the voltage provided at the output of the half-bridge inverter of FIG. 9 for a situation where: (i) slowdown capacitor SDC has been removed; and (ii) ballast output terminals BOT1/BOT2 are unloaded except for stray (or parasitic) capacitance associated with the wiring extending between ballast output terminals BOT1/BOT2 and lamp cathodes C1a and C2b.
It is noted that the waveform of FIG. 11G is substantially a true squarewave as opposed to the trapezoidal (or truncated sinusoidal) waveforms of FIGS. 11A and 11E.
FIG. 11H shows the waveform of the corresponding voltage present across ballast output terminals BOT1 and BOT2.
The basic inverter part of FIG. 9 operates much like the inverter part of FIG. 2, except that the switching transistors are field effect transistors instead of bi-polar transistors.
The loading of the inverter, however, is different. In the circuit of FIG. 9, the inverter's output voltage is applied to the primary winding of a leakage transformer (LT); and the output is drawn from a primary winding of this leakage transformer. In this connection, it is important to notice that a leakage transformer is a transformer wherein there is substantial leakage of magnetic flux between the primary winding and the secondary winding; which is to say that a substantial part of the flux generated by the transformer's primary winding does not link with the transformer's secondary winding.
The flux leakage aspect of transformer LT is illustrated by the structure of FIG. 10. Magnetic flux generated by (and emanating from) primary winding PW passes readily through the high-permeability ferrite of ferrite core FC1. However, as long as secondary winding SW is connected with a load at its output (and/or if there is an air gap, as indeed there is), the flux emanating from the primary winding has to overcome magnetic impedance to flow through the secondary winding; which implies the development of a magnetic potential difference between the legs of the long E-cores--especially between the legs of ferrite core FC1. In turn, this magnetic potential difference causes some of the magnetic flux generated by the primary winding to flow directly between the legs of the E-cores (i.e. directly across the air gap between the legs of the E-cores), thereby not linking with (i.e. flowing through) the secondary winding. Thus, the longer the legs of the E-cores and/or the larger the air gap, the less of the flux generated by the primary winding links with the secondary winding--and conversely. As a result, the magnitude of the current available from the secondary winding is limited by an equivalent internal inductance.
Due to the substantial air gap (AG), the primary winding of leakage transformer LT is capable of storing a substantial amount of inductive energy (just as is the case with inductor 51 of FIG. 2). Stated differently but equivalently, leakage transformer LT has an equivalent input-shunt inductance (existing across the input terminals of its primary or input winding) capable of storing a substantial amount of energy. It also has an equivalent output-series inductance (effectively existing in series with the output terminals of its secondary or output winding) operative to limit the magnitude of the current available from its output. It is important to recognize that the input-shunt inductance is an entity quite separate and apart from the output-series inductance.
Just as in the circuit of FIG. 2, when one of the transistors is switched OFF, the current flowing through primary winding PW can not instantaneously stop flowing. Instead, it must continue to flow until the energy stored in the input-shunt inductance is dissipated and/or discharged. In particular and by way of example, at the moment FET2 is switched OFF, current flows through primary winding PW, entering at the terminal connected with junction Jx and exiting at the terminal connected with junction Jc. Just after the point in time where FET2 is switched OFF, this current will continue to flow, but--since it can not any longer flow through transistor FET2--it must now flow through slow-down capacitor SDC. Thus, the current drawn out of capacitor SDC will cause this capacitor to change its voltage: gradually causing it to decrease from a magnitude of about +160 Volt (which is the magnitude of the DC supply voltage present at the B+ bus as referenced-to junction Jc) to about -160 Volt (which is the magnitude of the DC supply voltage present at the B- bus as referended-to junction Jc). Of course, as soon as it reaches about -160 Volt, it gets clamped by the commutating (or shunting, or clamping) diode built-into FET1; which built-in diode corresponds to shunting diode 67 of the FIG. 2 circuit.
The resulting waveform of the inverter's output voltage will be as illustrated by FIGS. 11A and 11E. The slope of the inverter output voltage as it alternatingly changes between -160 Volt and +160 Volt is determined by two principal factors: (i) the value of the input-shunt inductance of primary winding PW; and (ii) the magnitude of slow-down capacitor SDC. The lower the capacitance of the slow-down capacitor, the steeper the slope. The lower the inductance of the input-shunt inductance, the steeper the slope. Without any slow-down capacitor, the slope will be very steep: limited entirely by the basic switching speed of the inverter's transistors; which, for field effect transistors is particularly high (i.e. fast).
In particular, in the circuit of FIG. 9, the relatively modest up- and down- slopes of the inverter's output voltage (see waveforms of FIGS. 11A and 11E)--which are determined by the capacitance of the slow-down capactitor--are chosen to be far lower than the very steep slopes that result when the slow-down capacitor is removed; which latter situation is illustrated by FIG. 11G. In fact, the slopes of the inverter's output voltage are chosen in such manner as to result in this output voltage having a particularly low content of harmonic components, thereby minimizing potential problems associated with unwanted resonances of the output-series inductance with parasitic capacitances apt to be connected with ballast output terminals BOT1/BOT2 by way of more-or-less ordinary wiring harness means used for connecting between these output terminals and the associated fluorescent lamps (FL1 and FL2).
With the preferred capacitance value of slow-down capacitor SDC, the inverter output voltage waveform will be as shown in FIGS. 11E, and the output voltage provided from secondary winding SW--under a condition of no load other than that resulting from a parasitic resonance involving a worst-value of parasitic output capacitance--will be as shown in FIG. 11F.
On the other hand, without having any slow-down capacitor, the inverter output voltage waveform will be as shown in FIG. 11G, and the output voltage provided from secondary winding SW --under a condition of no load other than that resulting from a parasitic resonance involving a worst-value of parasitic output capacitance--will be as shown in FIG. 11H. Under this condition, the power drawn by the inverter from its DC supply is more than 50 Watt; which power drain result from power dissipations within the inverter circuit and--if permitted to occur for more than a very short period--will cause the inverter to self-destruct.
On the other hand, the power drawn by the inverter under the same identical condition except for having modified the shape of the inverter's output voltage to be like that of FIG. 11E (instead of being like that of FIG. 11G) is only about 3 Watt; which amount of power drain is small enough not to pose any problem with respect to inverter self-destruction, nor even with respect to excessive power usage during extended periods where the inverter ballast is connected with its power source but without actually powering its fluorescent lamp load.
One difference between the circuit of FIG. 2 and that of FIG. 9 involves that fact that the FIG. 9 circuit uses field effect transistors. Never-the-less, the control of each transistor is effected by way of saturable current feedback transformers. However, instead of delivering its output current to a base-emitter junction, each current transformer now delivers its output current to a pair of series-connected opposed-polarity Zener diodes (as parallel-connected with a damping resistor and the gate-source input capacitance). The resulting difference in each transistor's control voltage is seen by comparing the waveform of FIG. 3B with that of FIG. 11B. In either case, however, the transistor is not switched into it ON-state until after the absolute magnitude of the voltage across its switched terminals (i.e. the source-drain terminals for a FET) has substantially diminished to zero.
In further contrast with the arrangement of FIG. 2, the inverter circuit of FIG. 9 is not loaded by way of a series-tuned L-C circuit. Instead, it is in fact loaded with a parallel-tuned L-C circuit; which parallel-tuned L-C circuit consists of the slow-down capacitor SDC as parallel-connected with the input-shunt inductance of primary winding PW. Yet, in complete contrast with other inverters loaded with parallel-tuned L-C circuits, the inverter of FIG. 9 is powered from a voltage source providing a substantially fixed-magnitude (i.e. non-varying) DC voltage.
Also in complete contrast with other inverters loaded with parallel-tuned L-C circuits, the inverter circuit of FIG. 9 provides for clamping (or clipping or truncating) of the naturally sinusoidal resonance voltage that would otherwise (i.e. in the absence of clamping) develop across the parallel-tuned L-C circuit; which naturally sinusoidal resonance voltage is illustrated by the dashed waveform of FIG. 11E.
In the FIG. 9 circuit, the indicated voltage clamping (or clipping or truncating) is accomplished by way of the commutating (or shunting) diodes built into each of the field effect switching transistors. In the FIG. 2 circuit, this clamping is accomplished by shunting diodes 66 and 67.
As previously indicated, to minimize the spurious and potentially damaging resonances which might occur due to an unknown parasitic capacitance becoming connected with ballast output terminals BOT1 and BOT2, it is important to minimize the harmonic content of the inverter's output voltage (which harmonic content--for a symmetrical inverter waveform--consists of all the odd harmonics in proportionally diminishing magnitudes). To attain such harmonic minimization, it is important that the inverter's output voltage be made to match or fit as nearly as possible the waveform of a sinusoidal voltage; which "best fit" occurs when the duration of the up/down-slopes equals about 25% of the total cycle period; which, as can readily be seen by direct visual inspection, corresponds closely to the waveforms actually depicted by FIGS. 3A, 11A and 11E.
However, substantial beneficial effects actually results even if the total duration of the up/down slopes were to be less than 25% of the total duration of the inverter output voltage period. In fact, substantial beneficial effects are attained with up-down slopes constituting as little as 10% of the total cycle period.
ADDITIONAL EXPLANATIONS AND COMMENTS
(a) With reference to FIGS. 2 and 5, adjustment of the amount of power supplied to load 26', and thereby the amount of light provided by lamp 71, may be accomplished by applying a voltage of adjustable magnitude to input terminals IP1 and IP2 of the Toroid Heater; which is thermally coupled with the toroidal ferrite cores of saturable transformers 47, 49.
(b) With commonly available components, inverter circuit 24 of FIG. 2 can be made to operate efficiently at any frequency between a few kHz to perhaps as high as 50 kHz. However, for various well-known reasons (i.e., eliminating audible noise, minimizing physical size, and maximizing efficiency), the frequency actually chosen is in the range of 20 to 40 kHz.
(c) The fluorescent lighting unit of FIG. 1 could be made in such manner as to permit fluorescent lamp 11 to be disconnectable from its base 12 and ballasting means 16. However, if powered with normal line voltage without its lamp load connected, frequency-converting power supply and ballasting circuit 16 is apt to self-destruct.
To avoid such self-destruction, arrangements can readily be made whereby the very act of removing the load automatically establishes a situation that prevents the possible destruction of the power supply and ballasting means. For instance, with the tank capacitor (52) being permanently connected with the lamp load (11)--thereby automatically being removed whenever the lamp is removed--the inverter circuit is protected from self-destruction.
(d) At frequencies above a few kHz, the load represented by a fluorescent lamp--once it is ignited--is substantially resistive. Thus, with the voltage across lamp 11 being of a substantially sinusoidal waveform (as indicated in FIG. 3d), the current through the lamp will also be substantially sinusoidal in waveshape.
(e) In the fluorescent lamp unit of FIG. 1, fluorescent lamp 11 is connected with power supply and ballasting circuit 16 in the exact same manner as is load 26 connected with the circuit of FIG. 2. That is, it is connected in parallel with the tank capacitor (52) of the L-C series-resonant circuit. As is conventional in instant-start fluorescent lamps--such as lamp 11 of FIG. 1--the two terminals from each cathode are shorted together, thereby to constitute a situation where each cathode effectively is represented by only a single terminal. However, it is not necessary that the two terminals from each cathode be shorted together; in which case--for instant-start operation--connection from a lamp's power supply and ballasting means need only be made with one of the terminals of each cathode.
(f) In FIG. 9, a Parasitic Capacitance is shown as being connected across terminals BOT1 and BOT2. The value of this parasitic capacitance may vary over a wide range, depending on unpredictable details of the particular usage situation at hand. Values for the parasitic capacitance will expectedly vary between 100 and 1000 pico-Farad--depending on the nature of the wiring harness used for connecting between the output of secondary winding SW and the plural terminals of lamps FL1/FL2.
(g) The worst case of parasitic oscillation associated with the circuit arrangement of FIG. 9 is apt to occur when the value of the parasitic capacitance (i.e., the capacitance of the ballast-to-lamp wiring harness) is such as to cause series-resonance with the output-series inductance of secondary winding SW at the third harmonic component of the inverter's output voltage. The next worst case of parasitic oscillation is apt to occur when the value of the parasitic capacitance is such as to series-resonate with the output-series inductance at the fifth harmonic component of the inverter's output voltage. With the typical value of 5.4 milli-Henry for the output-series inductance, it takes a total of about 600 pico-Farad to resonate at the third harmonic component of the inverter's 30 kHz output voltage; and it takes about 220 pico-Farad to resonate at the fifth harmonic component of the inverter's output voltage. These capacitance values are indeed of such magnitudes that they may be encountered in an actual usage situation of an electronic ballast. Moreover, at higher inverter frequencies, the magnitudes of the critical capacitance values become even lower.
(h) FIG. 10 shows cathode heater windings CHW placed on a bobbin separate from that of primary winding PW as well as separate from that of secondary winding SW. However, in many situations, it would be better to place the cathode heater windings directly onto the primary winding bobbin B1. In other situations it would be better to place the cathode heater windings directly onto the secondary winding bobbin B2.
If the cathode heater windings are wound on bobbin B1 (i.e. in tight coupling with the primary winding), the magnitude of the cathode heating voltage will remain constant regardless of whether or not the lamp is ignited; which effect is conducive to maximizing lamp life. On the other hand, if the cathode heater windings are wound on bobbin B2 (i.e. in tight coupling with the secondary winding), the magnitude of the cathode heating voltage will be high prior to lamp ignition and low after lamp ignition; which effect is conducive to high luminous efficacy.
By placing the cathode heater windings in a location between primary winding PW and secondary winding SW, it is possible to attain an optimization effect: a maximization of luminous efficacy combined with only a modest sacrifice in lamp life. That is, by adjusting the position of bobbin B3, a corresponding adjustment of the ratio of pre-ignition to post-ignition cathode heater voltage magnitude may be accomplished.
(i) For easier lamp starting, a starting aid capacitor may be used in shunt across one of the fluorescent lamps FL1/FL2.
Also, a starting aid electrode (or ground plane) may advantageously be placed adjacent the fluorescent lamps; which starting aid electrode should be electrically connected with the secondary winding, such as via a capacitor of low capacitance value.
(j) To control (reduce) the degree of magnetic coupling between primary winding PW and secondary winding SW, a magnetic shunt may be positioned across the legs of the E-cores--in a position between bobbins B1 and B3.
(k) Considering the waveforms of FIGS. 1A, 11A and 11E each to include 360 degrees for each full and complete cycle: (i) each half-cycle would include 180 degrees; (ii) each total up-slope would include almost or about 60 degrees degrees; (iii) each total down-slope would include almost or about 60 degrees; and (iv) each horizontal segment would include about 120 degrees or more. Yet, as previously indicated, substantial utility may be attained even if each complete up-slope and down-slope were to include as little 18 degrees.
(l) In the FIG. 9 circuit, the inverter's operating frequency does not have to be equal to the natural resonance frequency of the parallel-tuned L-C circuit that consists of slow-down capacitor SDC and the input-shunt inductance of primary winding PW. In fact, depending in part on the degree of slow-down chosen, the inverter's actual operating frequency may be higher or lower than would be this natural resonance frequency.
(m) In a trapezoidal waveform that constitutes a best fit for a sinusoidal waveform, the peak magnitude is lower than that of the sinusoidal waveform, and the up-slope and down-slope are each steeper that the corresponding slopes of the sinusoidal waveform.
(n) The FIG. 9 inverter arrangement has to be triggered into self-oscillation. A suitable automatic triggering means would include a resistor, a capacitor, and a so-called Diac. However, manual triggering may be accomplished by merely momentarily connecting a discharged capacitor (of relatively small capacitance value) between the gate of transistor FET1 and the B+ bus.
(o) Most switching-type field effect transistors have built-in commutating (or shunting) diodes, as indicated in FIG. 9. However, if such were not to be the case, such diodes should be added externally, as indicated in the FIG. 2 circuit.
(p) In ordinary inverter circuits, the inverter output voltage is effectively a squarewave voltage with very steep up-slopes and down-slopes. In inverters using field effect transistors, the time required for the inverter's squarewave output voltage to change between its extreme negative potential to its extreme positive potential is usually on the order of 100 nano-seconds or less. In inverters using bi-polar transistors, this time is usually on the order of 500 nano-seconds or less. In the inverter of the FIG. 9 circuit, however, this time has been extended--by way of the large-capacitance-value slow-down capacitor SDC--to be on the order of several micro-seconds, thereby achieving a substantial reduction of the magnitudes of the harmonic components of the inverter's (now trapezoidal) output voltage.
(q) In an actual prototype of the FIG. 9 ballast circuit --which prototype was designed to properly power two 48 inch 40 Watt T-12 fluorescent lamps--the following approximate parameters and operating results prevailed:
1. operating frequency: about 30 kHz;
2. slow-down capacitor: 0.02 micro-Farad;
3. shunt-input inductance: 1.4 milli-Henry;
4. up-slope duration: about 4 micro-seconds;
5. down-slope duration: about 4 micro-seconds;
6. series-output inductance: 5.4 milli-Henry;
7. parasitic capacitance across BOT1/BOT2 terminals; 800 pico-Farad;
8. power consumption when unloaded: about 4 Watt;
9. power consumption when loaded with two F40/T12 fluorescent lamps: about 70 Watt;
10. power consumption when unloaded but with slow-down capacitor removed: about 80 Watt.
It is be noted that the natural resonance frequency of the L-C circuit consisting of a slow-down capacitor of 0.02 micro-Farad as parallel-combined with a shunt-input inductance of about 1.4 milli-Henry is about 30 kHz. This means that as far as the fundamental component of the 30 kHz inverter output voltage is concerned--the parallel-tuned L-C circuit represents a very high impedance, thereby constituting no substantive loading on the inverter's output.
(r) Of course, the FIG. 9 ballast circuit can be made in the form of a push-pull circuit such as illustrated by FIG. 7; in which case center-tapped transformer 96 would be modified in the sense of being made as a leakage transformer in full correspondence with leakage transformer LT of FIG. 9. Also, of course, inductor 119, capacitor 118, and load 121 would be removed. Instead, the load would be placed at the output of the secondary winding of the modified center-tapped transformer 96; which would be made such as to have appropriate values of input-shunt inductance and output-series inductance. Capacitor 117 would constitute the slow-down capacitor.
(s) It is thought that the present invention and many of its attendant advantages will be understood from the foregoing description and that many changes may be made in the form and construction of its components parts, the form described being merely a preferred embodiment of the invention.
|
A half-bridge inverter is powered from a constant DC voltage and provides an AC output voltage that is--in contrast with the usual squarewave voltage--describable as being a sinusoidal waveform with the tops clipped off at some fixed magnitude; or, described differently, a waveform composed of truncated sinusoidal waves; or, described still differently, a waveform having trapezoidally shaped half-cycles. This AC voltage is applied across the primary winding of a so-called reactance transformer, whose loosely coupled secondary winding is connected across a gas discharge lamp. The internal inductive reactance of the secondary winding constitutes a lamp ballasting means by way of limiting the magnitude of the resulting lamp current to a pre-established desired level. Potentially damaging parasitic resonances--which are very likely to occur under actual operational circumstances with an unloaded secondary winding when the primary winding is supplied with a squarewave voltage--are avoided because of the tuncated sinusoidal waveshape of the AC voltage; which truncated sinusoidal shape is effeciently attained by a combination of three factors: (i) using rapidly switching transistors in the inverter; (ii) having the transformer's primary winding exhibit a substantial shunt inductance; and (iii) providing for a slow-down capacitor coupled directly across the primary winding, thereby to substantially slow down the rise time of the inverter's output voltage as compared with what it would have been if it were to have been determined solely by the high switching speed of the transistors.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to catalysts for treating waste gases comprising nitrogen oxides. More particularly, the invention relates to prolongation in life of catalysts of the type which is very useful when applied to a process of treating waste gases comprising nitrogen oxides (hereinafter referred to simply as NOx) in which after addition of ammonia to the waste gas, NOx in the waste gas is suitably reduced with the catalyst into non-noxious gases.
2. Description of the Prior Art
As is well known in the art, waste gases from combustion furnaces such as large-size boilers for use in electric power plants and boilers for independent electric power plants, incinerators and chemical plants comprise NOx. Air pollution with NOx is one of serious social problems to solve. To this end, there have been developed a number of apparatus for the denitrification of waste gases. At present, selective catalytic reduction processes are predominantly used in which waste gases are treated in the presence of catalysts using ammonia as a reducing agent.
The catalysts used in the denitrifying apparatus should have not only high activity, but also a long-term performance stability.
According to our analysis of catalysts used in practical apparatus and various laboratory tests, it was found that denitrification catalysts deteriorated in performance by accumulation of alkali metal components such as Na and K contained in waste gas dust with an attendant shortage of the catalyst life.
SUMMARY OF THE INVENTION
The present invention is accomplished as a result of extensive studies made to reduce a degree of lowering of the catalytic performance caused by accumulation of the alkali metal components.
According to the present invention, there is provided a catalyst for treating waste gases comprising NOx which comprises an active metal-free protonized zeolite coating on a surface of any known catalyst for these purposes in a predetermined thickness whereby the alkali metal contained in waste gas dust are collected with the coating to suppress poisoning of catalytic active ingredients, thus prolong the life of the ingredients. More particularly, there is provided a catalyst for treating waste gases comprising nitrogen oxides by a process which comprises adding ammonia to the waste gas and reducing the nitrogen oxides with catalytic ingredients of the catalyst to convert the nitrogen oxides into non-noxious compounds, the catalyst comprising catalytic ingredients for nitrogen oxides and a coating formed on the catalytic ingredients and consisting of a protonized zeolite. The coating is preferably in a thickness of from 10 to 50 μm.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 through 4 are graphical representations of initial activity and life of catalysts of the present invention (indicated as values relative to values of coating-free catalysts) in relation to the coating thickness.
DETAILED DESCRIPTION OF THE INVENTION
The zeolite being coated on the catalyst according to the invention may be any of zeolite X, zeolite Y, mordenite and zeolite ZSM-5. These zeolites are used after protonization in a manner as will be particularly described in examples appearing hereinafter. The thickness of the coating is favorably over 10 μm, inclusive, because too thin a coating does not show a satisfactory effect. On the other hand, when the coating is too thick, the initial activity of the catalytic ingredients lowers and is not thus favorable. In this connection, catalysts which are currently employed for these purposes allow NOx and NH 3 to proceed very rapidly, so that the thickness may be up to about 50 μm within which the initial activity is not impeded significantly.
The catalytic ingredients useful in the practice of the invention may be any known ingredients and include, for example, V 2 O 5 , WO 3 , MoO 3 , Cr 2 O 3 and mixtures thereof, preferably, supported on a suitable carrier such as TiO 2 , Al 2 O 3 and the like.
The present invention is more particularly described by way of examples.
EXAMPLE 1
Na-X type zeolite was ion-exchanged with an aqueous NH 4 Cl solution and sintered at 500° C. for protonization. The resulting zeolite was dispersed in water to obtain an aqueous slurry, followed by coating onto a catalyst of 1 wt% of V 2 O 5 and 8 wt% of WO 3 supported on TiO 2 (anatase) in different thicknesses of 5, 10, 20, 30, 50 and 70 μm. The resulting catalysts were subjected to initial activity and life tests. The test results are shown in FIG. 1 in comparison with the results of a coating-free catalyst.
As will be seen from FIG. 1, the life of the coated catalysts remarkably increases by the coating of the protonized zeolite X.
EXAMPLE 2
The general procedure of Example 1 was repeated using protonized zeolite Y in thicknesses of 5, 10, 20, 30, 50 and 70 μm. The results of the initial activity and life tests are shown in FIG. 2 in comparison with the results of a coating-free catalyst.
As will be seen from FIG. 2, the life of the coated catalysts significantly increases by the coating of the protonized zeolite Y.
EXAMPLE 3
The general procedure of Example 1 was repeated except that zeolite ZSM-5 was protonized by treatment with HCl solution and coated in thicknesses of 5, 10, 20, 30, 50 and 70 μm. The initial activity and life tests were carried out.
The results in comparison with the results of a coating-free catalyst are shown in FIG. 3, revealing that the life of the coated catalysts remarkably increases as compared with the life of the coating-free catalyst.
EXAMPLE 4
The general procedure of Example 1 was repeated except that mordenite was protonized in the same manner as in xample 1 and coated on a catalyst of 10 wt% of V 2 O 5 on alumina in thicknesses of 10, 30, 50 and 70 μm. The respective catalysts were subjected to the initial activity and life tests.
The results of the tests are shown in FIG. 4 in comparison with the results of the coating-free catalyst, revealing that the life of the coated catalysts remarkably increases.
EXAMPLE 5
Protonized zeolites indicated in Table 1 were coated on catalysts indicated in Table 1 in thicknesses indicated in Table 1 to obtain coated catalysts. These coated catalysts were subjected to the initial activity and life tests with the results shown in Table 1.
As will be seen from Table 1, all the coated catalysts show remarkably prolonged life though slightly lowering with respect to the initial activity.
TABLE 1______________________________________Effects of Zeolite Coatings on the Life of Denitrifying Catalysts Coating Initial Kind of Thickness Activity LifeCatalyst Zeolite (μm) *1 *1______________________________________10 wt % WO.sub.3 /TiO.sub.2 Y type 40 0.86 1.8 " ZSM-5 40 0.88 1.9 " mordenite 40 0.85 1.715 wt % MoO.sub.3 /TiO.sub.2 Y type 40 0.87 1.6 " ZSM-5 40 0.87 1.7 " mordenite 40 0.86 1.65 wt % V.sub.2 O.sub.5 /TiO.sub.2 X type 50 0.85 2.0 " mordenite 50 0.85 2.0 " Y type 50 0.87 1.912 wt % Cr.sub.2 O.sub.3 /Al.sub.2 O.sub.3 Y type 30 0.92 1.5 " mordenite 30 0.93 1.5______________________________________ Note *1 The activity and life are indicated as an index to a coatingfree catalyst.
|
A catalyst for treating waste gases comprising nitrogen oxides, which catalyst comprises a protonized zeolite coating formed on the surface of a catalytic ingredient. This type of catalyst has a prolonged life and is very useful in treating waste gases comprising nitrogen oxides by adding ammonia to the waste gas and reducing the nitrogen oxides in the waste gas with the catalyst to render the nitrogen oxides non-noxious.
| 1
|
BACKGROUND OF THE INVENTION
[0001] Fluorescence microscopy is an essential tool in microbiology and medicine. In fluorescence, light of one wavelength is absorbed by molecules and re-emitted at a different wavelength. The absorption and emission wavelengths depend on the specific molecules. The separation in wavelengths between absorption and emission allows the background of non-fluorescent light to be filtered from the fluorescence signal, enhancing the sensitivity and providing for quantitative image analysis. In epifluorescence microscopy, the excitation light passes to the sample through the microscope objective that captures the fluorescent light, requiring access to one side of a sample only and allowing fluorescence microscopy on non-transparent objects. An assembly of precision filters and beam-splitters is typically used in epifluorescence. These elements are often conventionally mounted in an interchangeable filter cube that is inserted into a suitably designed microscope by the microscope operator.
[0002] Unfortunately, the filter cubes and microscopes are expensive objects. Operators may introduce dust, which can affect image quality, while changing out filter sets. Moreover, the conventional optical arrangement in epifluorescence microscopes passes the fluorescence through an inclined beamsplitter, with adverse effects on the microscope image.
SUMMARY OF THE INVENTION
[0003] The object of the present invention is to create an epifluorescence microscope that does not suffer from these conventional drawbacks. Embodiments of the present invention achieve a compact form factor without sacrificing optical sensitivity by the novel use of combined optic mounts and light baffles constructed using additive manufacturing processes. The use of additive manufacturing enables stray-light-capturing structures that are not practical to make by other techniques. The compact form of the microscope reduces cost, weight, and improves stiffness with no reduction in optical performance over larger conventional microscopes. Some embodiments of the present invention do not require installation of filters by an operator, reducing the likelihood of dust and contamination on optical surfaces. Some embodiments of the present invention employ a novel light path that avoids passing the fluorescent light through off-axis elements. This optical arrangement provides for the use of a microscope objective having a finite corrected-image distance, such as a DIN objective, rather than infinity-corrected objective that require additional optical elements to form an image. The reduction in complexity can both reduce system cost and improve optical performance by reducing Fresnel losses and imaging artifacts from Fresnel reflections.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 illustrates an epifluorescence microscope according to the present invention;
[0005] FIG. 2A shows a top isometric view of the epifluorescence microscope of FIG. 1 ;
[0006] FIG. 2B is a side view of the epifluorescence microscope according to the present invention;
[0007] FIG. 3 is a side view of an optical path through an epifluorescence microscope according to an embodiment of the present invention;
[0008] FIG. 4A shows a hatched center-section side view of an epifluorescence microscope according to the present invention;
[0009] FIG. 4B shows a cross sectional view of an epifluorescence microscope according to the present invention;
[0010] FIG. 5A shows a top isometric view of the body of an epifluorescence microscope according to the present invention;
[0011] FIG. 5B shows a bottom isometric view of the body an epifluorescence microscope according to the present invention;
[0012] FIG. 5C shows a top isometric view of a section of the body split down the center, revealing the inner features;
[0013] FIG. 6A is a top isometric view of the illuminator housing;
[0014] FIG. 6B is a bottom isometric view of the illuminator housing; and
[0015] FIG. 6C is a cross sectional view of the illuminator housing.
DETAILED DESCRIPTION OF THE INVENTION
[0016] FIG. 1A shows a bottom perspective view of a video microscopy system 100 containing an epifluorescence microscope 102 according to an embodiment of the present invention. The video microscopy system is disclosed in U.S. patent application Ser. No. 11/526,158, which was published as U.S. Patent Publication 2007-0081078 A1 on Apr. 12, 2007 and which is incorporated herein by reference. In this embodiment, a motorized traverse 112 provides panning motion 114 and focus motion 116 . FIG. 1B shows a top perspective view of the microscopy system.
[0017] FIGS. 1A and 1B show the epifluorescence microscope 102 according to an embodiment of the present invention in a motorized traverse. A housing 110 houses the entire epifluorescence optical train, camera, illuminator, and illuminator-strobing electronics such that the output of the microscope 102 is an electronic signal that conveys the epifluorescence image. In some embodiments, the image output in an analog format. In other embodiments, the image output is in a digital format.
[0018] As used herein an “additive manufacturing process” comprises any processes in which solid components are produced by a process of adhering, bonding, welding, soldering, brazing, sintering, polymerizing, chemically reacting, photolitically forming or otherwise linking precursor materials such as chemicals, polymers, metals, alloys, powders, beads, grains, micelles, liposomes, emulsions, epoxies, thermosets, thermoplastics, mixtures, aggregates, etc.
[0019] Examples of additive manufacturing processes include but are not limited to:
[0020] Stereolithography (SLA or SL), which generally may employ photopolymer materials;
[0021] Fused Deposition Modeling (FDM), which generally may employ thermoplastics, eutectic metals, etc.;
[0022] Selective Laser Sintering (SLS), which generally may employ thermoplastics, metal powders, etc.;
[0023] Laminated Object Manufacturing (LOM), which generally uses paper and like materials;
[0024] 3D Printing (3DP), which uses a range of materials; and
[0025] Polyjet Technology, a combination of SLA and FDM, which generally employs photopolymer materials.
[0026] In the present invention, at least one element of microscope 102 is manufactured using an additive process. Some embodiments employ a black rigid polyjet-produced material. In some embodiments, the material name is “VeroBlack,” having a hardness of 82 Shore D.
[0027] FIGS. 2A and 2B show basic external features of the epifluorescence microscope 100 according to the present invention.
[0028] FIG. 2A shows a top isometric view of a housing 110 that may be included in the epifluorescence microscope system 100 . The housing includes a microscope cover 201 that may be cut, folded, and welded from sheet metal, drawn by via progressive dies, injection molded, die cast, cast-in-place, or otherwise manufactured. In some embodiments, this cover 201 provides stiffening, light-proofing, and liquid spill resistance. In some embodiments the microscope cover 201 and a base 210 are permanently sealed against dust. In some embodiments the seal is light and dust tight. In some embodiments the seal is liquid tight. In some embodiments the seal is not air tight to all equalization of pressures or a dust-proof vent is included.
[0029] In some embodiments cover 201 supports other elements, such as a microscope objective lens 202 , one or more alignment and centering features, such as a post 204 , and an electronic interface 206 . In some embodiments, the electronic interface 206 carries circuits including power and signaling.
[0030] Power circuits may include power for logic, power for the illuminator, power for the camera, etc. In some embodiments, power is converted internally from one voltage to another within the microscope to support the requirements of different electronic devices.
[0031] In some embodiments signaling circuits may include digital communications lines, triggering or control lines, video signaling lines, etc. Digital communications may employ differential signaling, e.g., RS485 and the like, I2C, SPI standard communications, USB-1, USB-2, USB-3, Ethernet, IEEE1394, or other standards or custom signaling schemes known in the art.
[0032] In some embodiments, triggering or control lines may be used to control strobing of the illuminator and to transmit real-time triggering information to or from the microscope camera.
[0033] In some embodiments one or more electronic circuits may employ a connector 208 situated elsewhere, of example at an end of the housing 110 . In some embodiments, a connector may provide power. In some embodiments a connector may conform to USB, Ethernet, or IEEE1394 physical and signaling standards. In some embodiments, a custom connector may be employed. Some embodiments may power the microscope in part or full by power from a bus, e.g., USB, IEEE1394, power over Ethernet, and the like.
[0034] In other embodiments, at least one electronic circuit is made wirelessly, e.g., via radio techniques, inductive coupling, capacitive coupling, etc. Some preferred embodiments expose a reduced number of or no conductors to the exterior of the microscope, potentially providing a maximum protection against damage from spills. In some embodiments, the microscope transmits video information wirelessly. In some embodiments, the microscope control signals are transmitted wirelessly. In some embodiments, the microscope contains a power source, e.g., a battery, ultracapacitor, and the like.
[0035] Some embodiments of the present invention contain a heat sink/cooling plate in the base 210 .
[0036] FIG. 3 is a side view of the optical path 300 through epifluorescence microscope system 100 according to an embodiment of the present invention. A light source 302 , e.g., a power light-emitting diode (LED), laser, flashlamp, arc lamp, gas-discharge lamp, or the like provides illumination for the epifluorescence microscope 102 .
[0037] If the light source 302 has a narrow spectral bandwidth like an LED or laser, the light source 302 may comprise a plurality of individually controllable emitters having different spectral outputs to provide for tuning of the excitation wavelength. The design of such a compound emitter may be complicated by the need not to produce a marked shift in the illumination pattern when switching sources. Spatial interleaving or optical interleaving of emitter elements may be employed to produce a spatially stable illumination pattern.
[0038] Light from the light source 302 passes through a first condenser optic 304 and a second condenser optic 306 that are shown as being lenses. Some alternative embodiments of the condenser optics may employ reflective, diffractive, Fresnel, holographic optics and the like to direct illuminator light efficiently along the ray path 301 instead of refractive condenser lenses. An aperture 308 prevents stray rays from the light source 302 from entering the microscope or impinging on an excitation filter 310 at a significant angle, which may be important for maintaining a sharp pass-band cut-off if filter 310 is an interference filter. Excitation filter 310 removes components of the spectrum emitted by the illuminator 302 that overlap the fluorescence signal spectrum substantially. This filter 310 may be a colored glass or molecular filter. However, in preferred embodiments, this filter may be an interference filter or a combination of molecular absorption and interference filter because of the enhanced control over cut-off frequency and reduced autofluorescence provided by an interference filter. Filter autofluorescence may generate a false background signal and limit the sensitivity of the microscope.
[0039] In some preferred embodiments, the illumination wavelength may be adjusted by changing elements 302 , 310 , or a combination. If the illuminator 302 has a broad spectral output, it may be preferable to change the excitation filter 310 characteristics. This may be accomplished by the use of an excitation filter having a spatially varying passband and physically displacing the filter, angle-tuning the excitation filter by tilting it more or less with respect to the ray path 301 , arranging a plurality of filters having different passbands in a selectable fixture, the use of an electrically tunable filter such as an acousto-optic module, etc. In some embodiments, particularly when the illuminator has a narrow spectral emission, a plurality of illuminator elements, e.g., 302 and 310 , or 302 , 304 , 306 , 308 , and 310 may be changed in a group.
[0040] In some embodiments, these adjustments or changes may be manual. In some embodiments, these changes may involve removing and replacing elements in the system. In such embodiments, care should be exercised in the design to avoid the introduction of dust to the microscope, at least in locations where it produces a visible defect in the microscope image. In preferred embodiments these adjustments or changes may be mechanized, e.g., via a DC motor, solenoid, brushless DC motor, stepper motor, and the like.
[0041] The illuminator rays substantially follow path 301 to a beamsplitter 312 . In some preferred embodiments, this beamsplitter has a dichroic characteristic: passing the illumination or excitation wavelength selectively and reflecting the fluorescence or emission wavelength selectively. In other embodiments, this beamsplitter may have a substantially neutral spectral response and an approximately 50% reflectivity. Such an embodiment may be favorable for supporting multiple excitation and emission wavelengths without the need to change the beamsplitter. The advantage of using a dichroic beamsplitter is significantly greater fluorescence signal strength and a reduction in bleed through of the excitation light on the camera image.
[0042] Beamsplitter 312 has the unfortunate consequence of producing a stray reflection of the illuminator rays along path 311 . Surfaces that these stray rays land on are in the field of view of the camera and require careful attention to avoid contamination of the fluorescence image.
[0043] A fraction of excitation rays pass through the beamsplitter 312 and follow path 313 through the objective lens set 202 and onto sample 314 . A component of the fluorescence produced by those rays passes back through the objective lens set substantially along path 315 . When these rays reach the top surface 316 of beamsplitter 312 , a significant part of the rays reflect substantially along path 317 . Because these rays are reflected by the top surface of the beamsplitter, the beamsplitter produces no image aberrations.
[0044] This lack of aberrations is an important improvement over conventional epifluorescence microscopes in which the fluorescence rays pass through the tilted beam splitter on their way to forming an image, which might introduce aberrations, particularly for non-infinity corrected objectives.
[0045] The rays 317 reflect off a folding mirror 318 into rays 319 , and then reflect off mirror 320 into rays 321 . The purpose of the mirrors 318 and 320 is to keep the microscope body size compact. In some alternative embodiments, more, fewer, or no folding mirrors are used. The rays 321 pass through an emission filter 322 that provides a sharp cut off to block excitation wavelengths from passing while efficiently passing emission, or fluorescence, wavelengths.
[0046] In some embodiments, filter 322 can be changed or adjusted to provide good sensitivity for different fluorophores. In some embodiments, the filter 322 is adjusted or changed in a manner analogous to 310 . However, angle tuning and acousto-optical filtering of the fluorescence may produce image aberrations. In some embodiments, adjustments or changeouts of 310 and 322 are ganged. In some embodiments, adjustments or changeouts of 310 , 312 , and 322 are ganged. In some embodiments, filter changeouts or adjustments are ganged with changes in 302 .
[0047] Element 324 is a camera. In some embodiments the camera is monochromatic. In other embodiments, the camera has additional filters for color separation.
[0048] In some embodiments, the camera employs a charge-coupled device sensor. In other embodiments, the camera employs a CMOS sensor. In some embodiments, the camera has avalanche signal amplification, e.g., an electron-multiplied CCD. Some embodiments employ multi-channel plates for photon amplification.
[0049] In the embodiment in FIG. 3 , the optical path length through the microscope is fixed at 160 mm, in accordance with the DIN standard. Focus and panning is adjusted by moving the entire assembly with respect to the sample. In some alternative embodiments, at least some of the focus and panning is accomplished by changing the optical path through the microscope, e.g., modestly changing the path length to effect a focus or modestly tilting mirrors or beamsplitters to effect panning etc. These adjustments may be mechanized. In some embodiments, these adjustments are used to enhance depth resolution, enhance spatial resolution, remove imaging defects, enhance signal-to-noise, enhance edges, effect auto-focusing, track motion, automate acquisition over a range of depths, and a variety of other functions. An advantage of the use of internal microscope actuators over full-microscope motion may be radically reduced inertia, radically higher-frequency scanning. Actuators may include piezoelectrics, solenoids, and motors among others known in the art.
[0050] FIGS. 4A and 4B show a hatched center-section side view of an epifluorescence microscope according to the present invention. FIG. 4A shows a body 410 that is manufactured by an additive process. The surface and possibly bulk of this body is a black material such that light that contacts its surface is significantly absorbed, e.g., >70% and preferably >85%. The body 410 is designed so that stray light typically makes many reflections and passes through filters before potentially landing on the camera. In some embodiments the surface is glossy, reducing the quantity of diffusely scattered light. In some embodiments, the surface has a matte or flat sheen. In some embodiments, some parts of the surface have different reflective characteristics. In some embodiments, the surface is randomly textured so that light is trapped in the microstructure. In some embodiments the surface is deterministically textured in the fabrication process to enhance light trapping.
[0051] This body 410 contains a plurality of features 411 and 412 that act as internal baffles to enhance the absorption of stray light rays. It further contains an internal aperture 413 and apertures 414 and 416 for mirrors 318 and 320 , respectively. Such baffles and apertures dramatically reduce stray rays, providing for enhanced fluorescence detection sensitivity, however they may be cost prohibitive to produce using conventional machining, casting, or molding. The novel use of additive manufacturing to produce this body provides the design freedom to combine many conventionally challenging features into one or a few bodies economically.
[0052] FIGS. 4A and 4B show a combination condenser lens holder and stray-light reduction system 418 for the illuminator 302 . In some embodiments, it may be produced using an additive process. In some embodiments the aperture 308 may be combined with this element.
[0053] FIGS. 4A and 4B also show a beam-splitter holder 420 that holds the beam splitter 312 . In some embodiments, this beamsplitter holder 420 may be combined with body 410 , condenser lens holder and stray-light reduction system 418 , or the aperture 308 .
[0054] Circuitry for driving the illuminator 302 may be formed on a printed circuit board 419 . Having this driver board, the illuminator, and camera, three-heat generating elements of the microscope in intimate contact with the heat sink and exchanger 210 prevents excessive internal temperatures. In some embodiments, adhesive pads that enhance heat transfer are employed to make good thermal contact between heat generators and the heat sink. In some embodiments, thermally conductive greases may be used, provided these greases do not outgas or attack materials in the camera and that care is taken to avoid contamination of optical elements. In other embodiments, thermally conductive epoxies or mechanical pressure may be used to enhance heat transfer efficiency.
[0055] FIG. 4B shows a hatched section view 430 taken at the position of ray 301 looking toward mirror 318 . This view shows the boundaries of the baffles 411 . In this embodiment, the baffles are recessed considerably from the path of the rays. Recessing the baffles has the advantage of keeping light scattered from the edges of the baffles away from the field of view of the camera. The baffles should at least be recessed enough from the light path so that they do not limit spatial resolution or produce vignetting of the fluorescence image. The aperture 416 reveals enough of mirror 318 to pass the fluorescence light bundle and its diffractive lobes. The facets of 416 are oriented to reflect stray light onto the baffles. In some embodiments, the aperture itself contains a baffle substantially in the direction of the ray path. Whether an aperture having a faceted reflector oriented substantially normal to the incoming rays as in FIG. 4B or oriented substantially in the direction of the incoming rays performs better for eliminating stray beams depends on the surface properties of the baffle.
[0056] In some embodiments, additional cavities can be engineered into the solid-filled regions 432 to enhance trapping of stray light and to reduce the body fabrication times.
[0057] FIG. 5A shows a top isometric view of the body 410 . The mirror 320 is mounted on a mounting surface 502 . The mirror 318 is mounted on a mounting surface 504 . The recessed surface 506 provides space for a printed circuit board. The recesses 508 provide room for electrical connections. The openings 510 provide for enhanced removal of extraneous material from the additive manufacturing process.
[0058] FIG. 5B shows a bottom isometric view of the body 410 . A recess 532 is formed for mounting for the illuminator 302 , condenser optics 304 and 306 and beam splitter 312 . Mounts 536 mount the camera in a recess 534 . The emission filter 322 is mounted at a mounting site 538 for emission filter 322 . Drive electronics for the illuminator 302 is housed in a cavity 540 . The cavity 542 provides for enhanced removal of extraneous material from the additive manufacturing process.
[0059] FIG. 5C shows a top isometric view 550 of a section of the body 410 split down the center, revealing the inner features. The internal aperture 413 and the surrounding baffles contain cants 552 to enhance light trapping, features that may be impossible to manufacture conventionally. Beamsplitter 312 is mounted in a seat 554 . The stray rays from the illuminator 302 reflecting off the beam splitter 312 are incident upon a surface 556 . Light scattered from this surface 556 is in the field of view of the camera and is eliminated only by the emission filter. For this reason, the surface 556 may receive special attention, such as a gloss-black cover, e.g., from a self-adhesive tape or a thin neutral density absorption filter. The light reflecting off this surface enters a trap 558 having a rear cavity 560 .
[0060] FIG. 5D shows a bottom isometric view 570 of the top section of the body 410 split slightly above surface 556 , revealing details of the light trap 558 . In some alternative embodiments the trap cavity sidewalls 560 contain radially disposed baffles for enhanced light trapping. The port 562 enhances removal of extraneous material from the additive manufacturing process.
[0061] In some embodiments of the present invention, the body 410 is manufactured in pieces, e.g., split along the centerline similar to the view in FIG. 5C to facilitate cleaning, removal of extraneous material from the manufacturing process, and assembly of internal parts. Such an assembly may obviate ports such as 510 and 562 . In some embodiments, a plurality of parts to be assembled into a microscope, e.g., 410 or components that assemble to comprise body 410 , illuminator housing 418 , beam-splitter holder 420 and aperture 308 or a subset of these parts are manufactured in their proper relative position with fine seams between the parts, assuring accurate registration of size. In some preferred embodiments, the seams are engineered to follow a path that prevents light from entering or escaping, for example with overlaps. In some embodiments, these overlapped seams contain detents or features for interlocking.
[0062] FIG. 6A shows a top isometric view of the illuminator housing 418 . FIG. 6A shows a seat 602 is the seat for the condenser lens 306 . Baffles 604 surround the seat 602 . FIG. 6B shows a bottom isometric view of the illuminator housing. An indexing aperture 612 indexes with lens 304 to ensure proper relative alignment of lenses 306 and 304 . FIG. 6C shows a cross sectional view of the illuminator housing. Note that using an additive process to make such a part frees the designer to employ negative draft angles 622 and other features that enhance light trapping but would otherwise tremendously complicate manufacturing.
[0063] Some embodiments of the present invention are employed as swappable modules in a system such as shown in FIGS. 1A and 1B . In such use, a user may swap one epilfluorescence microscope for another when a difference set of colors or fluorophores are probed rather than change components internal to the microscope as in conventional epifluorescence modules. This allows embodiments of the present invention to be manufactured without dust, contaminants, and smudges on the internal surfaces, especially internal optical surfaces and to remain free of these defects in spite of operation in unclean environments.
[0064] In some embodiments, the epifluorescence microscope modules may be swapped with power on. In some embodiments the epifluorescence microscope contains a device, such as a serial EEPROM or microcontroller, that can be queried and written about information including some of the following items: the hardware version, firmware version, illuminator wavelength, characteristic of filters and beam splitters, microscope objective, indexes that identify the types of filters, beam splitters, objectives, and illuminators contained within the microscope, and the like.
|
An epifluorescence microscope achieves a compact form factor without sacrificing optical sensitivity by the novel use of combined optic mounts and light baffles constructed using additive manufacturing processes. The use of additive manufacturing enables stray-light-capturing structures that are not practical to make by other techniques. Some embodiments of the present invention do not require installation of filters by an operator, reducing the likelihood of dust and contamination on optical surfaces. Some embodiments of the present invention employ a novel light path that avoids passing the fluorescent light through off-axis elements. This optical arrangement provides for the use of a microscope objective having a finite corrected-image distance, such as a DIN objective, rather than infinity-corrected objective that require additional optical elements to form an image. The reduction in complexity can both reduce system cost and improve optical performance by reducing Fresnel losses and imaging artifacts from Fresnel reflections.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of and claims priority to PCT Application Serial No. PCT/ES2013/070437 filed Jun. 28, 2013 which claims the benefit of the filing date of Spanish Application Serial No. P201231019 filed Jun. 29, 2012, the entire disclosures of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The subject matter disclosed herein applies to the aeronautical industry, relating to aircraft stringers. It more specifically relates to T-shaped stringers with a rounded web end and their method of manufacture.
BACKGROUND
[0003] One type of conventional stringer has a T-shaped cross-section with a foot and a web. Such T-shaped stringers are usually made up of two L-shaped preforms having the same thickness in the foot and in the web, although there are also L-shaped preforms in which the web area is thicker than the foot area. This difference in thickness is because some stringers have to have higher inertias, so they have an additional number of fabrics as reinforcement in the web area. In both cases, they are manufactured by means of a process comprising a first tape laying step, a second shaping step and a third curing step.
[0004] Laying tape comprises stacking bands of pre-impregnated material, for which purpose an ATL machine is commonly used. In this step, the machine deposits bands of pre-impregnated material (carbon fibers pre-impregnated with a resin) on top of others until obtaining the desired laminate with the desired fiber orientation.
[0005] The second step for conventionally manufacturing stringers comprises shaping laminates to obtain L-shaped preforms, which will subsequently be attached to one another in twos to obtain a T-shaped stringer. Pressure and a temperature below 100° C. are normally applied when shaping. The purpose is to reduce the viscosity of the resin in order to give the desired shape to the laminate. The resin is never cured.
[0006] The third step of the conventional method for manufacturing stringers comprises attaching the preforms to one another such that they form the T-shaped stringer to subsequently cure it. The curing process can be carried out in different ways. The stringers can be placed on the overlay and cured at the same time as the overlay (co-curing), cured separately from the overlay and subsequently bonded on the overlay in an already cured state (secondary bonding), placed while fresh on the overlay in an already cured state and cured in the bonding cycle (co-bonding), or placed in an already cured state on the overlay before drying and the overlay being cured at the same time the stringers are bonded (also co-bonding). Pressure and temperature higher than those applied during shaping are applied when curing because the purpose is to cure the resin and to get the resin to be redistributed in order to fill the cavities that may exist in the part, thereby reducing porosity.
[0007] A problem with this conventional method of manufacture is that the stringers manufactured according to this method have beaked excess material at the end of the web that does not withstand loads and is therefore useless weight. Today, this excess material is machined and material is pulled off until obtaining an upper web surface of the stringer that is horizontal and planar. This machining operation can damage the end of the web of the stringer and, even while not damaging it, the resulting structure does not perform well in response to impacts, which can cause peeling in this area.
[0008] Another problem with the conventional method arises from the need to identify the damage that may occur given that this area is susceptible to receiving impacts. The dark gray color of these parts made of composite material does not allow the detection, so as of today, the upper portion of the web of the stringer is painted using paint with a color that is lighter than the color of the composite material in order to identify the damage. The problem with this solution is that it is a time-consuming process because since only the upper area of the web of the stringer has to be painted, the rest of it must be previously covered.
SUMMARY
[0009] An object of the subject matter disclosed herein is to provide a T-shaped stringer that performs better in response to impacts than the stringers known in the state of the art, in which one end of the web further comprises an area for easy detection of damage caused by the impacts, in addition to a method of manufacturing the stringers that is faster and less expensive than the conventional method.
[0010] The subject matter disclosed herein seeks to solve the aforementioned problems by providing a method of manufacturing stringers which comprise a rounded web end, eliminating the need to perform machining that can damage the web of the stringer, and which perform better in response to impacts.
[0011] All this entails a reduction of the total stringer manufacturing time, while simultaneously making better use of the material used. The present method of manufacturing stringers in turn comprises a curing tool with inner faces that are adapted to at least the outer geometry of the new stringer in the segment attaching the rounded web end and the foot area close to the fillet radius between the foot and the web. The two areas in which the angle must be adjusted to the part are the fillet radius between the web and foot and the upper area of the web which is rounded.
[0012] For the purpose of achieving the objectives and avoiding the drawbacks mentioned in the preceding sections, the subject matter disclosed herein discloses a method of manufacturing T-shaped stringers made of composite material. This method comprises a first tape laying step for laying tape on two planar laminates, a second shaping step for shaping the planar laminates into two L-shaped preforms; and a third step in which the two preforms are attached to one another and cured to obtain the T-shaped stringer.
[0013] The mentioned second shaping step comprises, on the one hand, providing a set of tools formed by a fixed tool comprising a lower portion and an upper portion, and a moveable tool comprising a lower element and an upper element, the fixed tool and the moveable tool being arranged at a pre-determined distance from one another. The shaping also comprises arranging each planar laminate in the set of tools such that the segment of the laminate intended for the foot of the L-shaped preform is arranged between the lower portion and the upper portion of the fixed tool and the segment of the laminate intended for the web of the L-shaped preform is arranged between the lower element and the upper element of the moveable tool. This second step of the method of manufacture additionally comprises vertically moving the moveable tool at a pre-determined speed to progressively bend the web of the preform supporting it on a vertical wall of the fixed tool. The end of its web therefore adopts a rounded shape.
[0014] One aspect of the present method is to provide the set of tools such that one corner of the fixed tool, towards which the moveable tool moves and on which the fillet radius between the foot and the web is formed, has a radius corresponding with the fillet radius between the foot and the web of the L-shaped preform. The subject matter disclosed herein comprises providing the set of tools such that the element of the moveable tool exerting a thrust pressure on the laminate has rounded corners. Furthermore, another aspect of the subject matter disclosed herein is that it comprises providing the set of tools such that a gap is left between the ends of the moveable tool and the vertical walls of the fixed tool according to the thickness of the preform.
[0015] A method object of the subject matter disclosed herein comprises in the tape laying step adding a strip to the laminate in the portion of the laminate which is on the visible face of the end of the web after shaping. Alternatively, the method can comprise adding the strip on the rounded end of the stringer formed after attaching the two preforms to one another and before curing. The strip is lighter in color than the T-shaped stringers, being distinguished from the rest of the laminate, for identifying possible damage. The strip is preferably made of glass fiber.
[0016] Another feature of the subject matter disclosed herein is that it comprises curing using a curing tool with inner faces replicating the outer geometry of the rounded web end of the stringer obtained after attaching the two L-shaped preforms to one another and the fillet radius between the foot and the web of the stringer in the case of conventional stringers. In the case of stringers with reinforcement in the web, the curing tool used replicates the outer geometry of the conventional stringer up to a certain height of the web and is placed above a vacuum bag that is placed on the stringer.
[0017] Another aspect of the subject matter disclosed herein is that it comprises a T-shaped stringer made of composite material manufactured according to the method described in any of the preceding claims. This stringer comprises a rounded web end.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] For the purpose of better understanding the description that is being made, a set of drawings is enclosed with the subject matter disclosed herein in which the following is depicted with an illustrative and non-limiting character:
[0019] FIGS. 1 , 2 and 3 schematically show the method for shaping L-shaped preforms according to the preferred embodiment of the subject matter disclosed herein.
[0020] FIG. 4 shows the L-shaped preforms obtained according to the subject matter disclosed herein.
[0021] FIG. 5 shows two L-shaped preforms forming a T-shaped stringer according to the subject matter disclosed herein.
[0022] FIG. 6 shows the T-shaped stringer inside a curing implement for curing thereof according to the subject matter disclosed herein.
[0023] FIG. 7 shows a T-shaped stringer with reinforcement fabrics in the web from the state of the art.
[0024] FIG. 8 shows a T-shaped stringer with reinforcement fabrics in the web according to the subject matter disclosed herein.
[0025] FIG. 9 shows a T-shaped stringer with reinforcement fabrics in the web inside a curing implement for curing thereof according to a preferred embodiment of the subject matter disclosed herein.
[0026] A list of the different elements depicted in the drawings integrating the subject matter disclosed herein is provided below:
1 =Fixed tool 2 =Strip 3 =Moveable tool 4 =Laminate 5 =Curing tool 6 =Preform 7 =Stringer 8 =Reinforcement fabrics 9 =Vacuum bag 10 =Curing tool for stringers with reinforcement in the web
DETAILED DESCRIPTION
[0037] Novelties of the method of manufacturing T-shaped stringers ( 7 ) disclosed by the subject matter disclosed herein compared to the conventional method lie in at least three aspects. One aspect is a novel method for carrying out a shaping step whereby obtaining a T-shaped stringer ( 7 ) with a rounded web end, another aspect is the inclusion of a strip ( 2 ) for identifying impacts such that a great deal of time is saved, and finally, another aspect is the use of a curing tool ( 5 ) with a geometry the inner faces of which are adapted to at least a portion of the outer geometry of the stringers ( 7 ) shaped according to the method of the subject matter disclosed herein.
[0038] Two L-shaped preforms ( 6 ) are simultaneously obtained in the shaping step, FIGS. 1 to 3 . To that end, planar laminates ( 4 ) having a cross-section such as that shown in FIG. 1 are used as a starting material.
[0039] For shaping, on the one hand, there are two fixed tools ( 1 ), each of them comprising a lower portion and an upper portion. The tools ( 1 ) are placed facing one another, as shown in FIG. 1 . A segment of the laminate ( 4 ) corresponding to the foot of each of the L-shaped preforms ( 6 ) to be shaped is placed between the upper and lower portions of each of the fixed tools ( 1 ), the rest of the laminate ( 4 ) cantilevered over the area between the mobile tools ( 3 ).
[0040] On the other hand, there is a moveable tool ( 3 ) comprising a lower element and an upper element, and it is placed between the fixed tools ( 1 ), holding the ends of each laminate ( 4 ) opposite to the ends which are placed in each of the fixed tools ( 1 ).
[0041] The preforms ( 6 ) are shaped by applying heat and very slow vertical movement of the moveable tool ( 3 ), at the rate of about 5 mm/min, which leads to bending the laminates ( 4 ). The segment of the laminate ( 4 ) which was cantilevered before applying this movement and which is now adjusted to the vertical wall of the portion of the fixed tool ( 1 ) towards which the moveable tool ( 3 ) moves is thus bent.
[0042] FIGS. 1 to 3 describe a preferred embodiment of the subject matter disclosed herein for shaping, in which the movement of the moveable tool ( 3 ) is downward, in the direction indicated by the arrow. The shaping process can be carried out by the upward or downward movement of the moveable tool ( 3 ). Choosing one direction or the other conditions the design of the set of tools, as explained below.
[0043] For the case shown in the drawings in which the moveable tool ( 3 ) moves downward, the inner corners of the lower portions of the fixed tools ( 1 ) are rounded, and the radius coincides with the fillet radius between the foot and the web of the preform ( 6 ). Furthermore, the lower portion of the fixed tool ( 1 ) is wider than the upper portion, the difference in width corresponding to the radius of the L-shaped preform ( 6 ). The lower corners of the upper element of the moveable tool ( 3 ) are also rounded, and the radius coincides with the fillet radius between the foot and the web of the preform ( 6 ).
[0044] In an embodiment not shown in the drawings in which the moveable tool ( 3 ) moves upward, in addition to having rounded inner corners, the upper portion of the fixed tool ( 1 ) is wider than the lower portion. For this embodiment, the upper corners of the lower element of the moveable tool ( 3 ) are the ones that are rounded.
[0045] Another aspect to be taken into account concerning the fixed tools ( 1 ) and the moveable tool ( 3 ) is the distance at which they are located from one another. The distance separating the ends of the moveable tool ( 3 ) from each of the fixed tools ( 1 ) is defined according to the thickness of the web of the L-shaped preforms ( 6 ) to be obtained.
[0046] A further aspect to be taken into account concerning the tools ( 1 , 3 ) is the pressure they exert on the laminate ( 4 ) during the shaping process. In the case of the fixed tools ( 1 ), the pressure must only be the pressure that is necessary for holding the carbon fiber laminate ( 4 ) while the moveable tool ( 3 ) moves the segment of the laminate ( 4 ) opposite the segment held by each fixed tool ( 1 ). It is important not to exert too much pressure. The reason for not holding the laminates ( 4 ) too tightly by the fixed tools ( 1 ) is that at this point of the manufacturing process, the carbon fiber laminate ( 4 ) is in a very fresh state, so it may be easily damaged. The pressure must be the pressure necessary for holding the laminates ( 4 ) without them coming out from between the upper portion and lower portion of each fixed tool ( 1 ) while shaping, without reducing thickness and without draining the resin off the laminate ( 4 ). This pressure can be between 1.5 bars and 1.8 bars.
[0047] For the case of the moveable tool ( 3 ) the pressure, which is always lower than in the case of fixed tools ( 1 ), can range between 0.5 bar and 0.01 bar throughout the shaping cycle. This pressure exerted by the moveable tool ( 3 ) only assures the holding by the upper side and by the lower side of the end of the laminate ( 4 ) that is gradually being bent during shaping. This bending occurs until the shaping step ends and the ends of the laminate ( 4 ) corresponding to the end of the web of each preform ( 6 ) come out from between the upper and lower portions of the moveable tool ( 3 ).
[0048] Another novel aspect of the method of manufacturing stringers ( 7 ) with an upper rounded web end, as indicated at the beginning of this section is the inclusion of the strip ( 2 ) for identifying impacts, comprising a thickness between 0.1 mm and 0.3 mm. An option for placing this strip ( 2 ) is placing it on the end of the web of the stringer ( 7 ) once the L-shaped preforms ( 6 ) have been shaped and attached to one another, FIGS. 4 and 5 respectively, to form the T-shaped stringer ( 7 ), right before curing.
[0049] Another option, being a preferred option, is to place the strip ( 2 ) during tape laying. The strip ( 2 ) is placed in the portion of the laminate ( 4 ) which will be on the visible face of the end of the web of the stringer ( 7 ) after shaping. If the moveable tool ( 3 ) moves downward during shaping, the strip ( 2 ) is placed on the first layer of the tape laying, at the end of the laminate ( 4 ) that is held by the two portions of the moveable tool ( 3 ), whereas if the moveable tool ( 3 ) moves upward during shaping, the strip ( 2 ) is placed on the last layer of the laminate ( 4 ), also at the end that is held by the two portions of the moveable tool ( 3 ).
[0050] A requirement that the material of the strip ( 2 ) must meet is that it has to be a lighter color than the carbon fiber of the stringers ( 7 ) to favor the identification of damage caused by impacts. In a preferred embodiment of the subject matter disclosed herein, the strip ( 2 ) is made of glass fiber.
[0051] The third novel aspect of the subject matter disclosed herein is the use of the curing tool ( 5 ) with a geometry of its inner faces that adapts at least in part to the outer geometry of the stringers ( 7 ) manufactured according to the method of the subject matter disclosed herein. For the case of T-shaped stringers ( 7 ) made up of two L-shaped preforms ( 6 ) having the same thickness in the web area and in the foot area, the curing tool ( 5 ) adapts in its entirety to the outer geometry of the stringers ( 7 ) manufactured according to the method of the subject matter disclosed herein, as seen in FIG. 6 . These curing tools ( 5 ) adapted to the new geometry of T-shaped stringers ( 7 ) are important so as to not deform the roundness achieved at the end of the web and in the radius while curing. A vacuum bag ( 9 ) is used together with the curing tool ( 5 ) in the curing step.
[0052] For the mentioned case in which the thickness is the same in the foot and the web, this bag ( 9 ) can be located between the T-shaped stringers ( 7 ) and the curing tool ( 5 ) or on the curing tool ( 5 ).
[0053] This second option entails covering the assembly shown in FIG. 6 with the vacuum bag ( 9 ). When choosing one of these two options, it is important to bear in mind that when the vacuum bag ( 9 ) is placed between the stringers ( 7 ) and the curing tool ( 5 ) as occurs in the first option, it is not necessary for the curing tool ( 5 ) to tightly surround the end of the web or the end of the foot, for example, given that the bag ( 9 ) itself encircles the area assuring the geometry obtained while shaping. In this first option, the vacuum bag ( 9 ) is what is completely tightly surrounding stringer ( 7 ) and it is therefore not necessary for the curing tool ( 5 ) to reach the ends of both the web and the foot, nor does it have to tightly surround it in such a reliable manner as occurs in the second option. As a result, it is not necessary to adapt or to have a curing tool ( 5 ) for each stringer specification, several configurations of a stringer ( 7 ) being able to share the same curing tool ( 5 ). Nor is it necessary for the tool to be made of invar (iron+nickel) given that is not necessary for the tool to have a coefficient of expansion that is as similar to that of the material of the stringer ( 7 ). Therefore, the use of less expensive materials such as iron also allows using a welding that is less expensive and simpler than the attachment required by a material such as “invar” during manufacture. Likewise, in this first option it is possible to dispense of silicone end retainers for preventing adhesive leaks or excessive expansions of the ends of the foot. These silicone end retainers are usually housed in a groove of the curing tool ( 5 ) that longitudinally extends close to the end of the foot. In the first option, it has been verified that the vacuum bag ( 9 ) performs the retaining function, preventing the need to manually place silicone retainer that gives rise to an expensive manual operation.
[0054] In contrast, since the vacuum bag ( 9 ) is placed on the stringer ( 7 )-curing tool ( 5 ) assembly according to the second option, the vacuum bag ( 9 ) cannot tightly surround the end of the web suitably, so in this case it is necessary for the curing tool ( 5 ) to tightly surround the end of the web. Nevertheless, in this case there is an additional advantage. An application of great interest uses a plurality of parallel stringers ( 7 ) located on the surface of a skin of an airplane wing such that the feet of the stringers ( 7 ) rest on the surface of the skin, and the curing tools ( 5 ) are in turn located on the corresponding stringer ( 7 ). The vacuum bag ( 9 ) is placed on the assembly of the skin and the plurality of stringers for curing inside the autoclave.
[0055] For the case of T-shaped stringers ( 7 ) made up of two L-shaped preforms ( 6 ) having a different thickness in the web area and in the foot area, modifications are possible to enable the manufacture thereof according to the subject matter disclosed herein. Reinforcement fabrics ( 8 ) are intercalated in the tape laying step. These additional fabrics ( 8 ) are usually intercalated in the web area, specifically from the area of the fillet radius between the foot and the web of the preform ( 6 ) to the end of the web, as can be seen in FIG. 7 . The problem with this arrangement of additional fabrics ( 8 ) is that the thickness of the area of the fillet radius between the foot and the web of the stringer is not constant and this makes it impossible to obtain stringers ( 7 ) with a rounded web end by the method object of the subject matter disclosed herein.
[0056] To enable manufacturing the mentioned reinforced T-shaped stringers ( 7 ) according to the method of manufacture object of the subject matter disclosed herein, the reinforcement fabrics ( 8 ) are intercalated covering at least a portion of the foot and to the end of the web such that the thickness of the area of the radius is constant, as can be seen in FIG. 8 . The fact that the fillet radius between the web and the foot of the L-shaped preforms ( 6 ) the thickness is constant is essential for manufacturing reinforced T-shaped stringers ( 7 ) according to the present method.
[0057] In contrast, the curing step for curing these reinforced T-shaped stringers ( 7 ) depicted in FIG. 8 requires the use of a vacuum bag ( 9 ) such that this bag ( 9 ) is placed on the stringer ( 7 ), and the curing tool ( 10 ) specific for this geometry of the stringers ( 7 ) is in turn placed on the vacuum bag ( 9 ), as shown in FIG. 9 . This is because as mentioned above for the case of stringers ( 7 ) with the same thickness in the feet and in the webs, the vacuum bag ( 9 ) is what assures compaction, whereas the curing tools ( 10 ) simply get the web of the stringers to remain in their plane.
[0058] The object of the subject matter disclosed herein is to get the outer layers of the web of the L-shaped preforms ( 6 ), which are longer than the inner layers due to the thickness of the laminate ( 4 ) and the fillet radius between the foot and the web of the preform ( 6 ), to adopt a rounded shape instead of a pointed shape during the shaping step. This is achieved by carrying out shaping with a moveable tool ( 3 ) with rounded corners and with lower and upper portions holding the laminate ( 4 ) during shaping, such that the outer layers adopt a rounded shape.
[0059] An additional reason for the corners of both tools ( 1 , 3 ) being rounded with a radius of curvature of 2 to 5 millimeters is that the corners could otherwise seriously damage the laminate ( 4 ) during shaping, and even more so considering that the laminate ( 4 ) in this step of the manufacturing process is fresh.
[0060] The persons skilled in the art will understand that various alterations and modifications can be made to the preceding description, although it must be understood that the scope of the subject matter disclosed herein is not limited to the described embodiments and is defined by the attached claims.
[0061] While at least one exemplary embodiment of the present disclosure has been shown and described, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of the disclosure described herein. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, and the terms “a” or “one” do not exclude a plural number. Furthermore, characteristics or steps which have been described with reference to one of the above exemplary embodiments may also be used in combination with other characteristics or steps of other exemplary embodiments described above.
|
A method of manufacturing T-shaped stringers made of composite material, including a second shaping step for shaping laminates into L-shaped preforms, which includes providing a set of tools formed by a fixed tool comprising a lower portion and an upper portion, and a moveable tool comprising a lower element and an upper element. It also includes the segment of the laminate intended for the foot of the preform being located between the lower portion and the upper portion of the fixed tool, and the segment of the laminate intended for the web of the preform being located between the lower element and the upper element of the moveable tool. It further includes vertically moving the moveable tool to progressively bend the web of the preform supporting it on a vertical wall of the fixed tool. The end of its web adopts a rounded shape.
| 8
|
RELATED APPLICATION DATA
This application is a continuation of U.S. patent application Ser. No. 10/701,715, filed Nov. 5, 2003, and titled “APPARATUS AND METHOD FOR DETECTING AN ANALYTE,” now U.S. Pat. No. 7,010,956, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The present invention generally relates to the field of wine bottling and, more particularly, to an automated apparatus and method for testing cork wine bottle stoppers for the presence of an analyte that causes cork taint in bottled wine.
BACKGROUND OF THE INVENTION
The wine industry produces approximately fourteen billion bottles of wine per year. The bottled wines range in price from inexpensive table wines to very expensive, high-quality wines. The more expensive wines (i.e., from fifty dollars to thousands of dollars per bottle) are typically produced by a small number (presently, about two thousand) of high-end wineries that produce 200,000 to 80 million bottles of wine each per year.
Most bottled wines, both inexpensive and expensive, are sealed with cork stoppers. Cork stoppers include natural cork stoppers punched from strips of bark and less expensive molded or extruded agglomerated cork with natural cork discs on each end. Wine makers generally prefer cork stoppers for sealing their bottles to maintain the traditional wine-opening experience that consumers expect. Unfortunately, the use of cork stoppers can adversely affect the taste of wine, a characteristic commonly referred to as “cork taint.” Cork taint describes the “off” smell and taste imparted to wine from chemical contaminants such as 2,4,6-trichloroanisole (TCA) in the cork stopper.
The incidence of cork taint is sporadic and random, typically affecting 1-2% of bottled wines. Since cork taint takes effect after bottling, it cannot be detected until after a bottle has been opened. Cork taint manifests as very undesirable aroma and flavor characters that are imparted to bottled wines following contact with the cork. There is nothing more offensive and embarrassing for wine consumers and producers alike than for their wine to be rated as “spoiled.” For consumers, opening a cork-tainted bottle of wine can be socially embarrassing, particularly if it is an expensive bottle of wine. For wine collectors, the 1-2% incidence of cork taint imparts uncertainty about the entire wine collection. For producers, cork-tainted wine can damage their reputation, causing consumers to question the integrity and quality of their wine. Thus, there exists a need for a means to ensure the quality of cork stoppers used to bottle wines.
The chemical compound contributing most significantly to cork taint is TCA, which is implicated in more than 80% of cork-tainted wines. The production of TCA is the result of complex chemical mechanisms, including the conversion of chlorophenols to chloroanisole by common microorganisms, such as fungi, in the presence of moisture. Chlorophenols are typically used as pesticides and wood preservatives, and, consequently, they are common environmental pollutants. The uptake of even minute amounts of chlorophenol by the bark of a cork tree at any stage during its growth can yield corks that will produce cork taint in wine. Alternatively, cork taint can be the result of interaction between naturally occurring fungi in the tree bark and chlorine, a chemical commonly used to sanitize the cork. Cork, like any other wine input, therefore demands exhaustive quality control.
Quality assurance at every step of the cork stopper manufacturing process is a major concern of the cork industry. This concern has led to the implementation of the “International Code of Cork Stoppers Manufacturing Practices.” The code establishes quality-control standards throughout the production process and aims to provide guarantees to cork suppliers, wine producers, and bottlers that they have a product that is free from contamination.
In addition, premium cork suppliers also insist on rigorous quality-control testing of their cork stoppers for TCA. Current industry practices for quality-control testing of cork stoppers include sensory-based methods (i.e., olfactory detection or human experts) and chemical analysis (e.g., cork soaks and gas chromatography/mass spectroscopy). However, these testing procedures are limited to testing batches of cork stoppers (e.g., statistical sampling). For example, for every 100 million or more cork stoppers produced, only a half-million to one million are tested for TCA. The batch sampling approach does not eliminate the possibility that a TCA-tainted cork will be undetected during quality-control testing and subsequently used by a wine producer or bottler. Thus, there exists a need for a testing process that provides 100% testing of cork stoppers for TCA prior to bottling.
Another limitation of current testing methods is that they are expensive and time consuming. Further, sensory-based methods that rely on human experts are subjective, variable and exhaustible. Thus, there exists a need for a low-cost, reliable testing process that provides 100% testing of cork stoppers for TCA prior to bottling.
The wine industry, seeking to increase consistency and consumer loyalty, has investigated alternative quality-control procedures. One alternative is the application of electronic nose technology to quality-control testing at all stages of wine production, e.g., bottling. An electronic nose is a sensing device capable of producing a fingerprint of specific odors. Current technology includes electronic noses that use odor-reactive polymer sensor arrays and a pattern-recognition system (i.e., e-Nose) and gas chromatography coupled to surface acoustic wave sensors (i.e., z-Nose). In one example of polymer sensor arrays, the electronic nose uses a one-inch-square microelectrical mechanical systems (MEMS) chip containing 32 pinhead-sized receptors forming a sensor array. The receptors are constructed from a conductive carbon black material blended with specific nonconductive polymers (manufactured by Cyrano Sciences, Inc., Pasadena, Calif.). When the MEMS chip is exposed to a specific vapor, a corresponding receptor expands, temporarily breaking some of the connections between the carbon black pathways and thereby increasing the electrical resistance in the sensor. Signals from the sensors are electronically processed by a microprocessor that interprets the data by using the pattern-recognition system to identify and/or quantify a specific odor contained in the vapor.
Application of electronic nose technology to quality-control monitoring of agricultural products is exemplified in U.S. Pat. No. 6,450,008 to Sunshine et al., entitled, “Food applications of artificial olfactometry.” The Sunshine et al. patent describes a method and device for evaluating agriculture products and, more particularly, for assessing and monitoring the quality of food products by using electronic noses. The quality control monitoring device includes two sensor arrays for comparative monitoring of an agricultural product, e.g., before and after a processing step such as blending or mixing, or detection of a contaminant (e.g., microorganism) relative to a clean sample. However, the quality-control monitoring device is a single device that typically requires up to three minutes to obtain a result and to cycle to the next measurement, thus limiting the number of measurements that can be determined by a single device. Further, the existing devices are expensive, which precludes purchasing multiple instruments to achieve 100% testing of a product in a production process. Thus, there exists a need for a means to test 100% of all corks in a fast and cost-efficient way.
The introduction of a new technology platform (e.g., electronic nose technology) into an existing industry (e.g., the wine industry) is often a difficult and expensive process. Often, a new technology platform is implemented by high-end or specialty producers (e.g., high-end wine producers), for which the costs associated with the production of a quality product are generally higher and the benefits provided by the new technology are initially greater. However, this approach neglects the general consumer market (e.g., inexpensive table wines), in which the volume of products consumed offers greater potential returns. Thus, there exists a need for a means to test 100% of all corks at production speed that is cost-efficient and scalable to the general consumer market.
SUMMARY OF THE INVENTION
In one aspect, the present invention is directed to a method of testing a plurality of cork wine bottle stoppers for the presence of an analyte known to cause cork taint in wine. The method comprises automatedly moving a first one of the plurality of cork wine bottle stoppers to a first position. A first sensor is automatedly moved to a second position proximate the first position. The first sensor is operatively configured to detect the presence of the analyte. It is determined via the first sensor whether the analyte is present in/on the first one of the plurality of cork wine bottle stoppers. The first one of the plurality of cork wine bottle stoppers is automatedly moved out of the first position. The first sensor is automatedly moved out of the second position. A second one of the plurality of cork wine bottle stoppers is automatedly moved into the first position. A second sensor is automatedly moved to the second position. The second sensor is operatively configured to detect the presence of the analyte. It is determined via the second sensor whether the analyte is present in/on the second one of the plurality of cork wine bottle stoppers.
In another aspect, the present invention is directed to a method of testing cork wine bottle stoppers for the presence of an analyte known to cause cork taint in wine. The method comprises providing at least 100 candidate cork wine bottle stoppers. The at least 100 candidate cork wine bottle stoppers are fed into an automated testing system comprising a plurality of electronic noses sensitive to the analyte. The automated testing system is caused to test each of the at least 100 candidate cork wine bottle stoppers for the presence of the analyte in rapid succession with others of the at least 100 candidate cork wine bottle stoppers using the plurality of electronic noses and to separate the at least 100 candidate cork wine bottle stoppers into an accepted set and a rejected set.
In yet another aspect, the present invention is directed to a cork sorting apparatus comprising a plurality of electronic noses each operatively configured to detect a chemical contaminant known to cause cork taint in wine. A stopper conveying system is operatively configured to hold and move each cork wine bottle stopper of a plurality of cork wine bottle stoppers in rapid succession to a first position. An electronic nose system is operatively configured to move each electronic nose of the plurality of electronic noses, in seriatim, to a second position proximate the first position in concert with the first system. Sensor electronics are operatively configured to identify from within the plurality of cork wine bottle stoppers via the plurality of electronic noses accepted cork wine bottle stoppers and rejected cork wine bottle stoppers. A sorting system is operatively configured to separate the rejected cork wine bottle stoppers from the accepted cork wine bottle stoppers.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, the drawings show a form of the invention that is presently preferred. However, it should be understood that the present invention is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein:
FIG. 1 is a perspective view of a testing apparatus of the present invention for detecting the presence of an analyte;
FIG. 2 is a high-level schematic diagram of a system of the present invention for operating the testing apparatus of FIG. 1 ;
FIG. 3A is an enlarged perspective view of one of the sensor units of the testing apparatus of FIG. 1 ;
FIG. 3B is a high-level schematic diagram of the sensor electronics of the testing apparatus of FIG. 1 ; and
FIG. 4 is a flow diagram of a method of using the testing apparatus of FIG. 1 to detect the presence of an analyte in a plurality of items, wherein the items are cork stoppers.
DETAILED DESCRIPTION OF THE INVENTION
Generally, the present invention is an apparatus and method for detecting an analyte and, more particularly, assessing and monitoring items, such as cork stoppers, for the presence of one or more chemical contaminants or other analytes using electronic noses or other sensors. In one embodiment, the invention uses sensors and detection sensor electronics that are separate from one another such that inexpensive sensors may be reused or discarded with a rejected item. The testing apparatus moves the sensors and items independently to align a sensor and item with a detection sensor unit and/or move each sensor into electrical contact with the detection sensor electronics.
The testing apparatus may utilize multiple sensor units to simultaneously test multiple items (e.g., cork stoppers) for a chemical contaminant (e.g., TCA). The invention provides a low-cost, reliable testing process for testing up to 100% of the items at production speed in a cost-effective way that is scalable to the general consumer market. Although the present invention is particularly described in connection with testing bottle stoppers made of cork for the presence of a particular analyte, those skilled in the art will readily appreciate that the invention can be adapted for testing virtually any type of item made of any type of material for the presence of one or more of a wide variety of analytes susceptible to detection by various sensors.
Referring now to the drawings, FIG. 1 shows in accordance with the present invention a testing apparatus, which is generally denoted by the numeral 100 . As mentioned, apparatus 100 may be adapted for testing virtually any items, but in the present example items are cork stoppers 110 . Apparatus 100 may include, among other things, a hopper/dispenser 105 , a plurality of receivers 115 (e.g., receivers 115 a , 115 b , 115 c , 115 d and 115 e ), a web 120 , a plurality of partitions 125 , a plurality of air movers 130 (e.g., air movers 130 a , 130 b , and 130 c ), a plurality of sensor units 135 (e.g., sensor units 135 a , 135 b , and 135 c ), a diverter 145 , a plurality of rollers 150 (e.g., rollers 150 a , 150 b , 150 c , and 150 d ), a recess 155 , an accept bin 160 and a reject bin 165 .
Hopper/dispenser 105 is a storing and dispensing device for stoppers 110 to be tested. Hopper 105 may be suspended over web 120 and controlled such that a single stopper 110 is dispensed into each receiver 115 . In alternative embodiments, hopper/dispenser 105 may be replaced with another device or mechanism, e.g., a conveyor or gated chute, that provides the same functionality of storing and/or delivering stoppers 110 to web 120 or other means for moving stoppers 110 .
Receivers 115 may be formed in web 120 such that they are open receptacles for stoppers 110 . The top opening of each such receiver 115 should be sufficiently large to receive one of stoppers 110 . Depending upon the location of sensor units 135 relative to web 120 , e.g., above or below, receiver 115 may include a bottom opening (not shown) that allows air to flow through the web. The bottom opening of each receiver 115 should be of sufficient size to retain stopper 110 on web 120 and provide sufficient airflow through web 120 to enable the detection of the analyte(s), if present, at sensor units 135 . Each stopper 110 may be helped into its proper position within receivers 115 by corresponding partitions 125 that provide a physical barrier between adjacent receivers.
Web 120 may be a continuous belt that is positioned around rollers 150 and formed of any suitable material, such as polyurethane or rubber that provides a sturdy, flexible support for stoppers 110 . Web 120 may be advanced, e.g., in a clockwise rotation, by rollers 150 or another means, not shown. Rollers 150 may be formed of any suitable material such as rubber or metal and may further include a recess 155 that facilitates passage of receivers 115 as web 120 is advanced. Of course, many alternatives to web 120 and rollers 150 exist for moving stoppers 110 into their testing positions proximate corresponding sensor units 135 . Such alternatives include other types of linear conveyors and rotational moving devices, among others. In other alternative embodiments, stoppers 110 may be fed to each sensor unit 135 by a feeder system dedicated to that sensor unit.
Sensor units 135 may be located in close proximity to receivers 115 , e.g., directly below the upper horizontal portion of web 120 . Of course, in other embodiments of apparatus 100 , sensor units 135 may be located in other suitable locations where testing can be effected, such as laterally adjacent to or above receivers 115 . Details and description of sensor units 135 are discussed below in connection with FIG. 3A .
Air movers 130 may by conventional air-moving devices that provide a flow of air over stoppers 110 in receivers 115 and to sensor units 135 . In the embodiment shown, air movers 130 are blowers located opposite corresponding sensor units 135 relative to corresponding receivers 115 . However, air movers 130 may be suction/blower devices located between corresponding receivers 115 and sensor units 130 or opposite the receivers relative to the sensor units. The airflow provided by air movers 130 is any airflow suitable to extract chemical vapors from stoppers 110 . For example, air movers 130 may be adapted to provide treated air, such as heated or pressurized air or nitrogen (N 2 ), and/or to facilitate removal of chemical vapors from stoppers 110 in receivers 115 . Depending upon factors such as the volatility and dispersion properties and amount(s) of the analyte(s) at issue and the proximity and sensitivity of sensor units 135 , air movers may not be required.
Diverter 145 may be provided to divert one or more contaminated stoppers 110 at a time from web 120 to prevent the rejected stoppers from being processed further along with the non-rejected, or “good,” stoppers. Diverter 145 may be any suitable device, such as a movable arm, and may divert the rejected ones of stoppers 110 to any suitable container, e.g., reject bin 165 , or location, e.g., a reject conveyor (not shown). Reject bin 165 , if provided, may be any suitable collection container that functions to hold rejected stoppers 110 (e.g., those determined to be contaminated with TCA). Similarly, accept bin, if provided, may be any suitable collection container that functions to hold accepted stoppers 110 (e.g., those determined to be not contaminated with TCA).
FIG. 2 is a high-level block diagram of a control system 200 for operating apparatus 100 of FIG. 1 . In one embodiment, control system 200 may include a computer 205 , a communication link 210 , a sensor system 215 and a conveyor controller 220 . Computer 205 may be any special-purpose or general-purpose computer, such as a desktop, laptop, or host computer having a processor, memory and storage (not shown) sufficient to run software applications for operating apparatus 100 .
Sensor system 215 may include a plurality of sensor electronics 225 (e.g., sensor electronics 225 a , 225 b and 225 n , where n indicates the corresponding sensor unit 135 in apparatus 100 ). Sensor electronics 225 includes the electronic circuitry, such as a power regulator, processor, memory and storage, sufficient to interface sensor system 215 to computer 205 so as to operate sensor units 135 of apparatus 100 . Sensor electronics 225 may further include the necessary circuitry, such as power regulator, processor, memory and storage, sufficient to run software applications (e.g., pattern signal handling capability and sensor pattern recognition algorithms) for sensor units 135 as described in more detail in reference to FIG. 3B . Such sensor electronics 225 can be readily designed by a person having ordinary skill in the art such that a detailed explanation of the sensor electronics is not necessary for those skilled in the art to understand and practice the present invention.
Conveyor controller 220 may include sub-controllers, e.g., a hopper/dispenser controller 230 , a web controller 240 , an air mover controller 250 , a diverter controller 260 and a bin-full controller 270 , to run the corresponding components of apparatus 100 . Hopper/dispenser controller 230 may include software algorithms to control the mechanical operation of hopper/dispenser 105 of apparatus 100 . For example, hopper/dispenser controller 230 may control the dispensing of stoppers 110 into receivers 115 . Web controller 240 may include software algorithms to control the mechanical operation of web 120 of apparatus 100 . For example, web controller 240 may control the rotation of rollers 150 to advance web 120 .
Air mover controller 250 may include software algorithms to control the mechanical operation of air mover 130 of apparatus 100 . For example, air mover controller 250 may control the flow of heated air from air movers 130 over stoppers 110 in receivers 115 and onto sensor units 135 . Diverter controller 260 may include software algorithms to control the mechanical operation of diverter 145 of apparatus 100 . Diverter controller 260 may be electrically connected to sensor units 135 .
Bin-full controller 270 may include software algorithms to control the mechanical operations of accept bin 160 and reject bin 165 of apparatus 100 . For example, bin full controller 270 may monitor the levels of stoppers 110 in accept bin 160 and reject bin 165 and indicate to computer 205 when accept bin 160 or reject bin 165 needs to be emptied.
Conveyor controller 220 and sensor system 215 may communicate with computer 205 via communication link 210 , which may be any suitable wired or wireless communications link. For example, communication link 210 may be a universal serial bus (USB) and may transmit data bi-directionally between computer 205 and sensor system 215 , and between computer 205 and conveyor controller 220 . Alternatively, communication link 210 may be a wireless link, such as an infrared or radio frequency link, among others.
FIG. 3A shows one of sensor units 135 . The others of sensor units 135 may be identical to the sensor unit shown for parallel testing of multiple stoppers 110 for the presence of the same analyte. However, the others of sensor units, if provided, may be different from the sensor unit shown. For example, one or more of the other sensor units 135 may be configured for different types of sensors for sensing other types of analytes. Each sensor unit 135 may include sensor electronics 225 , a plurality of nose chips 310 (only one being shown) or other sensors, a plurality of nose chip holders 315 (e.g., holders 315 a , 315 b , 315 c , 315 d ) a web 320 , a plurality of rollers 325 (e.g., rollers 325 a and 325 b ), and a plurality of probe fingers 330 (e.g., probe fingers 330 a , 330 b and 330 n , where n corresponds to the number of probe fingers needed to make nose chips 310 test-functional). Probe fingers 330 are in electrical communication with sensor electronics 225 .
Each nose chip 310 may include a plurality of sensor elements 311 and a plurality of contacts 312 . Each nose chip holder 315 may include a plurality of electrical leads 340 electrically connected to corresponding ones of contacts 312 and disposed on the holder such that when that holder is in its sensing position beneath a corresponding receiver 115 ( FIG. 1 ) containing one of stoppers 110 to be tested, the leads and probe fingers 330 may be contacted together so as to activate the corresponding nose chip 310 for testing that stopper. Such contact may be effected by moving nose chip holder 315 and/or probe fingers 330 into contact with one another.
Each nose chip 310 may include a sensor array containing a plurality of sensor elements 311 that detects a chemical analyte, such as TCA. Electrical traces or leads (not shown) may extend from sensor element 311 to contact pads 312 to electrically connect them to one another. Suitable sensor arrays include, but are not limited to, bulk conducting polymer films, semiconducting polymer sensors, surface acoustic wave devices, and conducting/nonconducting regions sensors. In one example, each nose chip 310 is a conducting/nonconducting region sensor in which conducting materials and nonconducting materials are arranged in a matrix (i.e., a resistor) and provide an electrical path between electrical leads. The nonconductive material may be a nonconducting polymer, such as polystyrene. The conductive material may be a conducting polymer, such as carbon black, an inorganic conductor. In use, the resistor provides a difference in resistance between the electrical leads when contacted with an analyte. In one example, nose chip 310 includes a sensor array specific for detection of a single analyte, such as TCA. Alternatively, nose chip 310 may include a sensor array for detecting two or more compositionally different analytes.
Each nose chip 310 may be attached to a corresponding nose chip holder 315 via wire bonds (not shown) between contact pads 312 and leads 340 on nose chip holders 315 . Leads 340 may be formed of any suitable material, such as a metal foil for conducting electrical current between nose chips 310 and probe fingers 330 . Probe fingers 330 provide a mechanical means to electrically connect nose chip holders 315 to sensor electronics 225 . Probe fingers 330 may provide standard electrical connections for lines, such as electrical power, ground, data input, and data output. Alternatively to providing probe fingers 330 , each nose chip 310 or nose chip holder 315 may have an on-board power supply (not shown), e.g., battery, for providing power to that nose chip and a wireless communication device (not shown), e.g., an infrared or radio frequency transceiver, for providing the communication link between the nose chip and sensor electronics 225 .
Nose chip holders 315 may be attached to and carried by web 320 , which may be formed of any suitable material, such as polyurethane or rubber, which provides a suitable support for the nose chip holders. Web 320 may be a continuous belt that is positioned around rollers 325 . Web 320 may be advanced, for example, in a clockwise rotation, by rollers 325 to align nose chips 310 with sensor electronics 225 . If finger probes 330 or other contact-type links are provided, they may be moved into contact with leads 340 using a suitable actuator (not shown) that may move the probes and/or sensor electronics 225 . Alternatively, when one of nose chip holders 315 is in its sensing position, that holder may be moved into contact with finger probes 330 , e.g., using an elevator (not shown) or other means. Rollers 325 may be conventional rollers formed of any suitable material, such as rubber or metal.
Nose chip holders 315 may be provided in any number on web 320 to suit a particular design. For example, if nose chips 310 are recycled, i.e., used over to test at least a second stopper 110 ( FIG. 1 ), the number of chip holders 315 and nose chips 310 will generally depend upon the recycle time, i.e., the time it takes a nose chip to recover from a worst-case analyte detection so as to be ready to detect the presence of the analyte again, and the frequency of the testing. For example, if the maximum recycle time for nose chips 310 is 60 seconds and the frequency of the testing is 0.5 seconds, then the number of nose chip holders 315 and nose chips should be greater than 60/0.5=120 to allow sufficient time for the worst-case nose chip(s) to recycle for another test. Alternatively, if nose chips 310 are not recycled but rather used only once, the number of nose chip holders 315 , if such holders are needed at all, may be practicably as few as two for a web-type delivery system, e.g., one of the two holders may be loaded with a fresh nose chip 310 while the other one is being used for a test. Then, the used nose chip may be removed from its holder as the fresh nose chip is moved into position for testing. Of course, more than two nose chip holders 315 may be used if desired. A single nose chip holder 315 may also be used, but would not be as efficient as having two or more such holders. Those skilled in the art will readily appreciate that nose chips 310 and/or nose chip holders 315 may be delivered to their testing locations by means other than a web-type conveyor. Such alternatives include other types of linear conveyors, rotational moving devices, ribbon-type feeding devices and cartridge-type feeding devices, among others.
Nose chip holders 315 and/or nose chips 310 may be covered with a removable cap (not shown) to protect nose chips 310 prior to a testing event. The arrangement of nose chip holders 315 and nose chips 310 on web 320 contains sufficient spacing between adjacent nose chip holders 315 such that nose chips 310 are not contaminated by overflow air during a testing event. For example, nose chip holders 315 b , 315 c and 315 d are sufficiently spaced from nose chip 310 such that when air is passed over nose chip 310 , the nose chips on nose chip holders 315 b , 315 c , and 315 d are not contaminated by overflow air when nose chip 310 is used to test stopper 110 ( FIG. 1 ).
Referring to FIG. 3B , sensor electronics 225 may include a power regulator 345 , a microprocessor 350 , a memory 355 , an analog-to-digital (AID) converter 360 , a digital-to-analog (D/A) converter 365 , a timing and control circuitry 380 and a computer interface 385 . Power regulator 345 may provide electrical power to microprocessor 350 , nose chip holders 315 and nose chips 310 . As mentioned above, electrical power to nose chip holders 315 and nose chips 310 may be provided via probe fingers 330 . For example, electrical power may be provided by probe finger 330 a and ground provided by probe finger 330 b . Power regulator 345 may provide a regulated or limited amount of power to nose chip holders 315 and nose chips 310 to optimize performance of nose chips 310 .
Microprocessor 350 may include the necessary processing electronics to extract and execute instructions stored in memory 355 . Such processing electronics are well-known in the art and, therefore, need not be described in detail herein for those skilled in the art to understand and practice the present invention. Memory 355 may provide storage of program codes, data, and other information. Examples of program code stored in memory 355 include program code that coordinates the operation of sensor units 135 and sensor pattern signal handling and pattern recognition algorithms or look-up tables to analyze data from nose chips 310 .
A/D converter 360 may provide analog-to-digital conversion of data (e.g., resistance measurements) as it passes from nose chips 310 to microprocessor 350 for further processing. D/A converter 365 may provide digital-to-analog conversion of data as it passes from microprocessor 350 to nose chips 310 . Timing and control circuitry 380 may provide, for example, timing signals for data acquisition from nose chips 310 and indexer functions to coordinate the advancement of web 320 by rollers 325 . Interface 385 facilitates communication between sensor electronics 225 and computer 205 and is in communication with computer 205 via communication link 210 .
The identification of an analyte may occur as follows. Power regulator 345 provides an electrical signal to nose chips 310 . A series of electrical traces (not shown) from each one of sensor elements 311 of nose chips 310 are connected to provide an electrical path through leads 340 and probe fingers 330 to A/D 360 and microprocessor 350 . Microprocessor 350 , using instructions stored in memory 355 and in timing and control circuitry 380 , converts an electrical signal generated from sensor elements 311 of nose chips 310 into a processed output signal. The instructions stored in memory 355 may include, e.g., a look-up table that compares incoming signals to stored reference values to provide an analysis. Alternately, an algorithm or other analytical means for providing a chemical analysis can be provided. In the presence of an analyte, e.g., TCA, a change in electrical resistance is detected and processed by microprocessor 350 . The results are output via interface 385 and communication link 210 to computer 205 .
FIG. 4 illustrates a method 400 of using apparatus 100 of FIG. 1 to provide screening of 100% of cork stoppers produced by a cork stopper manufacturer. Of course, method 400 and apparatus 100 may be adapted for testing of virtually any item other than a cork stopper, e.g., packaging, such as containers, lids, caps, etc., for foods and beverages. FIGS. 1-3 are referenced throughout the steps of method 400 , which may include the following steps. Those skilled in the art will recognize that method 400 is merely exemplary. Accordingly, the various steps of method 400 may be modified, deleted or replaced as needed to suit a particular design.
Step 405 : Setting Parameters
In this step, a user sets parameters for the testing operations desired. Examples of testing parameters include the number of stoppers 110 to be tested, the analyte(s) to be detected (e.g., TCA), acceptable concentration levels, i.e., testing thresholds, for the analyte(s), and baseline resistance values for sensor elements 311 for re-use calibration. Testing thresholds may be adjustable/selectable, e.g., to allow for quality variations or suit the particular items being tested. Testing threshold ranges will typically be dependent upon the sensitivity of nose chips 310 or other sensor to the analyte(s) being tested. For example and with regard to TCA, the most adept humans have a detection threshold of about 10-20 parts-per-trillion (PPT) in air. Consequently, it is desirable that nose chips 310 be able to detect the presence of TCA at a level lower than 10-20 PPT at the same conditions. Method 400 proceeds to step 410 .
Step 410 : Checking all Nose Chips
In this step, sensor unit 135 performs a scan of nose chips 310 on web 320 to ensure that all nose chips 310 are operational. For example, sensor electronics 225 may determine the baseline resistance values of sensor elements 311 . If the baseline resistance values are at or above a certain value, nose chips 310 are reset or discarded and replaced. Method 400 proceeds to step 415 .
Step 415 : Dispensing Stoppers
In this step, individual stoppers 110 are dispensed into receivers 115 in web 120 . For example, software algorithms on conveyor controller 220 (e.g., web controller 240 ) are used to move rollers 150 and align web 120 with hopper/dispenser 105 such that receiver 115 a is directly beneath the hopper/dispenser. Stoppers 110 in hopper/dispenser 105 are dispensed into receiver 115 a using software algorithms in hopper/dispenser controller 230 such that a single stopper 110 is dispensed. Web 120 is advanced, for example, in a clockwise direction, and the process is repeated until the appropriate numbers of receivers 115 (e.g., receivers 115 b , 115 c and 115 d ) are filled. Method 400 proceeds to step 420 .
Step 420 : Activating Airflow
In this step, airflow is activated and directed or drawn over stoppers 110 in receiver 115 to extract chemical vapors (e.g., TCA) from stoppers 110 . For example, air movers 130 may be activated using software algorithms in air mover controller 250 to provide airflow (e.g., a flow of heated air) over stoppers 110 . As air flows past stoppers 110 , the chemical vapors from stoppers 110 are mixed with the heated air and are carried toward sensor units 135 , where sensor elements 311 on nose chips 310 are exposed to the air/vapor mixture. Method 400 proceeds to step 425 .
Step 425 : Sensing Analyte
In this step, each sensor unit 135 determines the level of one or more analytes in the air/vapor mixture. The identification of an analyte typically occurs as follows. An electrical signal is provided by power regulator 345 to nose chips 310 . A series of electrical traces (not shown) from each of sensor elements 311 of nose chips 310 are connected to provide an electrical path through leads 340 and probe fingers 330 to A/D 360 and microprocessor 350 . Microprocessor 350 , using instructions stored in memory 355 and in timing and control circuitry 380 , converts an electrical signal generated from sensor elements 311 of nose chips 310 into a processed output signal. The instructions stored in memory 355 include, for example, a look-up table that compares incoming signals to stored reference values to provide an analysis. Alternatively, an algorithm or other analytical means for providing a chemical analysis can be provided. In the presence of an analyte, e.g., TCA, a change in electrical resistance is detected and processed by microprocessor 350 . The results are output via interface 385 and communication link 210 to computer 205 . Method 400 proceeds to step 430 .
Step 430 : Advancing Web
In this step, web 120 is advanced an appropriate increment to position the receiver, e.g., receiver 115 d , in proximity to diverter 145 . Method 400 proceeds to step 435 .
Step 435 : Bad Stopper?
In this decision step, software algorithms in sensor electronics 225 determine whether any of the one or more undesirable analytes being tested, e.g., TCA, is present on stopper 110 , as measured by the corresponding nose chip(s). If yes, method 400 proceeds to step 440 . If no, method 400 proceeds to step 450 .
Step 440 : Diverting Stopper
In this step, diverter 145 is activated using software algorithms in diverter controller 260 and a rejected stopper 110 is diverted to reject bin 165 . Nose chip 310 corresponding to that rejected stopper 110 may be discarded with the rejected stopper or, alternatively, may be recycled and reset for re-use, depending upon the reusability of the nose chip. Bin full controller 270 may monitor the levels of rejected stoppers 110 in reject bin 165 , and a signal is generated when reject bin 165 is full. Method 400 proceeds to step 445 .
Step 445 : Replacing Nose Chip
In this step, if nose chips 310 are of the non-reusable type, a new nose chip 310 and/or nose chip holder 315 is replaced on web 320 . Method 400 may proceed to step 455 .
Step 450 : Collecting Stopper
In this step, web 120 is advanced an appropriate increment to position the receiver, e.g., receiver 115 d , in recess 155 of roller 150 a . As receiver 115 d is advanced over roller 150 a , stopper 110 in recess 155 falls out of receiver 115 d into accept bin 160 . Bin-full controller 270 may monitor the levels of collected stoppers 110 in accept bin 160 and generate a bin-full signal when the accept bin is full. Method 400 proceeds to step 455 .
Step 455 : More Stoppers?
In this decision step, it is determined whether additional stoppers 110 are available for screening. For example, the total number of stoppers 110 to be screened are set in step 405 and software algorithms are used to track the number of stoppers 110 dispensed from hopper 105 and screened by sensor units 135 to determine whether a stopper 110 remains to be screened. If yes, method 400 returns to step 410 . If no, method 400 ends.
While the present invention has been described in connection with a preferred embodiment, it will be understood that it is not so limited. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined above and in the claims appended hereto.
|
An apparatus and method for automatedly detecting the presence of one or more chemical contaminants, such as 2,4,6-trichloroanisole, in/on a plurality of cork wine bottle stoppers in rapid succession using electronic nose chips. The apparatus moves the nose chips and the cork stoppers independently to align the cork stopper and a corresponding electronic nose chip with one another for testing. The automated apparatus and method provides a low-cost, reliable process for testing 100% of cork wine bottle stoppers in a fast and cost-effective manner.
| 6
|
FIELD OF THE INVENTION
The present invention relates to a framework system for use in creating a climbing frame or play enclosure for children. The framework system is particularly for use in construction by a final consumer on behalf of the children and can be of various sizes, which can be built up using a number of lengths of metal or plastic tubes or rods and novel connectors.
THE PRIOR ART
It is known but not commonly known to construct a heavy-duty frame structure that utilises lengths of square cross-section metal tubing, which are connected by means of a limited range of connectors each comprising a central body having two or more projections inserted into the ends of lengths of tubes to form a joint therebetween. The range of connectors includes 90-degree joints, T joints and corner joints, all requiring tubes to be joined at right angles. This use of right angles limits the frameworks to being of rectangular configuration.
The provision of a wider range of connectors is made difficult by the need to provide projections for all the required angles and to provide a connector, which is dedicated to a particular type of joint.
However of primary concern is that such connectors are generally metal prongs which frictionally and tightly fit into the square metal tubes to form rectangular shelving structures on which loads are supported. This known prior art system therefore does not allow forces in various directions without prospect of accidental disassembly as required for climbing structures and does not allow ready construction and deconstruction.
OBJECT OF THE INVENTION
It is an object of the present invention to overcome or at least ameliorate the problems of the prior art.
It is another object to provide an improved connector and interconnecting tube system, which can be used to form a framework system that will not accidentally disassemble.
It is a further object of the invention to provide a predetermined limited range of connectors and limited number of lengths of interconnecting tubes, which can be combined with each other to build up specific shaped frameworks that are able to be a climbing frame or play enclosure for children.
SUMMARY OF THE INVENTION
According to the invention there is provided a framework system comprising a plurality of cylindrical connector rods having predetermined fixed lengths; a plurality of connectors with angular spaced radially extending fingers and camber angle to a plane normal to the axis of the connector, the fingers allowing connection to the connectors rods.
A plurality of connector rods can be attached to a plurality of connectors connected to the ends of other connector rods to form an interconnected geometric shaped unit with base of substantially regular geometric shape for resting on the ground and an interconnected substantially hemispherical top shape wherein the continuous base and interconnected geometric top shape provide structural integrity to the framework system.
The framework system can use one or more adjustable length connector rods to fit between connectors and allow fitting of final connectors and adjustment to ensure a rigidity and structural integrity of continuous base and interconnected geometric top shape.
The connectors can be retained in connection with the connector rods by interconnecting detent means. The connector rods can be of a lightweight material with sufficient load bearing capacity but could be at least partially flexible and the connectors with the detent means interconnect sufficiently at each end with the connector rods to retain the interconnection of the continuous base and interconnected geometric top shape.
Also according to the present invention, there is provided a connector for use in creating a framework having a particular shaped framework formed by a plurality of connectors and a plurality of detachable connecting cylindrical rods for connecting between spaced connectors, the connector having a body portion having a plurality of emanating fingers with each finger having a shape able to interfit with the end of a connecting cylindrical rod; and each finger further having a spring mounted detent allowing for sliding of the finger into engagement with the end of the connecting cylindrical rod and receiving of the detent into a recess or opening at the end of the connecting cylindrical rod for selectively retaining the connection of the connecting cylindrical rod with the connector.
Preferably the fingers are sized to fit within the end of hollow ended connecting cylindrical rods. The rods can have a circular cross section and the fingers can be formed to fit within the circular cross section.
The detent means can be a protruding button able to interfit into a recess or opening in the hollow ended connecting cylindrical rods.
It can be seen that an important aspect of the connector is the detent means if the connecting cylindrical rods are to be allowed to be at least partially flexible. This avoids the need to avoid any flex and thereby avoids having to use heavy duty steel piping. The detent means will prevent the rod slipping off the finger to cause accidental disassembly. Therefore the connector allows construction of a safe climbing frame for children.
The connector in a particular form comprises a central circular shaped body with the fingers radially emanating at predefined radial angle between fingers and each finger at a predefined constant camber angle from a plane normal to the axis of the central circular shaped body. The central shaped body can be a substantially hemispherical shape.
An important result of this form of the connector is that the connector will have a consistent form regardless of the number of emanating fingers to allow a structure using a number of connectors with a different number of fingers to form an apparent uniform look.
A connector can have a plurality of fingers. In various forms there are two, three, four, five or six fingers to accommodate a variety of angles of interconnection of cylindrical connecting rods. It can include fingers protruding at inter radial angle of 72°, 60° or 45° in order to form substantially pentagonal, hexagonal or octagonal based frameworks respectively. Other predetermined angles can be used for other predetermined shaped framework.
The plurality of fingers on a single connector can emanate from the connector body at a constant camber angle. This camber angle for each finger is a consistent angle to a plane normal to the axis of the central circular body and can be of the order of 15° to 30°.
The fingers can protrude from a circumferential part of the central circular shaped body. However, preferably the fingers include a portion of ribbing extending radially from a more central portion of the inner side of the hemispherical shape. In this way the linear radially extending fingers including the ribbing and the hemispherical shape form a strong low weight connector with strength both along the radial direction and between the radial directions of the fingers.
The detent can be achieved by means of a resilient means mounted between radially extending ribbing of the fingers and connected to a protruding button which can extend outwardly from the cylindrical circumferential extremities of the finger to engage an opening in the side of a hollow cylindrical end of connecting rod, thus preventing relative sliding movement of the rod and finger of the connector for accidental disassembly.
The resilient means can be a spring means. The spring means can be a folded plastic element having an acute expanded angle as the rest position but the material allowing resilient compression to a compressed angle until released. Each finger can include a ribbing structure for receiving therebetween in sliding mode said folded plastic element.
The connector can include an opening for receiving a plug or extension member. In one form the opening is centrally located in the connector body with peripherally emanating fingers.
The plug insertion into the connector opening can be a cover disc mounted on a neck portion that can frictionally interfit in the centrally located connector opening. The plug insertion can further have a cylindrical body sized smaller than the cover disc and the frictional engaging neck and having spaced longitudinal slits to form resilient deformable legs. The legs can assist in resiliently holding material in the connector opening.
It can be seen that an important aspect of the connector is the central connector opening and plug means as it allows for selective connections and prevents openings being left which can cause injury to children allows construction of a safe climbing frame for children. However another fundamental advantage is that the plug can frictionally hold material such that the framework can provide a skeleton that is covered by material, which is held in place and provides shaped play enclosure for children. By particular printed material a theme structure can be readily constructed.
Another importance of the connector opening is for receiving collapsible framework with material attached. In this way an extension upwardly of the framework remains safe in that the collapsible framework readily expands to provide a shaped enclosure but upon any weight will collapse and therefore not provide an extension of the structure for further climbing.
The opening of connectors the framework system can be of a form that selectively can receive any one of a plug, an extension elbow or a collapsible framework. However in another form the connector opening could be able to only receive a plug or a collapsible framework. In this way the framework structure cannot be extended upwardly to cause a structure which no longer has sufficient base stability and is of a height that is dangerous if children fall.
Also according to the invention there is provided a framework system comprising a plurality of first cylindrical connector rods having a first length; a plurality of second cylindrical connector rods having a second length; a plurality of third adjustable connector rods having an adjustability of length around a third length; a plurality of first connectors with constant angular spaced radially extending fingers and constant camber angle to a plane normal to the axis of the connector, the fingers allowing connection to the connectors rods; a plurality of second connectors being interconnection connectors with angular spaced radially extending fingers and constant camber angle to a plane normal to the axis of the connector, the fingers allowing connection to the connectors rods; a plurality of third connectors being base connectors having a plurality of angular spaced radially extending fingers emanating from one side of the connector and constant camber angle to a plane normal to the axis of the connector, the fingers allowing connection to the connectors rods; one or more fourth connectors being top connectors having a plurality of angular spaced radially extending fingers emanating from central body with a constant camber angle to a plane normal to the axis of the connector, the fingers allowing connection to the connectors rods.
The framework system allows a plurality of first connector rods to be attached to a first connector and a plurality of second and third connectors connected to the ends of the first connector rods and connected therebetween by a plurality of second connector rods to form a geometric shaped unit with base connectors at the base of the geometric shape for resting on the ground; and interconnecting connectors allowing a plurality of said geometric shaped units to interconnect laterally wherein the constant camber forms an enclosed framework shape; and allowing for third adjustable connector rods to fit between the base connectors of adjacent geometric shaped units to form a continuous enclosed linear base extending in a plane; and allowing for one or more fourth top connectors to connect a top portion of the adjacent geometric shaped units to form a united top shape; wherein the continuous base and interconnected geometric shaped units and the united top shape provide structural integrity to the framework system.
The connectors can be retained in connection with the connector rods by interconnecting detent means.
The shaped unit can be a hexagon and the camber can be such that the framework provides four shaped units to interfit with a substantially distorted hexagonal base and a united top shape, which is rectangular.
It can be seen that the framework system allows a minimal required parts but due to the geometric shape and the continuous base and top provides a strong non rectangular and enclosed structure framework able to be used in creating a climbing frame or play enclosure for children. The detent means allows the connecting cylindrical rods to be at least partially flexible and the detent means will prevent the rod slipping off the finger to cause accidental disassembly. Therefore the connector allows construction of a safe climbing frame for children.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention is more readily understood, the invention will be further described by way of example with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of a first embodiment of a shaped framework formed by a framework system in accordance with the invention;
FIG. 2 is a side elevation of the shaped framework of FIG. 1 ;
FIG. 3 is an overhead perspective view of a first three fingered connector in accordance with an embodiment of the invention for forming the shaped framework of FIG. 1 ;
FIG. 4 is an underneath elevation of the first three fingered connector of FIG. 3 ;
FIG. 5 Is an overhead perspective view of a second three fingered connector forming a 45° base corner in accordance with an embodiment of the invention for forming the shaped framework of FIG. 1 ;
FIG. 6 is an overhead perspective view of a third six fingered connector in accordance with an embodiment of the invention for forming the shaped framework of FIG. 1 ;
FIG. 7 is an overhead perspective view of a fourth four fingered connector forming a base connector in accordance with an embodiment of the invention for forming the shaped framework of FIG. 1 ;
FIG. 8 is an overhead perspective view of a fifth five fingered connector with extension elbow connector in accordance with an embodiment of the invention for forming the shaped framework of FIG. 1 ;
FIG. 9 is an overhead perspective view of an extension elbow connector as used in FIG. 8 in accordance with an embodiment of the invention for forming the shaped framework of FIG. 1 ; and
FIG. 10 is an overhead perspective view of a plug for insertion into a connector in accordance with an embodiment of the invention for forming the shaped framework of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and particularly FIGS. 1 and 2 there is shown a framework system 11 in accordance with an embodiment of the invention, which is particularly for use in construction of a climbing frame or play enclosure for children by a final consumer on behalf of the children.
The framework system comprises a number of lengths of circular cross sectional hollow cylindrical rods and novel connectors. The fingers are sized to fit within the end of hollow ended connecting cylindrical rods. The rods have a circular cross section and the fingers are formed to fit within the circular cross section.
In particular the framework system 11 has a plurality of first cylindrical connector rods 31 having a first length; a plurality of second cylindrical connector rods 32 having a second length; and a plurality of third adjustable connector rods 33 having an adjustability of length around a third length.
The lengths of the connector rods are as follows:
Length
Connector Rods
(nearest mm)
Variation of length
First connector rods 31
600
Nil
Second connector rods 32
551
Nil
Third connector rod 33
402
+/−5 cm adjustable thread
The framework system also includes a plurality of connectors including first connectors 21 with six (6) equi-angular spaced radially extending fingers; a plurality of second connectors 22 being interconnection connectors with angular spaced radially extending fingers; a plurality of third connectors 23 being base connectors having a plurality of angular spaced radially extending fingers emanating from one side of the connector; and a plurality of fourth connectors 24 being top connectors having a plurality of angular spaced radially extending fingers.
Each connector has a central shaped body which is a substantially hollow hemispherical shape having a plurality of emanating fingers with each finger having a shape able to interfit with the end of a connecting cylindrical rod. From above such as in FIG. 3 each finger appears to protrude from a circumferential part of the central circular shaped body. However, from below as shown in FIG. 4 the fingers include a portion of ribbing extending radially from a central opening of the inner side of the hemispherical shape. In this way the linear radially extending fingers including the ribbing and the hemispherical shape form a strong low weight connector with strength both along the radial direction and between the radial directions of the fingers.
The various connectors have various angularly spaced radially extending fingers. The angles (to the nearest degree) between them are as follows:
No. of
radially angular
Connector
fingers
spacing
Camber
First connectors
6
All 60°
All 22°
(21)
Second connectors
5
66°, 66°,
39°, 38°,
(22)
66°, 66°, 96°
18°, 17°, 18°
down respectively
Third connectors
4
48°, 66°,
27°, 19°,
(23)
66°, 180°
18°, 19°
down respectively
Fourth Connector
6
66°, 66°,
(24) being
66°, 66°, 96 +
Combination
90 degree vert post
Connector of
Second connector
(22) and extension
connector (25)
The fingers further extend at a constant camber angle to a plane normal to the axis of the connector, the fingers allowing connection to the connector rods. As shown in FIG. 3 each of the fingers extends partially downwards at a constant angle. That camber angle is about 20 degrees.
There are other ancillary connectors 25 , 26 27 and 28 , which perform ancillary functions. For example ancillary connector 25 is an elbow joint such as shown in FIG. 9 and in effect only comprises the camber angle and allows for insertion in central body opening as shown in FIG. 8 for providing an extension element. That extension element can be an addition of a box on top of the shaped framework 12 as shown in FIG. 1 . Other ancillary connectors can complete the addition of triangular or rectangular extensions.
Each finger further has a spring mounted detent allowing for sliding of the finger into engagement with the end of the connecting cylindrical rod and receiving of the detent into a recess or opening at the end of the connecting cylindrical rod for selectively retaining the connection of the connecting cylindrical rod with the connector. The detent means will prevent the connector rod slipping off the finger to cause accidental disassembly. Therefore the connector allows construction of a safe climbing frame for children.
The detent is achieved by means of a resilient means mounted between radially extending ribbing of the fingers and connected to the protruding button which extends outwardly from the cylindrical circumferential extremities of the finger to engage an opening in the side of a hollow cylindrical end of connecting rod, thus preventing relative sliding movement of the rod and finger of the connector for accidental disassembly. The resilient means is a spring means in the form of a folded plastic element having an acute expanded angle as the rest position but the material allowing resilient compression to a compressed angle until released. Each finger can include a ribbing structure for receiving therebetween in sliding mode said folded plastic element.
In use the final consumer uses the framework system to form a framework shape 12 by the following steps:
1. a plurality of first connector rods of first constant length are attached to a first 6 fingered connector with each finger equally radially separated but with constant camber to form a spider arrangement; 2. two of the second base connectors connect to two separate adjacent unattached distal ends of the connected spider arrangement to form a ground engaging base of the spider arrangement; 3. two of the third interconnecting 5 finger connectors connect to the two laterally opposite unattached distal ends of the connected spider arrangement to allow attachment to adjacent spider arrangements; 4. and two of the fourth top connectors connect to the ends of adjacent top unattached distal ends of the connected spider arrangement; 5. six of the first connector rods having second length are connected between the connectors at the unattached distal ends of the connected spider arrangement to form a geometric hexagonal shaped unit with connectors able to interconnect with other adjacent connector rods; 6. steps 1 to 5 are repeated to form an identical structure; 7. the two structures are leant back to back such that the camber forms two concave shapes closing together like a clam shell but remaining spaced at the top 8. the spaced tops are connected together by two first connector rods to maintain the two concave shapes a fixed distance at the top; 9. steps 1 and 2 are repeated twice more to form two further spider forms with concave forms; 10. the two adjacent base connectors of each spider are each respectively joined by a second connector rod of second length to form ground engaging base; 11. the two separate adjacent unattached top distal ends of each of the connected spider arrangements are attached to opposite top connectors of the first and second joined geometric hexagonal shaped units; 12. the two separate adjacent unattached lateral distal ends of each of the connected spider arrangements are attached to opposite lateral interconnecting connectors of the first and second joined geometric hexagonal shaped units to thereby form four concave geometric hexagonal shaped units leaning towards each other and joined at a top position in a rectangular shape and joined at a lateral mid point to each other; 13. the spaced bases of each of the four concave geometric hexagonal shaped units due to the lean are then joined by third connectors of third length to form a continuous base; however to ensure tightness of the link and not rely on the flexibility of the connector rods the third connectors are extendible to be able to be placed between base connectors and then expanded; 14. other ancillary shapes can be added.
The connectors each include an opening for receiving a plug or extension member, centrally located in the connector body with peripherally emanating fingers. The plug as shown in FIG. 10 is inserted into the connector opening and has a cover disc mounted on a neck portion that can frictionally interfit in the centrally located connector opening. The plug further has a cylindrical body sized smaller than the cover disc and the frictional engaging neck and having spaced longitudinal slits to form resilient deformable legs. The legs can assist in resiliently holding material in the connector opening such that the framework provides a skeleton, which is covered and provides shaped play enclosure for children. By particular printed material a theme structure can be readily constructed.
It can be seen in this embodiment that the fourth connector uses the second connector with an extension joiner from the centre. Further the third base connectors have a left or right orientation dependent on whether the large angle is to the left or right. The base connectors in this embodiment need to be fitted alternatively with either a left or right orientation third base connectors around the base.
It should be understood that the above description is of a preferred embodiment and included as illustration only. It is not limiting of the invention. Clearly variations of the framework system would be understood by a person skilled in the art without any inventiveness and such variations are included within the scope of this invention as defined in the following claims.
|
A load bearing framework system ( 11 ) for use as ready to assemble playground equipment constructed of a plurality of connector rods ( 31, 32 ) having fixed lengths and one or more adjustable length rods ( 33 ) and a plurality of connectors ( 21, 22, 23, 24 ) with angular spaced radially extending fingers and a camber angle to a plane normal to the axis of the connector, the fingers shaped relative the end of the connector rods allowing connection of a plurality of the connectors rods. The framework forms an interconnected geometric shaped unit with a substantially planar base of regular closed geometric shape for resting on the ground and an interconnected substantially hemispherical top shape. Detent means can retain connector rods and connectors together.
| 0
|
FIELD OF THE INVENTION
This invention relates to cigarette making machines and is particularly concerned with a portable machine for filling a preformed paper tube with a compressed plug of tobacco to form a cigarette.
SUMMARY OF THE PRIOR ART
In its simplest form, a manually operated machine for filling preformed paper tubes comprises a two-part casing defining a cylindrical cavity and an ejector piston within the said cavity. Examples of such machines are to be found in U.K. Patent Specifications Nos. 340841 (Cantounis), 717167 (Bloom) and 902887 (Ritter et al). In a modified form of machine described in U.K. Specification No. 507125 (Boerner) tobacco is forced into a cylindrical trough by means of a compression member or rammer and then injected into the cigarette tube by means of a combined tobacco spoon and rammer. Both of these types of machine are operated directly by the user without any mechanism intervening between him and the tobacco.
In addition to these simple machines there has been a requirement for a slightly more elaborate machine in which the operations of compression of a charge of tobacco to form a cylindrical plug and injection of the tobacco plug into the paper tube are carried out through an intermediate mechanism which reduces the operating force required and provides a more consistent product. A known type of mechanism for these machines which employs connecting rods forming a pair of jointed parallelograms to actuate a compression device and employs a combined ejector piston tobacco spoon is described in U.K. Specifications Nos. 464948 (Chaze) and 726742 (Kastner) and Canadian Specification No. 973048 (Kastner). Other known machines are described in U.K. Specifications Nos. 725058 (Kastner), 1176433 (Efka-Werke) and 1321015 (Kastner).
As will be apparent from the references mentioned above, attempts have been made to operate both the tobacco compression and the tobacco ejection mechanisms by means of a single operating lever in order to make the machines more convenient and simple to use. However, the known machines require complicated linkages involving a large number of 15 working parts and are thus expensive owing to their complexity.
SUMMARY OF THE INVENTION
The present invention aims to provide a cigarette making machine which is simple and compact and enables the machine to be operated by a single lever.
According to the invention, there is provided a cigarette making machine comprising:
a fixed member having a first semi-cylindrical surface;
a compression member having a second semi-cylindrical surface and movable between a first position in which said first and second surfaces are radially spaced and a second position in which said surfaces abut to define a cylindrical cavity for a charge of compressed tobacco;
means defining a slot through which tobacco can be inserted, with the compression member in the first position, into a space between said first and second surfaces;
a nozzle communicating with an end of said cavity and adapted to receive the end of a preformed paper tube; means for ejecting a charge of compressed tobacco through said nozzle into said paper tube;
a sliding member actuated for movement towards or away from the first semi-cylindrical surface and including a first rack;
a lever pivotally secured to said compression member, operatively secured to said ejection means and having gear teeth in meshing engagement with said rack; and
restraining means adapted to restrain rotation of said lever in a first portion of the travel of said sliding member from its rest position in which said compression member travels from said first to said second positions, and to disengage from said lever when said compression member has moved to said second position whereby said lever rotates in a second portion of the travel of said sliding member to cause said ejection member to force said compressed tobacco through said nozzle into said paper tube.
The foregoing and other objects of the present invention will be apparent from the following more detailed description of a preferred embodiment thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be further described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is an exploded perspective view of one embodiment of a machine according to the invention;
FIG. 1a is an enlarged detail view of the tobacco receiving chamber in the top face of the packing block shown in FIG. 1;
FIG. 2 is a plan view of the machine shown in FIG. 1 with the top cover removed and showing the operating lever in the inoperative position;
FIG. 3 is a section taken on the line III--III in FIG. 2 and showing the top cover in position; and
FIGS. 4 and 5 are views, corresponding to FIG. 2, showing intermediate positions of the mechanism during operation of the operating lever.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, it will be seen that the machine is generally T-shaped in plan with a tobacco receiving chamber 34 in the head portion of a T-shaped casing and an actuating mechanism in the tail portion of the casing to which an operating handle 58 is also pivoted.
The machine includes a casing comprising a base 1 and a lid 62. A pin 9 projects upwardly from the base 1 (FIG. 3) adjacent the end of the tail portion thereof and on the longitudinal central line. It carries a sleeve or bush 18 of nylon or other plastics material which is free to rotate on the pin 9. The base has a peripheral wall 2, in one side of the tail portion of which a semi-circular recess 3 is formed at an intermediate lengthwise position. A bearing cup 4 is disposed against the inner face of the peripheral wall 2 on the opposite side of the tail portion at the same longitudinal position as the recess 3. Located on the base of the casing between the recess 3 and the bearing cup 4 is a guide channel 5 defined by a ring having linear side edges directed longitudinally and having semi-circular ends. A pair of longitudinally directed guide ribs 8 is also disposed symmetrically in the tail portion of the base 1 each intermediate the guide channel 5 and a respective part of the peripheral wall 2. A recess is provided in a first side face of the head portion of the base. The region of the peripheral wall 2 at the base of the recess is formed with a spigot slot 6 directed longitudinally and the region of the peripheral wall 2 defining a forward lateral wall of the recess is formed with a further slot 7 for the reception of a buffer 11 of rubber or like resilient material. The lid 62 is shaped in conformity with the base 1 and has a peripheral wall dimensioned so as to butt against the peripheral wall 2 of the base and having a semi-circular recess corresponding to the recess 3 and a slot corresponding to the spigot slot 6. The top cover has in its head region an opening 63 which overlies the tobacco receiving chamber 34 and by means of which the chamber can be charged with tobacco. A rib 64 (FIG. 3) depending from the inner face of the cover is disposed parallel to the opening 63 on the head side of the opening. The cover 62 is further provided with a projection 68 depending from its inner face and positioned so as to be engageable with the pin 9 projecting from the base of the casing. The top cover and the base can be secured together by any suitable means, e.g., they may be screwed or snap-fitted together.
A U-shaped plate 12 is fitted in the casing to rest on the base 1 with the limbs of the U facing towards the tail of the machine and located to either side of the guide channel 5. The lower face of the plate is provided with ribs 13 which slidingly engage the ribs 8 on the base of the casing. The upper face of the plate 12 is provided along each side edge with a toothed rack 14 and spaced laterally from the racks 14 with a pair of guide ribs 15 and 16. The rib 16 is wider than the rib 15 and is provided on its inner side edge with a toothed rack 17.
The teeth of a toothed quadrant are meshed with the teeth of the rack 17. The quadrant is formed with a radially extended sector defining a cam surface 23 bounded by end faces 22, 24. The quadrant is further provided with a central bore 25 and an arm 26 extending radially from it substantially opposite the radially extended sector. A bore 27 is provided adjacent the outer end of the arm 26. The central bore 25 receives the larger diameter portion of a compression member or stepped circular projection 32 on the lower face of a packing block 31 (described below), and the smaller diameter lower end portion of the projection 32 engages within the guide channel 5. When the projection 32 is at the tail end of the channel 5 the end face 22 engages the bush 18 on the pin 9 and prevents rotation of the quadrant. Movement of the U-shaped plate 12 forwardly towards the head of the machine moves the surface 22 past the sleeve or bush 18 until the surface 22 has disengaged therefrom and the projection 32 has reached the head end of the channel 5, after which further forward movement of the plate 12 causes the quadrant to rotate on the projection 32 in an anti-clockwise direction as seen in FIGS. 4 and 5, the curved outer face of the cam surface 23 moving past the bush 18. The above movement is reversible, rearward movement of the plate 12 first rotating the quadrant clockwise as seen in FIGS. 4 and 5. During the initial portion of the reverse movement, the cam surface 23 engages the bush 18 to permit reverse rotation of the quadrant, but to prevent tailward movement of the quadrant until the quadrant has rotated back to its original position in which the end face 22 is engageable with the bush 18 after which the quadrant is free to move tailwards and the projection 32 moves towards the tail end of the guide channel 5 while the end face 22 slides past the pin 9 supported on the sleeve or bush 18.
A packing block 31 which may be made of plastics or other suitable material is fitted over the quadrant 21 and is dimensioned to fit within the T-shaped casing. The tail portion of the packing block bears the stepped projection 32 on its lower face at an intermediate longitudinal position, and it also has a pair of depending side walls 33 which are engaged and guided by the guide ribs 15 and 16 on the plate 12. The head end of the packing block is provided in its upper face with a recess defining part of a tobacco receiving chamber 34 having a semi-cylindrical end wall 35 and front and rear side walls 34B and 34A respectively. A nozzle 38 is provided on the front side wall 34B of the block, and it surrounds and extends from a bore in the side wall at the front end of the tobacco receiving chamber. A generally horizontal slot 37 is formed in the semi-cylindrical end wall 35 and is continued in a rearward extension 31A of the packing block, the head end face of the extension 31A conforming to the curvature of the wall 35 and a bore being formed in the rear side wall 34A in alignment with the end wall 35. A plunger 41 has a pair of axially spaced apertures alignable with a corresponding aperture at the rear end of a tobacco spoon 45. A slide comprises a plate 43 bearing on its lower face a peg 44 and on its upper face a vertical web 43A terminating in horizontally directed fixing lugs 43B and 43C. The slide is fitted to the packing blocks with the fixing lugs 43B and 43C projecting through the slot 37, and the slot in the tobacco spoon 45 is engaged with the fixing lugs, after which the plunger 41 is snap fitted to retain the tobacco spoon in place. Accordingly the resulting tobacco spoon assembly is slideable in either direction transversely of the machine between an extended position in which the front end of the tobacco spoon projects through nozzle or the spigot 38 and a retracted position in which the front end of the tobacco spoon overlies the semi-cylindrical end wall 35 and the plunger 41 has moved backward into the rearward extension 31A. The tobacco spoon 45 may be provided, in known manner, throughout its length with projections which serve to advance the tobacco into a preformed paper cigarette tube but which permit the spoon to be withdrawn from the tube after filling without disturbing the tobacco therein. The upper ends of the side walls 34A and 34B bear inwardly directed flanges 34C and 34D which retain a fixed member 65 of plastics or the like material which has a semi-cylindrical tail end face 67 and a transverse slot 66 in its top face which engages the rib 64 on the inner face of the cover to prevent relative longitudinal movement between the compression member and the cover. The upper surface of the packing block is extended to form a top wall 80 to the compression chamber in spaced parallel relationship to the floor thereof and terminating in a cutting edge 81 directed obliquely at a small acute angle to the top edge of the compression member 65. When the packing block 31 is at the tail end limit of its travel the fixed member 65 is moved clear of the cutting edge 80 to define an opening into the tobacco receiving chamber 34, which opening registers with the tobacco slot 63 in the cover. As the packing block moves towards the head of the machine, the cutting edge 81 passes over the top inner end of the fixed member 65 and because of its slightly oblique direction cooperates with the adjoining edge of the compression member to exert a guillotine-like cutting action on strands of tobacco protruding from the tobacco receiving chamber 34. At the head end of the travel of the packing block, the semi-cylindrical surfaces 35 and 67 define a generally cylindrical cavity containing a plug of compressed tobacco.
The slide is connected to the quadrant 21 by a connecting link 46 having a peg 47 for engaging in the bore 27 at the outer end of the arm 26 of the quadrant and a bore 48 for receiving the peg 44 projecting from the lower face of the plate 43. The pegs 44 and 47 are free to rotate in their respective bores 48 and 27.
A driven pinion assembly comprising a pair of pinions 51 and 52 interconnected by a bar 53 of T-shaped cross-section lies on top of the packing block 31 with the teeth of the pinions 51 and 52 in meshing engagement with the racks 14 on the plate 12. The pinion 51 is provided with a cylindrical stub shaft 54 on the side remote from the bar 53. A bearing cup 55 of nylon or like material is fitted over the shaft 54 and, in the assembled condition of the mechanism, is received in the cup 4 in the casing. The other pinion 52 is provided, in its side remote from the bar 53, with a substantially D-shaped recess (not shown) adapted to receive a projection 57 of corresponding section provided on a handle 58. The projection 57 forms the end of a shaft extending at right-angles from one end of the handle and provided intermediate its ends with a flange 59. Between the flange 59 and the handle 58 the shaft is of circular cross-section and a split bearing 61 of nylon or like material is fitted thereover. When the projection 57 is located in the recess in the pinion 52 and said pinion is meshed with the corresponding rack 14, the bearing 61 is received in the recess 3 in the wall 2 of the casing.
In order to make a cigarette with the machine according to the invention, the operating handle 58 is located in the position shown in FIGS. 2 and 3 in which the handle extends substantially parallel to the base and cover of the casing. In this position of the handle 58, the stepped projection 32 is located at the tail end of the oval guide channel 5, the end face 22 of the quadrant 21 bears against the bush 18 and the nozzle 38 is at the rear end of the recess 6. The end of a preformed paper tube is fitted onto the nozzle 38 and an appropriate charge of tobacco for a single cigarette is inserted through the tobacco slot 63 into the chamber 34. The handle 58 is then pivoted away from the top of the casing, i.e., in the clockwise direction as viewed in FIG. 3. Pivoting of the handle causes the pinions 51 and 52 to rotate which, by virtue of their engagement with the racks 14, causes the plate 12 to slide along the ribs 8 on the base of the casing towards the head of the machine. The teeth 17 on the guide rib 16 are meshed with the teeth of the quadrant 21 but rotation of the quadrant is prevented because the end face 22 remains in engagement with the bush 18 as shown in FIG. 4. The quadrant is therefore forced to move bodily with the plate 12. Since the quadrant is mounted on the packing block 31 by means of the stepped projection 32, the packing block is also moved so that the wall 35 is advanced towards the wall 67 to reduce the volume of the chamber 34, which becomes closed off by movement of the wall 80 over the compression member 65. Further pivoting of the handle 58 continues to move the quadrant and the packing block longitudinally towards the head of the machine until the end of the projection 32 abuts the head end of the oval guide channel 5. In this position, the packing block 31 has been moved to a position in which the ends of wall 35 meet the ends of the wall 67 to define a cylindrical chamber holding a compressed plug of tobacco and the nozzle 38 abuts the buffer 11 whereby the end of the paper tube is gripped between the nozzle and the buffer. At the same time, the quadrant 21 has been moved to a position in which the end face 22 disengaged from the bush 18. With further pivoting of the handle 58, the quadrant 21 is now caused to rotate in an anticlockwise direction as viewed in FIG. 5 since the plate 12 is still being driven towards the head of the machine by the pinions 51 and 52 engaging the racks 14. Rotation of the quadrant 21 causes the arm 26, via the link 46, to move the plunger 41 to the left as viewed in FIG. 5 so that the plug of compressed tobacco and the spoon 45 are fed into the paper tube on the nozzle 38.
The pivoting movement of the handle is stopped when the end face 22 abuts the rib 16 and anti-clockwise movement of the arm 26 has moved the plunger 41 to the end of its travel. In this position, the spoon 45 has fully entered the paper tube and the front, tobaco advancing, end of the plunger 41 is located within the nozzle 38. The handle is then pivoted in an anti-clockwise direction as viewed in FIG. 3. Initial pivoting of the handle causes the quadrant to rotate in a clockwise direction, the cam surface 23 slidably or rotatably engaging the bush 18 and preventing tailward movement of the packing block until the end face 22 registers with the bush 18 during which the plunger 41 is retracted and the tobacco spoon 45 is withdrawn from the paper tube.
When the plunger 41 has been moved to its fully withdrawn position in which it is no longer located in the chamber 34 and the spoon has been completely withdrawn from the paper tube, the quadrant has been rotated to a position in which the bush 18 is no longer engaged by the cam surface 23 but is engaged instead by the end face 22 and in which further rotation of the quadrant is prevented by the abutment of the arm 26 with the rack 16. On further pivoting of the handle 58, the quadrant 21 now moves bodily with the plate 12 to return the packing block to the position shown in FIG. 2. Since the nozzle 38 is now no longer in engagement with the buffer 11, the formed cigarette can be pulled off the nozzle.
It will be seen that, with the machine according to the invention, cigarettes can be made by operating a single lever which actuates a relatively simple mechanism involving few moving parts. The casing and cover may be die-cast metal components or may be made of plastics mouldings or other suitable materials. The plate 12, quadrant 21, pinions 51, 52 and bar 53, and the handle 58 may be made of metal, plastics or other suitable materials.
Other embodiments and modifications are envisaged without departing from the scope of the invention.
|
The invention relates to a cigarette making machine of the kind having a fixed member and a movable packing block together defining a cylindrical cavity for compressed tobacco, a nozzle communicating with the end of the cavity for supporting a preformed paper tube and an ejector for ejecting the charge of compressed tobacco through the nozzle into the paper tube. A new operating mechanism for such a machine comprises a sliding member including a rack and a pivoted lever secured to the compression member having gear teeth in meshing engagement with the rack and operatively connected to the ejector. Restraining means restrains rotation of the lever during a first portion of the travel of the sliding member during which the tobacco is being compressed, after which said means disengages from the lever to permit rotation thereof in a second portion of the travel of the sliding member in which said ejector forces the charge of compressed tobacco through the nozzle into the paper tube. The mechanism is simple and compact and it enables both the compression and the ejection operations to be carried out smoothly using a single operating handle.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to embedding data in an information signal. Examples of the invention relate to: a method of and system for controlling copying of an information signal; an information signal; a data carrier on which an information signal is recorded; apparatus for modifying an information signal; a reproducing apparatus; and a computer program.
2. Description of the Prior Art
U.S. Pat. No. 5,161,210 (US Philips Corporation) discloses a system for inhibiting copying of audio signals. An audio signal is divided into frequency sub-bands and sub-band samples are quantized. The quantized samples are combined with samples of an auxiliary signal. The combined audio signal is recorded on a record carrier or transmitted. The auxiliary signal is inaudible in the combined audio signal. An audio signal reproducer having a recording unit also has a unit for detecting the auxiliary signal and generating a record control signal. The recording unit is constructed so that if a record control signal appears on its record control input the recording unit does not record the audio signal.
WO 00/51348 (Macrovision) discloses a method and apparatus for inhibiting copying of audio or video signals transmitted over a cable television or direct satellite broadcast or the Internet. The signal is protected from unwanted copying by the combination of a watermark embedded in the signal at the head end together with additional copy protection data inserted in the signal. The additional data is a ticket. If the consumer pays a fee, the signal is transmitted to the consumer. The consumer can record only if the watermark and a mathematical function of the ticket match. The function is for example a hash function.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided a method of controlling copying of an information signal in a system having a source of the information signal and a device for copying the information signal, the method comprising the steps of:
at an information signal modification source, prior to transmission of the information signal to the copying device, generating a copy control password and a related reference password, and applying to the information signal a substantially imperceptible modification representing copy control data including the copy control password securely encoded according to a predetermined algorithm;
delivering the modified information signal from the modification source to the copying device via a communications channel;
delivering the reference password from the modification source to the copying device via a separate communications channel independent of the modified information signal;
upon reception of the modified signal deriving the copy control data from the modified information signal;
comparing the derived securely encoded password with the separately provided reference password securely encoded according to a predetermined algorithm; and
enabling copying of the information signal if the securely encoded password derived from the information signal and the securely encoded reference password have a predetermined relationship.
Thus the present invention provides for conditional control of recording of an information signal instead of, or in addition to, simple denial of any recording and simple complete freedom to record or otherwise copy. Recording may be any form of storage including but not limited to storage on a linear data carrier, for example magnetic tape.
Furthermore, the reference password is not in the information signal or on any carrier of the information signal but is provided to the copying device independently of the information signal.
The information signal may represent any one of, or a combination of, image information (including still and moving images), audio, video, text, and data which may be executable or otherwise.
In examples of the invention the said copy control data includes other data indicating that copying is permitted subject to the provision by a user of a correct reference password.
The reference password is preferably securely encoded according to the same algorithm as the password derived from the information signal. The said predetermined algorithm may be an encryption algorithm. Preferably the said algorithm is a hash function in which case the reference password and the password derived from the information signal are the same. The reference password may be delivered to the copying device as a plain password or securely encoded, e.g. encrypted in which case it is decrypted at the copying device.
The reference password may be provided via a secure communications channel which is separate from the transmission channel of the information signal.
In an example of the invention, the reference password is provided to a user who wishes to copy the information signal. The password may be provided on a secure data carrier, e.g. a smart card or in some other, preferably secure, way. If provided on a smart card the reference password can be kept secure even from the user. The user provides the password to the copying device via an input device , e.g. a keyboard or a card reader. The user may be prompted to provide the password. Preferably that is done in response to the copy control data which indicates that copying is conditional upon the provision of the password. Thus the user is required to take positive action if they wish to copy an information signal for which copying is conditionally allowed.
A second aspect of the invention provides a method of applying copy control data to an information signal comprising the steps of:
determining whether copying of the information signal is allowed, not allowed or conditionally allowed; and
applying to the signal a substantially imperceptible modification representing copy control data, the copy control data comprising
a) first data if copying is allowed,
b) second data if copying is not allowed, and
c) third data if copying is conditionally allowed,
the third data including at least a password securely encoded according to a predetermined algorithm.
A third aspect of the invention provides a method of controlling the operation of a signal copying device having a recording unit controlled by a processor, the copying device being operable to record an information signal produced by the method of the second aspect, the method comprising the steps of:
using the processor to derive the copy control data from the information signal and to determine whether the control data is the first, second or third data and to
a) allow the recording unit to record if the first data is present in the information signal,
b) disable the record unit if the second data is present in the information signal; and
c) allow the recording unit to record if the third data is present in the information signal and a reference password is provided which when securely encoded by a predetermined algorithm has a predetermined relationship to the said securely encoded password of the third data.
The second and third aspects of the present invention provide copy control data which explicitly indicates, and allows, conditional control of recording of an information signal and, in addition, simple denial of any recording and simple complete freedom to record.
It is possible that the copying device receives an information signal which does not have an imperceptible modification representing copy control data. In that case the copying device may be arranged to allow copying (or in the alternative not allow copying).
The copy control data may be used to control the copying device to operate in a predetermined manner. For example it may control the form of any copies for example indicating the form of copy control data to be included in any copy.
These and other aspects of the invention are set out in the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the invention will be apparent from the following detailed description of illustrative embodiments which is to be read in connection with the accompanying drawings, in which:
FIG. 1 is a schematic block diagram of an illustrative apparatus for applying a modification to an information signal in accordance with the invention;
FIG. 2 is a schematic block diagram of an illustrative signal reproducing and recording apparatus in accordance with the invention;
FIGS. 3A and B are flow diagrams illustrating an operation performed by a processor of the apparatus of FIG. 2 ;
FIG. 4 is a schematic block diagram of an illustrative system for controlling copying in accordance with the invention;
FIG. 5 is a schematic block diagram of an illustrative watermarking apparatus useful in the apparatus of FIG. 1 ; and
FIG. 6 is a schematic block diagram of an illustrative apparatus useful in the apparatus of FIG. 2 for detecting a watermark and extracting data therefrom.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 , a signal modifying apparatus 30 comprises a source 2 which produces an information signal which may be for example an audio signal, a video signal, an audio/video signal, a data signal and/or an image signals. The source 2 may be any suitable source for example a signal reproducer which reproduces the signal from a record or an original source for example a camera in the case of video or microphone in the case of audio.
For ease of explanation the following description assumes the information signal is a video signal, but the invention is not limited to video.
A watermarking apparatus 6 receives the video signal from the source 2 and applies to it copy control data from a source 4 . In this example the watermarking apparatus 6 embeds the copy control data in the video in such a way that the embedded data is substantially imperceptible in the video. Watermarking techniques are known in the art of video and an example of such a technique is described below with reference to FIG. 5 but any other suitable known watermarking technique may be used.
The watermarking apparatus may optionally embed as a watermark provenance data, metadata, or other data in addition to the copy control data.
The copy control data is embedded for the purpose of controlling copying of the video signal. In one example of the invention, the data comprises a code h which is a hash function H(p) of a password p: i.e. the code h=H(p). In another example of the invention, the control data h is associated with further data, for example 01 or 10, which indicates the presence of the code h.
In an example of the invention, the copy control data comprises a selected one of the following copy status codes:
00 which indicates no copying is allowed;
11 which indicates copying is freely allowed; and
01 or 10 together with code h which indicates that copying is allowed provided a reference password is provided which when hashed by the hash function H matches the code h.
The codes 00, 11 and 10 or 01 are examples of codes for simplicity of explanation. More complex codes may be used, Preferably codes which are unlikely to occur by chance are used.
The following description describes the currently preferred example but the invention is not limited to that example.
The video into which the control data is embedded by the watermarking apparatus 6 is fed to a recorder or transmitter 8 . If fed to a recorder, the recorder 8 may record the watermarked video on a data carrier for example a disc or tape or semiconductor memory. If transmitted, the transmitter 8 may be for example a broadcast apparatus or a server which transmits the watermarked video to a distribution system.
Reference numeral 10 indicates a schematic representation of a distribution system which may be amongst other examples: an electronic communications network 15 for transmitting the video e.g. a broadcast network, a PSTN or the Internet; or a physical distribution network via which tapes 13 or discs 11 or other data carriers on which the video is recorded are distributed.
The code source 4 also provides a reference password which in this example is the password p. The reference password p is fed via an interface 5 to a secure data carrier, e.g. a smart card SC for delivery to a user of the video separately from the video. It will be appreciated that the reference password could be delivered by other means, e.g. another form of data carrier, on paper through the post or via the Internet or telephone system.
FIG. 2 illustrates a copying device which in this example is a reproducing and recording apparatus 32 . The apparatus 32 comprises a source 12 of video which may or may not be watermarked. The source 12 may reproduce the video from a data carrier or receive the video from a broadcast or other communications system as described above. The video is applied to a recording unit 22 . The recording unit 22 is controlled by a record control signal produced by a control processor 14 .
Assume the video is watermarked.
The control processor 14 comprises a watermark processor 16 which detects the watermark and derives the copy control data therefrom. Watermark processors capable of doing that are known and an example is described with reference to FIG. 6 below. A processor 18 decodes the copy control data and applies the appropriate record control signal to the recording unit. The control processor also has an input device 20 for entering the reference password. The input device may be a keyboard, smart card reader, an interface with an electronic communications channel, amongst other examples. In addition a display 17 may be provided. The display is used in an example of the invention to prompt the user to enter the reference password via the input device, for example by inserting the smart card SC into the input device 20 .
Referring to FIGS. 3A and B, the control processor 14 operates as follows:
In step S 1 the watermark processor 16 detects the watermark and derives the copy control data. In step S 3 the processor 18 determines the value of the copy control data.
If the copy control data is:
00 then the record control signal is set S 7 to disable the recording unit;
11 then the record control signal is set S 5 to enable recording by the recording unit; and
01 or 10 together with a code of any value then the user is requested S 8 to provide a reference password p′.
Referring to FIG. 3B , in step S 81 , the processor 18 detects whether the copy control data includes the code 01 or 10 indicating copying is allowed if the reference password is provided. If so, it causes a prompt to be displayed S 82 by the display 17 requiring the user to enter the password.
If a reference password p′ is entered S 9 via an input device 20 the processor performs S 11 A hash function H(p′) on the password and compares S 13 the hashed reference password with the hash value h derived from the watermarked video. If the hashed values are the same S 15 then copying is allowed S 5 . If the hashed values are not the same S 15 then the recording unit is disabled S 7 .
If recording is enabled because the reference password is correct or because the copy control data=11, then the watermarked video including the original copy control data is recorded to provide copy control of the copy.
The user of the reproducing apparatus 32 requires the reference password to copy video which has as copy control data the code 01 or 10 plus the hash value h. As will be described with reference to FIG. 4 , the reference password is supplied to the apparatus 32 separately from and independently of the watermarked video. In this example the password is provided on the smart card SC which is read by a card reader 20 which is the input device 20 . This enables the password to be provided to a user and kept secret even from the user.
The smart card may be provided to a user on payment by the user of a fee.
The video form the source 12 may not have a copy control watermark. If the watermark processor 16 detects the absence of such a watermark, it indicates that to the processor 18 ; see step S 1 of FIG. 3A ). The absence of the watermark may be regarded as either indicating copying is not allowed so that the processor outputs code 00 to processor 18 . Currently it is preferred that the absence of the watermark indicates copying is allowed. Thus the processor 16 outputs code 11 to the processor 18 .
The system of FIGS. 1 and 2 is illustrated by way of example as a special purpose system but could be implemented using programmable data processors.
In the system of FIG. 4 , the modifying apparatus 30 and the reproducing apparatus 32 are linked by communications interfaces I/F to a communications network 38 which is for example the Internet. There may be many reproducing apparatus 321 to 32 n connected to the network 38 . For simplicity of description, it is assumed that the apparatus 30 is controlled by a seller and the user of the reproducing apparatus 32 is a buyer. Watermarked video is sent to buyers for example on a disc D via a distribution channel 10 for example a postal service or shop. If a buyer wishes to copy the watermarked video and it is watermarked with the copy control code 01 or 10 plus the hash value h, then the copy function in the reproducing apparatus 32 is disabled until the buyer pays a fee. The fee may be paid via the network 38 and a server 34 , which for that purpose is linked to a financial institution 36 , e.g. a credit card company.
The copy control hash values and/or the password may be unique to each user for increased security and traceability of unauthorised copies.
The payment of the fee is communicated to the seller via the network 38 . The seller then releases the reference password for example on a smart card SC or in a secure manner via the communications network 38 . Alternatively, the server may release the reference password on a smart card or via the network 38 . For that purpose the server may communicate with the seller to obtain the reference password. It will be appreciated that the reference password could be delivered by other means, e.g. on a data carrier, on paper through the post or via the Internet or telephone system. Preferably the reference password is encrypted before transmission to the copying device 32 in which case it is decrypted at the copying device. Any known encryption system may be used.
The present invention assumes that all reproducing and recording apparatus are, equipped with watermark detection and decoding apparatus which disables the recording unit of the apparatus.
Watermarking, FIG. 5
FIG. 5 illustrates the watermarking apparatus denoted as embedder 120 in more detail. The watermark embedder 120 comprises pseudo-random sequence generator 220 , an error correction coding generator 200 , a wavelet transformer 210 , an inverse wavelet transformer 250 , a first combiner 230 , a data converter 225 and a second combiner 240 . The wavelet transformer 210 includes a frame store FS 1 . The inverse transformer 250 includes a frame store FS 2 . The frame store FS 1 stores a frame of unmodified coefficients Ci. The frame store FS 2 stores a frame of modified coefficients Ci′.
The error correction coding generator 200 receives the copy control data and outputs an error correction coded copy control data to the first combiner 230 . The pseudo-random sequence generator 220 outputs a pseudo-random binary sequence (PRBS) Pi, where i is the i th bit of the sequence, to the first combiner 230 . The PRBS has a length L×J of bits where J is the number of bits in the error correction encoded copy control data. Each bit j of the error correction encoded copy control data then modulates a section of length L of the PRBS. The first combiner 230 logically combines the error correction encoded copy control data with the PRBS to produce a watermark having bits Ri. A bit Wj=0 of the error correction encoded copy control data inverts L bits of the PRBS. A bit Wj=1 of the error correction encoded copy control data does not invert the PRBS. Thus bits Wj of the error correction encoded copy control data are spread over L bits of the PRBS. The data converter 225 converts binary 1 to symbol +1 and binary 0 to symbol −1 to ensure that binary 0 bits contribute to a correlation value used in the decoder of FIG. 5 .
The wavelet transformer 210 receives the video image I from the source 110 and outputs wavelet coefficients Ci to the second combiner 240 .
The second combiner 240 receives the watermark Ri, the wavelet coefficients Ci and watermark strength αi and outputs modified coefficients Ci′ where
Ci′=Ci+αi Ri
The inverse wavelet transformer 250 receives the modified coefficients Ci′ and outputs a spatial domain watermarked image I′.
The embedder includes an ECC generator 200 . The use of error correction coding to produce an error correction coded copy control data is advantageous since it allows the copy control data 175 to be reconstructed more readily should some information be lost. This provides a degree of robustness to future processing or attacks against the watermark. The use of a pseudo-random sequence Pi to generate a spread spectrum signal for use as a watermark is advantageous since it allows the error correction coded copy control data 205 to be spread across a large number of bits. Also, it allows the watermark to be more effectively hidden and reduces the visibility of the watermark. Applying the watermark to a wavelet transform of the image is advantageous since this reduces the perceptibility of the watermark. Furthermore, the strength of the watermark is adjusted by αi to ensure that the watermark is not perceptible.
Detecting Copy Control Data in Watermarked Video, FIG. 6
The operation of the watermark processor denoted as decoder 140 will now be explained in more detail with reference to FIG. 6 . The watermark decoder 140 receives the watermarked image I′ and outputs the restored copy control data. The watermark decoder 140 comprises a wavelet transformer 310 , a reference pseudo-random sequence (PRBS) generator 320 , a correlator 330 , a selector 340 and a error correction coding decoder 350 . The PRBS generated by the generator 320 is identical to that generated by the PRBS generator 220 of FIG. 2 and converted by a data converter (not shown) to values +1 and −1 as described above.
The wavelet transformer 310 receives the watermarked image I′ and, in known manner, outputs the modified wavelet coefficients Ci′. The correlator 330 receives the reference pseudo-random sequence PRBS having symbols Pi of values +1 and −1 from the pseudo-random sequence generator 320 , and the wavelet coefficients Ci′ and outputs a watermark image bit correlation sequence 335 . The watermarked image bit correlation sequence is determined in the following way.
The modified wavelet coefficients Ci′=Ci+α i R i where R i are bits of PRBS modulated by error-correction encoded bits Wj of copy control data. Each bit Wj modulates L bits of PRBS. There are JL bits in the modulated PRBS. For each error correction encoded bit Wj, the correlator 330 calculates a correlation value
S j ′ = ∑ i = jL + 1 jL + L Ci ′ · Pi
where j=0, 1, 2 . . . J−1, and J is the number of error correction encoded bits. A sequence 335 of correlation values S′ j is produced.
The correlation sequence 335 is received by the selector 340 which outputs an uncorrected copy control data 345 . The selector 340 outputs a bit value “1” for a value of S′ greater than 0 and a bit value “0” for S′ less than or equal to 0. The error correction code decoder 350 receives the uncorrected copy control data 345 and in known manner outputs the restored copy control data 145 .
The reference PRBS Pi is synchronised with the modulated PRBS in the watermarked image. For that purpose a synchroniser (not shown) is used. Such synchronisation is known in the art.
Modifications
Although FIGS. 5 and 6 give an example of watermarking using Wavelet coefficients, the invention is not limited to Wavelets but can be implemented using other watermarking techniques including the use of DCT coefficients.
Although the invention has been illustrated by reference to FIGS. 1 to 4 which show schematics of special purpose hardware, it is envisaged that the invention may be implemented in software on programmable machines. Thus the invention also encompasses software which when run on suitable data processing equipment implements the functions described herein.
The information signal whether stored on a data carrier or sent as a signal via a communications channel may include several parts representing different sections of content or different items of content. For example a disc or tape typically has several tracks. In an embodiment of the invention each section may have its own copy control data embedded as an imperceptible watermark each with its own copy status and/or its own password. For example if a disc has tracks one to four the copy control data may be as follows:
Track Copy Status Data Password Track 1 00 — Track 2 01 nnnnnn Track 3 01 mmmm Track 4 11 —
Thus track 1 can be copied freely. Track 2 may be copied if the password nnnnn is provided. Track 3 may be copied if password mmmmm is provided, Copying of track five is not allowed. A user may be provided with only one of the passwords.
In a further embodiment, the copy status codes define copying rights for a user in addition to copying allowed, not allowed and conditionally allowed. For example code 01(plus the password) may indicate copying is conditionally allowed but the copies retain the original copy control data signifying the conditional copying status whereas code 10 may indicate copying is conditionally allowed and the copy may be freely copied, the copy control data not being retained in the first copy. Code 10 may be used to protect content whilst in transit between a supplier and the user for example.
Other status codes with passwords forming the copy control data may indicate other copying status.
In embodiments in which the copy status data is changed, the watermark must be amendable. Watermarks which may be removed are described in for example co-pending European patent application 1215880. The processors 16 and 18 in the control processor 14 of FIG. 2 are arranged to remove the original watermark and replace it with a new one. The new one may be permanent or removable.
Although illustrative embodiments of the invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope and spirit of the invention as defined by the appended claims.
|
The present invention controls copying of an information signal, comprises the steps of prior to recording and/or transmission, applying to the information signal a substantially imperceptible modification representing copy control data including a password securely encoded according to a predetermined algorithm; upon reproduction for copying by a user, deriving (S 1 , S 3 ) the copy control data from the modified information signal; comparing (S 8 , S 9 , S 11 , S 13 , S 15 ) the derived securely encoded password with a reference password securely encoded according to a predetermined algorithm; and enabling (S 5 ) copying of the information signal if the securely encoded password derived from the information signal and the securely encoded reference password have a predetermined relationship, otherwise disabling copying (S 7 ). The reference password is sent to the user via a channel, which is separate from a channel used to send the information signal to the user.
| 6
|
[0001] This application is based on and claims priority from U.S. Provisional Patent Application No. 60/216,772, filed Jul. 7, 2000.
FIELD OF THE INVENTION
[0002] The present invention relates to a system and methods of determining air content and pressure in fluid, especially in association with an infusion pump.
BACKGROUND OF THE INVENTION
[0003] There is a need in the field for methods of measuring air content and pressure of a sample fluid. Particularly in an infusion pump, it is critical to determine the air content of the infusion fluid and the fluid pressure down stream of the outlet valve of the infusion pump.
SUMMARY OF THE INVENTION
[0004] The present invention is directed in part to unique methods of content measurement of a sample fluid. The present invention is based on the discovery that volume change in a chamber, as the chamber transitions between negative and positive pressure relates to the air content in the chamber. In particular, in an infusion pump, the volume change of infusion fluid as it transitions between being under negative pressure and positive pressure within a cassette central chamber, e.g., pumping chamber, relates to the air content in the infusion fluid. In addition, the present invention provides methods for determining pressure of a sample fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] These and other objects and advantages of the invention will become more apparent and more readily appreciated from the following detailed description of an exemplary embodiment of the invention taken in combination with the accompanying drawings, of which:
[0006] [0006]FIG. 1 is a block diagram illustrating the fluid delivery system topology of an infusion pump.
[0007] [0007]FIG. 2 is a block diagram illustrating a cross-sectional view of the cassette assembly of an infusion pump.
[0008] [0008]FIG. 3 illustrates changes in cassette central chamber volume as a function of pressure.
[0009] [0009]FIG. 4 illustrates changes in piston position as a function of time.
DETAILED DESCRIPTION
[0010] Infusion pumps are widely used for administering medications to patients over an extended time period. During an infusion of medication, it is critical to monitor the air content of the fluid medication administered to a patient. In addition, it is often convenient/helpful to measure the pressure on the patient side of the pump, e.g. measure the blood pressure of the patient. One of the applications of the methods for air content measurement of a sample fluid is to measure the air content in a cassette central chamber in an infusion pump. In addition, the mechanism for air content measurement also provides means to monitor the blood pressure of a patient connected to an infusion pump.
[0011] [0011]FIG. 1 is a block diagram illustrating one embodiment of the present invention. The fluid delivery system 100 includes a cassette assembly 20 and a shuttle mechanism 40 . A suitable cassette assembly is described in patent application Ser. No. 60/216,658, filed Jul. 7, 2000, entitled “Cassette”, to Carlisle, Costa, Holmes, Kirkman, Thompson and Semler, the entire contents of which are incorporated herein by reference. Within the cassette assembly 20 is a cassette piston 60 and a cassette central chamber 80 . A spring 120 biases shuttle mechanism 40 which is connected to the cassette piston 60 . Piston 60 slides freely in the cassette central chamber 80 to draw fluid into central chamber 80 and pump fluid out of central chamber 80 . A motor 140 is activated in one direction to draw the cassette piston 60 out of cassette central chamber 80 via cam 160 and shuttle 40 . When the cassette piston 60 is fully withdrawn, shuttle 40 disengages from cam 160 and motor 140 , so that spring 120 pushes the cassette piston 60 into the cassette central chamber 80 via shuttle 40 to apply positive pressure to the fluid in the cassette central chamber 80 . The shuttle mechanism 40 is also operably linked to an optical position sensor 180 . A suitable position sensor is described in patent application Ser. No. 60/217,885, filed Jul. 7, 2000, entitled “Optical Position Sensor and Position Determination Method”, to Carlisle, Kaplan and Kirkman, the entire contents of which are incorporated herein by reference. A processor 220 is connected to motor 140 and the position sensor 180 .
[0012] [0012]FIG. 2 is a diagram illustrating a cross-sectional view of a cassette assembly 20 . The cassette assembly 20 contains an inlet valve 200 , an outlet valve 210 , a cassette central chamber 80 , and a cassette piston 60 . Cassette piston 60 is connected to shuttle 40 .
[0013] In operation, the motor 140 is activated in one direction to withdraw the cassette piston 60 against the force of spring 120 via cam 160 , creating a relative vacuum in the cassette central chamber 80 and pulling fluid through a one-way passive inlet valve 200 into the cassette central chamber 80 . During this fill stroke, the pressure in the cassette central chamber 80 is negative, e.g., between 0 and −10 psi. The amount of negative pressure depends on the withdrawal speed of the piston, fluid resistance, fluid viscosity, etc. Once the cassette piston 60 has been withdrawn, cam 160 disengages from the shuttle 40 , enabling the spring mechanism 120 to urge shuttle 40 to drive piston 60 into the cassette central chamber 80 . The pressure in the chamber then moves from a negative value through zero to a positive value. The one-way passive inlet valve 200 is now fully closed. The positive pressure in the cassette central chamber 80 is typically between +2 and +7 psi depending on the spring force applied to the cassette piston 60 through the shuttle 40 which is directly related to the length of the withdrawal stroke, e.g., the further the withdrawal stroke the stronger the spring force.
[0014] In a closed cassette central chamber, the volume changes as a function of cassette central chamber pressure. In theory, when the cassette central chamber 80 is closed and contains only liquid, i.e., air free fluid, the cassette central chamber is not compressible, thus no volume change occurs. Nevertheless in practice, a “base volume change” exists when the chamber contains just air free fluid (as shown in FIG. 3). Such “base volume change” is irrelevant to the air content in the fluid and is mostly due to system designs such as the shape of a sealing member of the cassette piston 60 or the flexing of elastomeric inlet and outlet valve elements connected to the cassette central chamber 80 .
[0015] For example, the cassette piston 60 in the cassette central chamber 80 acts as a nearly ideal piston when under positive pressure from the spring mechanism 120 ; thus a change in the axial position of the piston represents a fluid volume change in the cassette central chamber. Nevertheless, when cassette central chamber pressure changes from negative to positive, the shape of a sealing member of the cassette piston changes and results in piston travel without any change in central chamber fluid volume. This amount of travel contributes to the “base volume change”; it is significant, however, that this travel is a relative constant of the system design and does not change over time. In addition, the elastomeric valve elements connected to the cassette central chamber have some inherent displacement determined by their geometry and material properties. When under pressure, these elements move and to an insignificant degree, continue to move (creep) over time. The movement of these elements also contributes to the “base volume change”.
[0016] The “base volume change” of the cassette central chamber 80 can be determined by detecting the volume change of a control fluid under the pressure change of the cassette central chamber. The volume change can be measured by determining the change of shuttle position, i.e., the piston travel position when the cassette central chamber pressure changes from negative to positive. The change of shuttle position is determined by the precision position sensor 180 linked to the shuttle mechanism 60 . For example, one can compare the shuttle position in two states: the peak position during piston withdrawal and the shuttle position after the spring pressure is applied (as shown in FIG. 4). This net displacement change of the shuttle position as a result of the pressure change in the cassette central chamber 80 filled with control fluid is a measure of the “base volume change” of the system 100 , e.g., the volume change that is inherent in the system 100 .
[0017] In one embodiment, the “base volume change” of a control fluid is determined more than once and statistically conservative limits of “base volume change”, e.g., lower than average, is selected as the “base volume change” for calculating the fluid air content. In another embodiment, the base volume change of a control fluid for a sample infusion fluid is determined by measuring the median volume change of more than one sample of the same infusion fluid, e.g., over more than one fill stroke, resulting from the pressure change of the cassette central chamber. In yet another embodiment, the base volume change is the median volume change of an infusion fluid over eleven (11) contiguous fill strokes, and is updated or modified periodically throughout an infusion therapy; and such base volume change is used to measure the sample fluid air content of the same infusion fluid.
[0018] In a closed cassette central chamber, e.g., both inlet and outlet valves are closed, any cassette central chamber volume-versus-pressure changes above the “base volume change” are interpreted as volume changes in the cassette central chamber due to the presence of air (as shown in FIG. 3). The air content of fluid contributes to the total volume change of the cassette central chamber and is proportional to the total volume change, e.g., sample volume change minus the base volume change.
[0019] For example, one can fill the cassette central chamber 80 with a sample fluid until the volume (gVolMax) in the chamber is greater than the desired volume of fluid to be delivered in a single pump stroke (gvdue) plus the “base volume change” (Vbase). During the fill cycle, the fill volume can be monitored through the piston position, i.e., the shuttle position which is determined by the optical position sensor 180 . As a result of the geometry and design of the cassette assembly 20 , there is a linear relationship between the shuttle position and the fill volume. Once the fill volume (gVolMax) is achieved, the motor direction is reversed so that the shuttle 40 falls off the cam 160 and rides freely on the spring mechanism 120 . Similarly the end-diastolic volume (gVolEnd) can be determined from the stabilized shuttle position alter the cam 160 releases shuttle 40 . The sample volume change is the difference between the gVolMax and gVolEnd. The air content of the sample fluid is calculated in processor 220 as follows:
Air content (Volair)˜Sample volume change−Base volume change
˜(gVolmax-gVolEnd)−Base volume change
[0020] The air content measured according to the present invention is independent of the size and shape of the air bubble contained in a sample fluid, e.g., the air content includes the content of big bubbles, small bubbles, integrated bubbles, and unintegrated bubbles.
[0021] In one embodiment, the effective amount of fluid that is pumped out of cassette central chamber 80 is calculated based on the air content of a sample fluid. For example, for a given stroke, the effective amount of fluid that is infused is calculated in processor 220 as follows:
effective amount of fluid infused˜gvolmax−Volair
[0022] In another embodiment, the proportion of air content and volume content in a given stroke is calculated directly on the change of position of the piston. Specifically the proportion is calculated in processor 220 as follows:
proportion of air/fluid content=(position change due to pressure change)/(max. position under neg. pressure)
[0023] The processor 220 adjusts subsequent fluid flow rate based on the air/fluid content proportion in a given stroke to compensation for the air content detected in a sample fluid.
[0024] In yet another embodiment, processor 220 compares the air content of a sample fluid to a predetermined value stored in the processor 220 ; the processor 220 activates an alarming device if the air content of the sample fluid is close to or beyond the predetermined value. Alternatively, the processor 220 activates an alarming device as well as shuts down the out flow of sample fluid from the cassette central chamber 80 , e.g., closes the outlet valve 210 of the cassette central chamber 80 and shuts down infusion process by the fluid delivery system 100 .
[0025] According to another feature of the invention, sample fluid continuously passes through cassette central chamber 80 and the air content of the sample fluid is determined at different time points and stored in processor 220 . The processor 220 calculates accumulated air content of the sample fluid by adding the air content values collected at different time points. Such accumulated air content over a period of time is compared to a threshold air content value stored in the processor 220 ; the processor 220 triggers a notifying device, e.g., an alarm, if the accumulated air content is close or beyond a predetermined limitation. Alternatively, the processor 220 activates a notifying device as well as shuts down the out flow of sample fluid from the cassette central chamber 80 , e.g., closes the outlet valve 210 of the cassette central chamber 80 and shuts down infusion process by the fluid delivery system 100 .
[0026] In one embodiment, the outlet pressure of the cassette central chamber, e.g., the blood pressure of a mammal such as a human connected to the infusion pump is monitored. For example, during the fluid displacement, the outlet valve 210 of the cassette central chamber 80 is opened via external actuation. Fluid then flows from the higher pressure in the cassette central chamber 80 to the outlet via the outlet valve 210 . If the outlet valve 210 remains open, the cassette piston 60 will stop when the cassette central chamber pressure equals the outlet pressure. The position of the piston on the spring load is associated with a known spring force. Processor 220 then calculates the outlet pressure from the fixed geometry of the cassette central chamber 80 . With the outlet valve 210 open, the outlet pressure including even rapid changes in arterial, vein, or capillary pressure of a patient can be measured.
[0027] For example, the spring rate, k (in units of force/distance), of the shuttle mechanism 40 and the piston cross-sectional area, A, are known system design constants. Such system design constants, i.e., k/A are pre-calculated and stored in the processor 220 as Design Constant. During the empty cycle, the outlet valve 210 of the cassette central chamber remains open. Once the spring 120 reaches a stabilized position, the system reaches equilibrium, e.g., the outlet pressure equals the cassette central chamber pressure. Subsequently the shuttle position, i.e., X, is measured by the optical position sensor 180 and processor 220 calculates the outlet pressure as the following:
Outlet pressure=Design_Constant*X
[0028] In another embodiment, processor 220 monitors the outlet pressure of the cassette central chamber and compares it to a predetermined value over a period of time. An increase of the outlet pressure indicates a partial or complete blockage of the cassette central chamber outlet, i.e., blockage of the outlet pathway or a body fluid pathway receiving fluid displaced from the cassette central chamber 80 . Depending on the degree of outlet pressure increase, processor 220 generates a signal to either alert the pressure increase or stop the fluid displacement of the system 100 .
[0029] Other Embodiments
[0030] Although several exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiment without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims.
|
Methods and apparatus for air content and pressure measurement of sample fluid, especially sample fluid in association with an infusion pump. Volume change in a chamber as the chamber transitions between negative and positive pressure relates to the air content in the chamber. In particular, in an infusion pump, the volume change of infusion fluid as it transitions between being under negative pressure and positive pressure within a cassette central chamber, e.g., pumping chamber, relates to the air content in the infusion fluid. The outlet pressure of the cassette central chamber, e.g., blood pressure, can be monitored based on the cassette central chamber pressure.
| 0
|
BACKGROUND OF THE DISCLOSURE
This is a continuation-in-part application of Ser. No. 08/730,476 having a filing date of Oct. 16, 1996, now abandoned.
This disclosure is directed to an external pipe wiping apparatus. It is a device which is used in drilling an oil well with drilling fluid. The drilling fluid is typically made of water and clay, and is, therefore, often called drilling mud. Sometimes, it is even made with oil additives, some of which additives are extremely expensive. While the mud and additives are not only expensive, they also pose a number of problems when spilled near or around the drilling rig. At best, work on the rig floor is dangerous, but it is especially dangerous at the time of pulling a drill string. This is typically described as making a trip. It is necessary to make a trip when the drill bit is worn. When the drill bit becomes worn, drilling is slowed and the bit must, therefore, be replaced. It is not uncommon to pull the drill pipe from the partially drilled well by removing the drill pipe, raising the pipe string in the derrick and unthreading the pipe. While the pipe is normally made in 30' lengths, it is often unthreaded to reduce the handling by standing three joints of pipe in the derrick. They are pushed to the side after unthreading from the drill string. As each stand of pipe is pulled above the rig floor, it will drip on the rig floor. As it drips, the rough necks on the rig floor have the risk of slipping and falling. More than that, the drilling mud on the floor poses a hazard should it simply wash over the side of the rig. Whether on land or in offshore waters, the drilling fluid needs to be contained.
Various and sundry wiping devices have been used in the past. The present disclosure is directed to an external pipe wiping device which enables pipe wiping to be done in a regular systematic way. Moreover, it is a device which reduces significantly the amount of drilling fluid clinging to the outer wall of the drill pipe. When pulling 100 stands of pipe from a 9,000' well, a substantial amount of drilling mud can cling to the pipe and run down the side of the pipe. Without wiping, the rig floor can become quite dangerous.
The present disclosure is a device which is installed under the rig floor. It is relatively light weight. More than that, it is a device which can be installed under the rig floor and operated automatically so that it wipes the pipe on tripping the pipe out of the well. One aspect of this operation is the fact that the pipe has external upsets on it. The most common type of drill pipe is constructed with a pin and box connection which is accomplished at an enlargement. This protrudes to the exterior. This causes something of a problem as the pipe is moved upwardly. The present apparatus is well able to wipe the exterior of the pipe even with the external upsets on it. For that reason, the pipe wiping mechanism of the present disclosure mounts a set of wipers so that they are readily able to deflect, thereby permitting the upsets to pass through the equipment, and yet continue wiping the external surface.
The wiping element of the present disclosure is a relatively small resilient member. It is implemented by installation at spaced locations around the pipe. In the optimum construction, four similar devices are installed so that wiping elements are extended toward the pipe and contact against the pipe. They are, however, mounted on a pivot to swing between two positions. One position is retracted and the other extends the wiper element to contact the side of the pipe. When extended, the contact of each individual wiping element is less than the whole of the circle, but there are preferably four such units which overlap, and collectively they wipe the entire exterior. This is done, however, with extended wiping members which are positioned so that continual progression of the pipe from the well is permitted. When an upset passes through the equipment, the wipers are simply deflected.
The present invention utilizes a replicated system featuring a pivot connection for a cam actuated mechanism extending the wiper element from the retracted to the extended position. This is done by pneumatic cylinder. When air is applied at a relatively low pressure, the wiping element is extended. When air pressure is applied to the opposite piston face, pressure causes the wiper to retract. The device is summarized as incorporating four similar actuator units which are mounted in pairs on opposite sides of the pipe. This defines a relatively small and light weight structure having actuator units located at 90° intervals around the circle. This is supported in a streamlined housing to reduce the diameter or size of the housing. One construction is an octagon although a cylindrical container will also suffice. The actuator units are arranged to permit passage of the drill string along the centerline axis of the housing. Since the fur modular units are identical, each is provided with its own pneumatically operated cylinder which extends the wiping element. Return pressure or a spring pulls the wiping element to the retracted or withdrawn position. A bell crank cooperates with a mounting bracket which serves as a pivot. The wiping element is ideally mounted on an extending shaft pivotally mounted to permit deflection to the left or right so that the pipe can be tracked even when it is no longer coincident with the centerline axis of the equipment. Lateral movements necessary to achieve tracking are minimal and are sufficient to follow any crooked pipe. Even when a change of diameter occurs at external upsets, deflection is readily accommodated so that larger or smaller diameters can be wiped with one set of wiping elements. Typically, the equipment of the present disclosure is spaced just above the blowout preventer (BOP) which normally is positioned just over a bell nipple. The equipment can be supported just above the bell nipple where it is installed with a pneumatic sealing mechanism as will be described.
In field use, pipe is, in actuality, bent, crooked and otherwise irregular within a fairly large range. Such difficulties create problems with the mechanism extending the wiper elements. Not only must they extend towards a centerline position engaging an arc of the outside surface of the pipe, but they must flex to the right and left. On flexure, this enables each individual wiper to continue wiping an approximately 90° interval of the circle of the outer wall of the pipe. In actuality, they overlap somewhat so that each one wipes perhaps 90° to 100° of the circle. The four actuator units for the four wipers are mounted so that they provide pivotal rotation brining the individual wiper elements into proper engagement. This pivotal rotation must be modified so that each wiper element is brought into contact no matter how much flexure occurs in the particular wiper. With each pivotally mounted wiper, there is a range of movement permitted to accommodate the flexure.
BRIEF DESCRIPTION OF THE DRAWING
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawing.
It is to be noted, however, that the appended drawing illustrates only typical embodiments of this invention and is, therefore, not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 shows the pipe wiping apparatus of the present disclosure installed on a drilling rig where it is located below the rig floor and just above a bell nipple;
FIG. 2 is a sectional view showing the internal apparatus of the pipe wiping apparatus of the present disclosure incorporating evenly spaced actuators;
FIG. 3 of the drawings is a side view of an individual actuator in the retracted position showing the wiping element withdrawn from contact against the drill pipe;
FIG. 4 is a view similar to FIG. 3 showing the wiping element extended so that contact is made with the pipe;
FIGS. 5 and 6 together show the wiping element which is a planar flexible sheet;
FIGS. 7 and 8 together jointly show the wiping element mounting clamp; and
FIG. 9 is a view of the wiper mechanism shown in FIG. 2 in an extended pipe wiping position showing elongation of the equipment to reach the pipe; and
FIG. 10 is a schematic flow diagram for air pressure provided for operation of the system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Attention is first directed to FIG. 1 of the drawings which will be described very briefly to set forth the context of the present invention. The pipe wiping apparatus of this disclosure is identified generally by the numeral 10. It is a preferably octagonal or circular housing which is installed under a rig floor 12 and is located on the centerline of the rig equipment. A drill pipe 14 is rotated thereabove. The drill pipe extends through a rotary table 16. Rotation is imparted from an overhead draw works and Kelly (not shown) which support the drill pipe for rotation in the rotary table 16. The overhead equipment is suspended in the derrick 18. Under the rig floor, there is a BOP stack (omitted for sake of clarity) and that is connected to control mud flow return in the annular space on the exterior of the drill pipe 14. The BOP stack typically is connected with an upstanding conductor pipe. The conductor pipe directs the annular flow of mud upwardly which is finally delivered back for recirculation. FIG. 1 also includes a bell nipple 20 which is located under the rig floor. Drilling mud is delivered from the annular space in the well up into the bell nipple 20. FIG. 1 shows the bell nipple with the typical funnel at the top end. This wiping apparatus 10 is positioned on the bell nipple and rests on it after the funnel is trimmed square at the top end; FIG. 9 shows one mode of connection to assure easy mounting.
The apparatus of the present disclosure is enclosed in a housing which is not relatively thick. Typically, it can stand about 8 to 16" tall, and has a diameter or width of about 30 to 36". The size of the equipment is tailored to a set of pipe diameters; typically, one size of equipment will suffice for a range of pipe sizes. Changes in pipe size are normally accommodated without change of equipment but, in the event of very large changes in pipe size, the wiper elements are changed to handle different pipe sizes. This will be explained in some detail later. Suffice it to say, the pipe wiping apparatus 10 is installed as close to the bell nipple 20 as possible to deflect dripping mud so that it does not fall on the rig floor 12. It is dripped back into the bell nipple 20.
Attention is now directed to FIG. 2 of the drawings which shows the housing 22 to comprise a cylinder or octagon in the preferred embodiment. An L-shaped mounting bracket 24 mounts each of the several actuators. They are identical in construction and differ only in the relative position. As will be understood, the housing 22 has a circular opening through it so that the drill pipe can extend through the cabinet or housing 22. There are four actuators located at 90° spacing around the circle of the drill pipe. Four are used so that they can wipe the exterior surface with some measure of overlap. This assures that wiping can be accomplished easily in cleaning the drill pipe and protecting the rig floor.
The mounting bracket 24 is an L-shaped bracket which serves as an anchor for the equipment to be described. The mounting bracket 24 supports the actuator 25. The actuator is fastened to the housing by one or more mounting bolts 26. Each individual actuator is similar to the others and can be more readily understood on reference to FIG. 3 of the drawings. There, the mounting bracket 24 is shown bolted by the bolts 26 with the wiping element in the retracted position. Considering the structure of the actuator 25 shown in FIG. 3, the mounting bracket 25 supports a mounting tab 28 located at the top end. A clevis 30 anchors a pneumatic cylinder 32 at that location. The cylinder 32 encloses a piston 34 which connects with the piston rod 36. In the retracted position of FIG. 4, it is shown connected with a bell crank 38 at a pivot connection 40. The crank 38 extends downwardly and mounts on a shaft terminating in a bolt head 42. The shaft passes through a pair of upstanding spaced mounting lugs 44. The shaft of specified length is sufficiently long to support a sleeve 46 which has an extending center leg 48. The operation of the pneumatic cylinder 32 moves the crank 38. The crank 38 is pivoted around the shaft 42 and is, therefore, rotated by approximately 60 and 80° in contrast between FIGS. 3 and 9. The crank 38 rotates an elongate shaft 49 connected with a pair of mounting plates 52 which form a clamp on the wiper. The clamper plates 52 are all formed of metal and are bolted together by the bolt 54.
To complete the description of the wiping system which has been described in part, attention is momentarily directed to FIGS. 7 and 8 together. A rubber wiper 60 is shown in both views. The distal end is able to deflect depending on the stiffness of the rubber or resilient sheet to permit substantial flexure without breaking. As shown in FIG. 6, similar right and left clamps 52 terminate in upstanding tabs which are bolted together by a bolt 54. The bolt provides alignment for the upstanding tabs on the wiper clamps. The clamps 52 are constructed in a similar fashion and together provide symmetrical support for the wiper element 60. The wiper element 60 is pliable so that it will curve. A number of anchor bolts 62 fasten the wiper element holes 64.
Going now to FIGS. 6 and 7 jointly, the wiper element 60 is shown in detail. In the edge view of FIG. 6, it will be observed to have parallel faces, and it is constructed with a number of similar holes 64 which are matched in location to the mounting bolts 62 to anchor the wiper element firmly. It has a notched edge 66 which interrupts the extended edge 68 extended towards the pipe. The sheet of material is curved so that the end located curvature 66 fits around the pipe more readily. For that reason, the width of the wiper element and the profile of the curvature 66 are both tailored to a particular pipe size, or more accurately to a range of sizes. Indeed, the device can be used to wipe the exterior of production tubing, even tubing as small as 2.375". On the other hand, it is much more successful in wiping the exterior of conventional size drill pipe including drill pipe having nominal dimensions of 5 or 6". The curvature 66 is shaped so that wiping contact with the pipe is achieved over an included angle of about 100°.
FIG. 3 shows the curving edge 66 on the wiper element 60. The wiping element is made of resilient sheet material so that gentle contact can be made at the exterior over an included angle of about 100° to wipe drilling mud and cause it to flow downwardly on the exterior of the pipe. When an upset is encountered, or perhaps a crooked joint of pipe, the flexibility of the wiper element 60 permits easy passage.
The preferred form of wiper 60 utilizes a relatively soft rubber material which is typically provided with a hardness of only about 20 to 40 durometer. It is provided in sheet stock which is at least about 1/8" thick, and has a width which is sufficient to encompass or match the selected pipe size. Thus, the wiper is deployed subject to the curvature in the wiper 60 as a result of mounting on the wiper clamps 52.
Attention is now directed to FIG. 9 of the drawings which shows the pneumatic power system. An air pressure supply line 70 is connected with a controlled source of air (not shown) which is switched to extend the four actuators and thereby initiate pipe wiping. The air line is located on the interior of the housing 22 and extends fully around the interior. Preferably, the four cylinders are pneumatic in operation. They are preferably double acting cylinders which include high and low pressure sides.
In FIG. 9 of the drawings, an inflatable seal ring 80 is incorporated to assure a tight connection between the bell nipple and the housing 22. This firmly and snugly hold the present invention 10 to the mud return system. This is mounted easily by cutting the top end of the pipe flush to support the weight of the wiping device 10.
Each individual actuator is similar to the others and can be more readily understood on reference to FIGS. 2 and 3 of the drawings. FIG. 2 shows two opposing brackets raised on pedestals or mounting spacers 27 while the orthogonal pair are not elevated. The mounting bracket 24 is fixed in position by the bolts 26.
Viewing FIGS. 3 and 4 jointly, the pneumatic cylinder 32 extends the piston rod 36. This causes rotation around the shaft 31. The journalled sleeve 46 is caused to rotate as a result of the linkage to it through the bell crank 38. The bell crank provides rotation which, in theory, can approach about 90°; in actuality, approximately half that rotation is needed, and rotation beyond that does not serve any significant purpose. As reviewed, therefore, in FIG. 3 of the drawings, rotation about the shaft 31 prompts rotation of a tee 29 which is joined by a bolt 33 to the journalled sleeve 46. The tee 29 has an upstanding leg which supports a mounting shaft 49. By the use of many turns of threads on the shaft 49 and a suitable lock nut positioned around the shaft, the relative extent or length of the shaft 49 can be adjusted. Ultimately, adjustment at this location changes the length of the extended wiper element to be described. This changes the reach of the equipment when it rotates. As viewed in FIG. 3, it is retracted. As will be discussed later, it is able to extend as shown in FIG. 9. The locus of the pipe in FIG. 9 can vary dependent on pipe diameter and other factors. The extended mounting shaft 49 is therefore varied to enable the reach to be modified. This change in reach or extent is an adjustment which can be made for a given pipe size and later changed should the size of the drill pipe change. Drill pipe ranges from as much as 7" down to smaller diameters. It may be necessary to extend the wiper to contact even against tubing which is smaller than 3". Whatever the circumstances, adjustments in the threaded connection of the shaft 49 help accommodate changes of pipe size.
Continuing now with FIGS. 3 and 4, rotation to the retracted position is limited by a stop bolt 35. This is the beginning point of operation. As shown in FIG. 3, the shaft 49 is positioned where it is more or less vertical and is parallel to the mounting bracket 24. The tee 29 is located at the center of the journalled sleeve 46. This center location assists in centering the wiper element so that it moves along a radial line approaching the pipe, of course, assuming that the pipe is round and centralized in the conductor pipe below and the rotary table above. That is assumed to be the norm but reality suggests that the pipe maintain the centerline position, but departures from that will occur. Movement to the left or right from the centerline position of FIG. 4 may be required. Movement occurs by rotation around the mounting bolt 33 and the tee 29. This prompts the mounting shaft 49 to swing through a limited arc of perhaps 5° or 10° to the right or to the left as reviewed in FIG. 4. This mounting shaft 49 can swing to the left or right pivoting around the bolt 33 as noted. It is helpful, however, to restore it to the initial location. Restoration is accomplished by the spring 39 better shown in FIGS. 4 and 5 together. The spring includes several turns coiled in a circle and terminates in a pair of crossed legs. The legs 41 and 43 are crossed in FIG. 5 to bracket the mounting shaft 47 and clamp around the upper end of the tee 29 shown in side view in FIG. 3. The upper leg 41 in both FIGS. 3 and 4 will be observed spaced vertically above the leg 43. The vertical spacing is defined by the height of the coil spring 39. The legs are limited in their flexure by an upstanding alignment pin 45. The alignment pin is upright, and does not move to the left or right. The coil spring 39 is wound around an upstanding mounting post 47, see FIG. 5. The post 47 is the mount for positioning the circular turns of the coil spring 39 to assure that it is installed at the right location. The post 47 has a height to support the coil spring positioned around it. The post 47 is threaded at the lower end to thread into the centered leg 48 previously defined. In summary, the coil spring and post restore the shaft 49 to the desired centerline and vertical position shown in FIG. 4.
Consider, for the moment, operation of the equipment. The tee 29 is able to oscillate around the shaft 33. It is centered in FIG. 4 but deflects about 5° or 10° to the left or right. When that occurs, the spring 39 applies a force through either the leg 41 or the other leg 43 to restore the centerline position. While deflection is permitted, it occurs only so long as required. In turn, that is determined by the engagement of the wiper element to be described with the outside wall of the pipe. This mode of operation accomplishes all that is needed in following movement of the pipe dynamically during a actual drilling operation. Again, this occurs as a result of crooked pipe or pipe which is not necessarily round. The restoring force of the spring accomplishes restoration as desired.
FIG. 3 shows the equipment retracted so that no wiping occurs. For contrast, attention is now directed to FIG. 9 of the drawings where it is shown extended with the wiping element 60 contacting the pipe at a non perpendicular angle. The operation of the pneumatic cylinder 32 moves the crank 38. The crank 38 is pivoted around the shaft 42 and is, therefore, rotated by approximately 60 to 80° in contrast between FIGS. 3 and 4. When it rotates, it also rotates the clamp plate securing the spring blade 50. The crank 38 is attached for rotation with a pair of mounting plates 52 which form a clamp around the blade 50. The blade 50 and the clamp plates 52 are all formed of metal and are bolted together by bolts 54 to fasten the blade 50. It extends laterally in such a position that the wiping element is deployed for wiping.
Attention is now directed to FIG. 10 of the drawings which shows the pneumatic power system. An air pressure supply line 70 is connected with a controlled source of air (not shown) which is switched to extend the four actuators and thereby initiate pipe wiping. The air line 70 is connected to a lubricator 71 mounted in a cabinet 72 which protects the air flow equipment from the weather. The cabinet 72 has attached, at the bottom, a set of magnets 73 which enable the cabinet 72 to be anchored temporarily in place on the steel deck plate 74. The drilling rig is normally formed with steel plates. Magnetic attachment serves to anchor the cabinet. The cabinet encloses the lubricator 71 which delivers air under pressure to a manifold 75, and that, in turn, delivers air under pressure to a regulator 76. The regulator 76 provides a regulated output pressure on a line 77 which extends to the interior of the cabinet 22. The line 77 extends in a circular path on the inside and connects with the four identical pneumatic cylinders 32. The cylinders 32 are preferably double acting so that the piston in each is driven positively in one direction and also positively driven in the opposite direction. There is another regular 78 in the cabinet. It provides air under pressure on the line 79 which connects to a similar parallel line 79 in the cabinet or housing 22. The lines 77 and 79 have branches as illustrated in FIG. 10 showing how they operate the four pneumatically powered cylinders in unison. They extend and retract together. Extension is obtained as illustrated in FIG. 9 by extending the piston rod 36. This requires an increase in pressure in the line 79. An increase in pressure in the line 77 signifies retraction. A dump valve is included at 80, and a movement indicator 81 extends, thereby providing a visual signal that the pressure status is readable from a distance. One or two such indicators can be included, perhaps marked with different colors to provide different indications. Without limiting the invention, color indications are used to provide appropriate signals to the driller. The driller operates the equipment from the rig floor and relies on the signals which provide a visible indication of the wipers even though they are located out of sight and their condition cannot be directly known. Generally, it is desirable that a positive signal be provided when the wipers are extended and contacted against the pipe as illustrated in FIG. 9. The wipers are extended, and that signal is formed to the driller.
The pressure of the two regulators should be noted. Pressure to extend is obtained through the line 79 which is provided through the regulator 78. Assume, for purposes of discussion, that pressure regulator is set at 50 psi. That is enough to overcome pressure through the regulator 76 which might be 20 psi. Other examples can be given for the two representative pressures. Suffice it to say, positive pneumatic pressure is applied in both extension and retraction conditions to assure positive action. The indicator 81 gives the driller the necessary signal. This deploys the air line 70 so that it connects with the four actuators. It is connected to extend the piston rods 36 as shown in FIGS. 3 and 4. Preferably, the four cylinders are pneumatic in operation. They are double acting cylinders which include a low pressure side. The exhaust line 77 is connected to the four cylinders. This, therefore, ties operation of the system to a single pneumatic signal, namely, the application of air to the supply line 70 under control of the operator.
In FIG. 9 of the drawings, an inflatable seal ring 80 is incorporated to assure a tight connection between the bell nipple and the housing 22. This firmly and snugly holds the present invention 10 to the mud return system. This is achieved easily by leveling the top end of the pipe flush to support the weight of the wiping device 10.
The wipers bear against the drill pipe with a force which is controlled by the pneumatic pressure applied to the system. As shown above, air is delivered to the pneumatic cylinders. Each pneumatic cylinder 32 has a specified piston diameter. They are preferably equal because they function in the same manner. With four pneumatic cylinders arranged in a circle around the drill pipe, each is provided with the same air pressure working against the same size piston. Since piston size is fixed with construction, pressure can be varied to thereby control the force. The wiping force applied at each wiper against the pipe is counteracted by the coil spring which tends to return the wiper to the retracted position. By properly balancing these two so that the pneumatic cylinder slightly overcomes the coil spring, a very light or delicate touch can be obtained. It is not necessary to bear had against the drill pipe. It is not necessary for effective cleaning. Proper wiping or cleaning is therefore obtained with the wipers inclined upwardly toward the pipe in the extended position, and the force on the wipers enables the wipers to easily deflect with crooked pipe or external upsets on the pipe. Every shoulder readily passes through the wipers.
While the foregoing is directed to the preferred embodiment, the scope thereof is determined by the claims which follow.
|
This device is a pipe wiping apparatus. The pipe wiping structure incorporates a housing and the housing is provided with a central opening to enable the housing to be positioned along the pathway of a pipe string. The pipe string is extended upwardly and passes through the housing. The pipe string is made of a number of drill pipes which are serially connected to extend through the housing so that the external surface can be wiped. As the pipe string passes through the housing, it is exposed to the action of similar wipers which are mounted on multiple actuators where each actuator incorporates a low pressure pneumatic cylinder. The cylinder operates a piston which moves a piston rod which operates a belt crank. This belt crank mechanism rotates an arm to thereby rotate a curving conformed resilient wiper element of sheet material. It is supported on the arm extending radially inwardly toward the pipe. Retraction is permitted to pull the wiper away from the pipe. Each wiper element can move radially toward the pipe to accommodate external upsets in the pipe string.
| 4
|
STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to apparatus for interconnecting of two submerged bodies and is directed more particularly to such apparatus as will automatically align the two bodies upon interconnection to facilitate establishment of communication between the two bodies.
(2) Description of the Prior Art
The underwater connection of two bodies may be required to establish communication between the two bodies in situations in which covertness and/or high data rate transmission is required. Such connections are required, for example, between submarines and underwater vehicles, such as torpedoes.
In an illustrative system, an unmanned undersea vehicle (UUV) is provided with a communication line extending to a control vessel, typically a submarine. A controlled body, typically a weapon, such as a torpedo, is deployed in a water column and has extending therefrom a communication line connected at a remote end to a submerged free-floating buoy. The buoy is connected by a communication cable to a free-floating pod of greater buoyancy than the buoy. Thus, the pod floats above the buoy with the communication cable disposed generally vertically therebetween. In operation, the UUV is maneuvered into contact with the vertical cable between the buoy and the pod, connects to the cable, and rides along the cable to a point adjacent to, or engaging, the pod. Communication is established between the UUV and the pod which effects communication between the submarine and the torpedo. Accordingly, from a relatively safe distance the submarine may send instructions to the torpedo.
While in some communication systems, it is acceptable for the UUV merely to be proximate the pod, in fiber-optic and free space laser communications, particularly where multiple spatially separated channels are involved, engagement and highly accurate alignment of the UUV and the pod are required. In such instances, only a single orientation of the UUV relative to the pod is acceptable.
More particularly, the single orientation includes orientation along an axis of substantially translational motion of the UUV relative to the pod; and an angular position of the UUV relative to a reference angular position of the pod (i.e., azimuthal position of the UUV). Positioning underwater bodies for their interconnection with azimuthal accuracy has heretofore required extensive human interaction and has been difficult, at best, in view of local currents and sea conditions.
There is, therefore, a need for a UUV adapted to engage a generally vertical communication cable extending in a water column between a lower free-floating buoy and an upper free-floating pod and adapted to ride along the cable into interlocking engagement with the pod in a selected orientation and azimuth for interconnection of communication components requiring precise alignment.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide apparatus for interconnecting underwater bodies, such as a UUV and a communications pod, the apparatus including a UUV adapted to automatically engage a generally vertical cable suspended in a water column.
A further object of the invention is to provide such apparatus in which the UUV is adapted, after engagement with the cable, to ride along the cable into engagement with the pod.
A still further object of the invention is to provide such apparatus in which the UUV and the pod are adapted to automatically engage each other in a manner facilitating correct alignment of the two bodies so as to provide precise alignment of communication components.
With the above and other objects in view, as will hereinafter appear, a feature of the present invention is the provision of apparatus for interconnecting an unmanned underwater vehicle and a free-floating communication pod, the apparatus comprising a communication cable depending from the pod and extending to a buoy of less buoyancy than the pod, such that the cable extends generally vertically in a column of water between the pod and the buoy, the buoy being in communication with a distal station, a mobile unmanned underwater vehicle having therein guidance means for directing the vehicle to the cable, the vehicle being in communication with a control vessel, connector means mounted on the vehicle and adapted to intercept the cable, the connector means being further adapted to permit the cable to slide therethrough as the vehicle continues movement after the intercept of the cable, and complementary alignment means on the vehicle and the pod adapted to cause the vehicle to engage the pod in a preselected orientation and azimuth, whereby to place the control vessel in communication with the distal station.
The above and other features of the invention, including various novel details of construction and combination of parts, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular apparatus embodying the invention is shown by way of illustration only and not as a limitation of the invention. The principles and feature of this invention may be employed in various and numerous embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is made to the accompanying drawings in which is shown an illustrative embodiment of the invention, from which its novel features and advantages will be apparent wherein:
FIG. 1 is a partially perspective, partially diagrammatic view, of apparatus illustrative of an embodiment of the invention;
FIG. 2 is a top plan view of a mobile underwater vehicle component of the apparatus;
FIGS. 3-5 are side elevational diagrammatic views illustrating a sequence of events in the interconnection of the vehicle and pod;
FIGS. 6 and 7 are enlarged diagrammatical illustrations of further sequential events in the interconnection of the vehicle and pod, FIG. 7 showing the pod seated in the vehicle; and
FIG. 8 is a top plan view of alignment means disposed in the vehicle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, it will be seen that an illustrative apparatus includes a communication cable 10, which may, for example, be a fiber-optic cable. Cable 10 is connected at a first end thereof to a free-floating communication pod 12 and at a second end thereof to a buoy 14 of less buoyancy than the pod. The buoy is in communication, as by a line 17, with a distal station, typically a weapon, such as a torpedo (not shown). Pod 12, being more buoyant than buoy 14, floats above the buoy, causing the cable 10 to be generally vertical in attitude. The buoy 14 is typically also free-floating, but in shallow water applications may be bottom-stationed. In the cable 10, there is disposed an acoustic beacon 16 adapted to signal omnidirectionally.
Pod 12 includes a hull portion 18 which is conically shaped. Cable 10 is fixed to hull portion 18 of pod 12 at a connection point 20 close to, but spaced from, a central point 22 at the cone-shaped hull portion 18. The pod 12 is provided with a stationary rudder 24 fixed to the upper surface of the pod.
The system includes a mobile unmanned underwater vehicle (UUV) 30. The UUV 30 is provided with apparatus (not shown) adapted to detect and "home" on the signal of acoustic beacon 16, in both azimuth and depth. Homing devices of this general type are known and have been used extensively in mobile underwater vehicles, such as homing torpedoes.
The UUV 30 is provided with extendable arms 32 which project from sides of the UUV and are angled forwardly. The UUV is further provided with propulsion means (not shown) adapted to move the vehicle through the water. The UUV is in communication, as by a line 34, with a control vessel (not shown), such as a submarine.
Upon passage of the UUV in close proximity to cable 10, the cable is engaged by one of the arms 32 and is guided by arm 32 into one of the two slots 36. Each of the slots 36 is associated with one of the arms 32. Referring to FIG. 8, it will be seen that an arm 32 of UUV 30 is arranged and disposed so as to guide intercepted cable 10 into slot 36. Slot 36 preferably is provided with a one-way locking mechanism, which may be in the form of a simple leaf spring 38 which permits passage of cable 10 through the slot 36 to a closed end 40 thereof, but prohibits movement of the cable back out of the slot.
The UUV is provided with two or more conical recesses 50 having central points 52, shown in FIGS. 2 and 6. As shown in FIGS. 6-8, the slots 36 are disposed, respectively, in the recesses 50 and extend through the UUV. The closed end 40 of each slot 36 is spaced from central point 52 of the associated recess 50. The space between central point 52 and slot end 40 of each recess 50 is equal to the space between connector point 20 and central point 22 of the pod. The slot closed ends 40 are, respectively, just aft of their associated recess central points 52.
After engagement of the cable by the UUV and movement of the cable along arm 32 into slot 36, passed leaf spring 38, the UUV continues moving forward (FIGS. 4 and 5), causing the cable to slip through the slot as the pod 12 is drawn toward the UUV. As shown in FIG. 6, the conical hull portion 18 of the pod 12 is pulled toward one of the complementary recesses 50 (FIG. 6) and the UUV recess and pod conical portions gradually are directed into alignment.
The off-axis position of the pod connection point 20 and slot closed end 40 eliminates any rotary degree of freedom in the mating of the pod and UUV. The rudder 24 of pod 12 guides the pod through the water (FIGS. 4-6) in approximate alignment with the connection point 20 and central point 22, such that the pod arrives at the recess 50 in position to be readily received in the recess.
Referring to FIG. 7, when pod 12 is fully seated in recess 50, a locking means secures the pod in place. The locking means comprises a groove 60 in a peripheral portion of the pod hull portion 18, and a plurality of spring loaded detents 62 disposed in bores 64 in the wall of each of the conical recesses 50. Upon seating of pod 12 in recess 50, detents 62 snap into groove 60 to lock the pod in the recess 50. Connections 70, shown in FIG. 7 for illustrative purposes, are then in alignment and in abutting engagement. The connections may be for optical, electrical, acoustic, or other communications modes, or a combination thereof.
In operation, the distal station, typically a weapon, the buoy and pod components are launched by a control vehicle, typically a submarine. The pod assumes a position above the buoy with the cable 10 extending therebetween. The submarine then maneuvers to a relatively safe location and launches the UUV. As described above, the self-propelled UUV homes in on the cable, tracking along signals emitted from the beacon in the cable, and intercepts the cable. Continued movement of the UUV causes the UUV to ride up on the cable, relatively, until the UUV lockingly connects with the pod in an orientation and azimuth dictated by the complementary configurations of the interlocking components. Once fitted together, the pod and UUV automatically lock together to establish a communication path including the control vessel, the UUV, the pod, the cable, the buoy and the distal station.
It is to be understood that the present invention is by no means limited to the particular construction herein disclosed and/or shown in the drawings, but also comprises any modifications or equivalents within the scope of the claims. For example, though the UUV has been illustrated and described as having conical recesses therein adapted to receive a conical portion of a pod, it will be apparent that it is the complementary configurations that are critical and that the recess could well be in the pod and the conical protrusion of the UUV, with the UUV conical protrusion being drawn into the pod conical recess. Further, while the above description is directed in large measure to establishing a communication path between a submarine and a weapon, the control vessel may well be a surface ship, helicopter, or lighter-than-air craft, and the distal station may well be another ship, or the like. Communications links, as above described, are useful in establishing paths of communication under certain circumstances between surface ships, between surface ships and submarines and between submarines and various sensor systems.
|
Apparatus is provided for interconnecting an unmanned underwater vehicle V) and a free-floating pod, the apparatus comprising a communications cable extending between the pod and a less buoyant buoy, the buoy being in communication with a distal station, a mobile UUV in communication with a control vessel, connector structure on the UUV adapted to intercept the cable and adapted to slide along the cable toward the pod, and complementary engagement structure on the UUV and the pod adapted to cause the UUV to engage the pod in a preselected orientation and azimuth, to place the control vessel in communication with the distal station.
| 1
|
BACKGROUND OF THE INVENTION
A typical refrigeration control system consists of a compressor to compress gaseous refrigerant, a condenser in which the refrigerant liquefies, an evaporator in which the liquid refrigerant transforms back to a gaseous state, an accumulator which collects refrigerant, and an adjustably controllable expansion valve to control the flow of liquid refrigerant to the evaporator. The expansion valve is controlled to maintain a constant superheat value such that high thermal efficiency is achieved while ensuring that liquid refrigerant does not flow out of the evaporator which would be potentially damaging to the compressor. Superheat is defined as the difference between the vapor temperature of the refrigerant and the saturation temperature of the refrigerant when it is at its liquid-vapor transition point. Two sensors are required to determine the superheat value at the exit of the evaporator. One sensor is used to obtain the vapor temperature and the other sensor is used to obtain the saturation refrigerant temperature.
The expansion valve is controlled by electronic means which senses the superheat value and correspondingly provides an output to change the opening or closing of the valve and hence maintain the value of sensed superheat to a set point. In order for the electronic control means to be highly responsive to adjust for start-up transients and for variations in parameters during steady state operation, an unfiltered, high control gain is provided by the control.
Problems occur in this prior art control mechanism in that the high control gain may result in hunting of the superheat value because of the time lag between changes in the expansion valve and corresponding changes in superheat. Hunting is defined as the condition when the superheat value, instead of stabilizing, oscillates continuously about the set point, resulting in decreased efficiency and possible passing of liquid refrigerant to the compressor.
SUMMARY OF THE INVENTION
The present invention alleviates the problems incurred due to excessive hunting of the superheat by providing signal conditioning means for modifying the sensed superheat signal as a function of a selected characteristic of the sensed superheat signal to provide a modified superheat signal. The modified superheat signal is subtracted from a desired superheat set point signal, and the difference in the two signals provides an output control signal for the expansion valve.
In a preferred embodiment of the invention, the signal conditioning means includes separate paths which have variable authority, or variable transfer functions, depending upon the refrigeration system conditions. One of the paths is filtered and is given authority when it is desired to decrease the amplitude, or overall swings, of the superheat oscillations. The filtered path partakes in creating a delayed and less responsive control to variations in the sensed superheat signal. Another path is unfiltered and is given authority initially at system start-up and during the time when a given steady state stability of superheat is reached. This second path ensures expedient response to dynamic changes in the system by providing a non-delayed feedback signal to the expansion valve. After system start-up, the respective transfer functions, or authority, of the unfiltered path and the filtered path are variable and are functions of the rate of change in the sensed superheat signal with respect to time, or the superheat differential with respect to time.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic view of a preferred embodiment of the control connected to a heat pump refrigeration system in heating mode; and
FIG. 2 is a group of curves representing possible sensed superheat values versus time oscillating about a set point value.
DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a typical refrigeration or heat pump system 10 with which the present invention adapts itself has a compressor 11 to compress gaseous refrigerant, a condenser 12 to liquefy the two-state refrigerant, an electronically controlled expansion valve 13 to limit the circulated flow of refrigerant, an evaporator 14 to evaporate liquid refrigerant, and an accumulator 15 which collects refrigerant to be re-circulated. A means for sensing the value of superheat is provided by the two superheat sensors 16 and 17 and the subtracter 18. A sensed superheat signal representative of the value of superheat, as determined in subtracter means 18, is applied to the input line 21.
The sensing of the superheat value could be accomplished using a variety of methods known to those skilled in the art. One of these methods would require one of the superheat sensors 16 or 17 to measure the temperature at the exit of the evaporator 14 and the other sensor to measure the pressure within evaporator 14. The temperature at the exit of the evaporator 14 is indicative of the vapor temperature of the exiting refrigerant, and the pressure within the evaporator 14 is indicative of the saturation temperature of the refrigerant.
The expansion valve position is controlled by an actuator 33 which is responsive to an electrical output control signal provided by the present invention. A preferred embodiment of the present invention has panel 20 with an input line 21 receiving a sensed superheat signal, representative of the value of superheat in evaporator 14. The sensed superheat signal is connected to a signal conditioning means including an unfiltered path or means 22, such as an amplifier having voltage gain of 1-c, connected in parallel to a filtered path or means 23, such as a single pole low pass filter having a DC gain of c and time constant of τ. The transfer functions of both the unfiltered path 22 and the filtered path 23 are electronically adjustable. Specifically, the gain of the unfiltered path 22 and the gain and time constant of the filtered path 23 can be varied in response to an electrical transfer function control signal.
The sensed superheat signal is also provided to an input circuit of a control means 24 whose control function could be accomplished by way of a microprocessor with support circuitry. Control means 24 is responsive to the operation of the refrigeration system to control the relative transfer of the sensed superheat signal through unfiltered means 22 and filtered means 23. A differentiator 25 within control means 24 provides a differentiation function to monitor the rate of change of the sensed superheat signal with respect to time. This could be accomplished using a microprocessor by sampling the sensed superheat signal in fixed time intervals and providing an output signal representative of the overall change in the sensed superheat signal during that time period, referred to as the discrete slope of the superheat signal. The output signal from the differentiator 25 is compared to a reference signal or threshold slope in comparator 26. The output signal representative of the discrete slope of the superheat signal is compared to the threshold slope so that the transfer function control 27 of the control means 24 can determine the appropriate overall transfer function needed to induce the proper opening or closing of the expansion valve 13. For example, if the discreet slope of the superheat signal were greater than the threshold slope, the transfer function control 27 would provide signals to affect the respective transfer functions of the unfiltered path 22 and the filtered path 23 such that the filtered path 23 would have a more dominant influence on the conditioning of the output control signal to be provided to the expansion valve 13. An extension of the invention would also provide a control signal from the transfer function control 24 which would cause a decrease in the amplification of the gain stage 32 to further modify the effect of the sensed superheat signal on the control of expansion valve 13. Thus, the overall result due to the conditioning of the sensed superheat signal in this example is a feedback signal to the actuator 33 which is lower in amplitude and delayed. This signal causes less fluctuation in the position of the expansion valve and also delays the opening or closing of the valve, both of which contribute to stabilizing the superheat. The delay contributes to the stabilization of the superheat when it decreases the phase difference between a change in the expansion valve position and a corresponding change in superheat.
The respective outputs of paths 22 and 23 are combined in an adder means 25 whose output at 30 is a modified superheat signal. This modified superheat signal is subtracted from a set point value in subtracter means 31. The output of the subtracter means 31 is applied to a gain stage 32 which changes the level of the control signal to the expansion valve 13 and whose gain is a function of the control means 24. The output of the gain stage 32 is an output feedback signal to be applied to the control input of the expansion valve control actuator 33.
OPERATION OF THE INVENTION
Referring to a preferred embodiment of the present invention shown in FIG. 1, a signal is provided to the control input to actuator 33 of adjustable expansion valve 13 connected within the heat pump refrigeration system 10 shown in its heating mode. The sensed superheat signal from subtracter mean 18 is electrically connected to the input of unfiltered path 22, the input of filtered path 23, and an input of the control 24.
When control 24 detects system start-up, the respective transfer functions of unfiltered path 22 and filtered path 23 are assigned by control 24 such that unfiltered path 22 has authority over filtered path 23 for a given amount of time determined by timer 28. When unfiltered path 22 has authority over filtered path 23, the resulting modified superheat signal, as combined by the adder 25, is predominantly influenced by unfiltered path 22. This condition would exist whenever the magnitude of the gain of unfiltered path 22 is greater than the magnitude of the gain of filtered path 23. This could be accomplished in a system with an unfiltered transfer function of 1-c and a filtered transfer function of ##EQU1## by assigning the value of c to 0.2 initially. The amplification of the gain stage 32 would also be assigned by the transfer function control 27 to provide a relatively high level of amplification.
The purpose for this initial assignment of the overall transfer function of the present invention after system start-up is to provide an unfiltered, relatively high feedback gain to ensure immediate and substantial response by the expansion valve 13. This immediate response by the expansion valve will contribute to high system efficiency by quickly allowing the system to reach the desired level of superheat.
When the given amount of time after system start-up has elapsed, the present invention provides an appropriate feedback signal to the refrigeration system by monitoring the change in the sensed superheat signal with respect to time in discreet steps and modifying the amplification of the gain stage 32 and the respective authority of the unfiltered path 22 and filtered path 23 accordingly. FIG. 2 shows three possible signals representing the sensed superheat signal as provided by the output of subtracter 18 at input line 21. Tangent to each of these sinusoidal signals are shown the positive and negative values of the threshold slope whose magnitude has been arbitrarily chosen for this illustration.
The value of the threshold slope in application is chosen to optimize the desired performance of the system. The threshold slope could also be made variable and responsive to other refrigerant system operating conditions.
As is apparent from each signal of FIG. 2, the duration of time shown as time period Y, during which the magnitude of the discreet change in the sensed superheat signal with respect to time or discreet slope is greater than the shown threshold slope, illustrates the condition existing during which the filtered path 23 is given more authority and the amplification of the gain stage 32 is reduced by the control 24. The time period X, illustrating the duration during which the discreet slope is less than the threshold slope, shows the condition existing during which the unfiltered path 22 is given more authority and the amplification of gain stage 32 is raised by the transfer function control 27.
Comparing signal A to signal B reveals that the time duration Y occurs for a higher percentage of a cycle of the signal (half cycle duration given by the sum of time periods X and Y) for signal A than for signal B. Similarly, the time duration Y of signal B occurs for a higher percentage of its cycle than for signal C. Thus, for a superheat signal represented by signal A, the filtered path 23 will be given more authority and the amplification of the gain stage 32 reduced for a greater percentage of time than would a superheat signal represented by signal B or signal C. This assignment in the transfer function of the system reduces the swing and creates a delay in the output signal provided to change the valve position, and consequently results in reducing the hunting of the superheat set point value during steady state.
As the discrete slope of the sensed superheat with respect to time reduces below the threshold slope for a greater percentage of its entire period, as would occur with the less oscillatory and lower amplitude signals represented by signal B and signal C, then authority is increasingly transferred to the unfiltered feedback path 22, and the amplification of gain stage 32 is raised. This assignment of transfer function ensures that the overall system will respond quickly to outside parameter changes which cause dynamic change in the value of sensed superheat. This control causes the refrigeration system to establish a compromise between low superheat oscillation during steady state and quick response when system parameter variations occur.
It is apparent from the description of this embodiment that several variations could be adopted which would result in essentially the same control function. For example, a single feedback path with an adjustable time delay and gain could replace and serve the functions of both the unfiltered and filtered paths. Alternatively, a plurality of feedback paths, each having a fixed transfer function, could be selectively controlled to condition the sensed superheat signal.
While the foregoing specification describes a preferred embodiment of the invention, other embodiments will be apparent to those skilled in the art, without departing from the spirit of the invention which is limited only by the following claims:
|
A refrigeration system comprises a compressor, a condenser, an evaporator, an accumulator, and an adjustable controllable expansion valve. An electronic control system monitors the value of superheat and accordingly provides an electrical control signal to adjust the controllable expansion valve in order to maintain a set point superheat value. An unfiltered path is provided to ensure expedient response when the system starts operation and when dynamic changes occur. A filtered path is provided to reduce hunting, or oscillations about the set point, of the superheat value during steady state operation.
| 5
|
CROSS-REFERENCE TO RELATED DOCUMENTS
[0001] The present invention is a continuation-in-part (CIP) of co-pending application Ser. No. 14/031,966, filed Sep. 19, 2013, which was filed claiming priority to provisional Patent Application (PPA) 61/704,902, filed Sep. 24, 2012. Accordingly priority is claimed for the present application to the filing date of PPA Ser. No. 61/704,902 for claims enabled in that PPA.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is in the technical field of games, and pertains more particularly to word games.
[0004] 2. Description of Related Art
[0005] Word games are played by many people both young and old. A challenge of finding correct letters to spell words appeals to many players. Games such as Scrabble®, Scattergories®, and Boggle® are popular, but players may often desire a different game that offers different challenges. What is needed in the art is a game that provides a plurality of game pieces each having a plurality of letters that may be arranged to spell words. In some embodiments one or more categories may be provided on cards, such that the players may spell words that fit the categories.
BRIEF SUMMARY OF THE INVENTION
[0006] In one embodiment of the invention a word game is provided, comprising a plurality of tennis balls bearing alpha-numeric characters, spaced apart uniformly on the spherical surface of the tennis balls, a support structure having a thickness, parallel upper and lower surfaces, and an arrangement of indentions configured to support individual tennis balls in a manner to primarily display one alphanumeric character on each ball placed, a mechanism enabling selection of one or more categories for words in a specific game, and a rule set for the specific game, in which athletic activities with the tennis balls may be a part of the rules, wherein the athletic activities may server to acquire balls by players or teams, or to define specific used of balls and characters on the balls in the game.
[0007] In one embodiment the alpha-numeric characters are in different colors or different fonts and colors an fonts are included as conditions in the rule set. Also in one embodiment indentions in the support structure are circular through-holes, the support structure has a specific thickness and the relationship of the diameter of the through holes to the thickness is such that a tennis ball placed over one of the through holes is supported entirely by the peripheral edge of the through-hole without the tennis ball touching a surface upon which the support structure rests. Still in one embodiment the support structure has a specific thickness, and the indentions are spherical in form without penetrating entirely through the thickness of the support structure.
[0008] In one embodiment the arrangement of indentions is a Cartesian array having uniform rows and columns of indentions, and a number of indentions equal to or greater than 25. Also in one embodiment the rule set includes requirements for carrying out at least one physical task with the tennis balls in acquiring individual ones of the balls by an individual player or team. Still in one embodiment physical task involves throwing or catching a tennis ball by one or more players.
[0009] In some embodiments the physical task involves rolling one or more tennis balls by one or more players of the game. Also in some embodiments the physical task involves throwing a tennis ball against a wall and catching it on a rebound by one or more players of the game. And in other embodiments the physical task involves determining by a result of the task with a tennis ball a particular character on the ball to be presented as a part of a word in the game.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] FIG. 1 illustrates game pieces in an exemplary embodiment.
[0011] FIG. 2 illustrates a card in an embodiment of the invention.
[0012] FIG. 3 illustrates a playing surface in an embodiment of the invention.
[0013] FIG. 4 illustrates a timer in an embodiment of the invention.
[0014] FIG. 5 illustrates a method of playing a game in an embodiment of the invention using “BASIC” rules.
[0015] FIG. 6 illustrates a method of playing a game in an embodiment of the invention using “SIMPLE” rules.
[0016] FIG. 7 illustrates a method of playing a game in an embodiment of the invention using “VANISHING” rules.
[0017] FIG. 8 illustrates a method of playing a game in an embodiment of the invention using “MESSY” rules.
[0018] FIG. 9A illustrates a method of playing a game in an embodiment of the invention using “STACKED” rules.
[0019] FIG. 9B illustrates an arrangement of base and dependent words in an embodiment of the invention.
[0020] FIG. 9C illustrates a second arrangement of base and dependent words in an embodiment of the invention.
[0021] FIG. 10A illustrates a method of playing a game in an embodiment of the invention using “SHRINKING” rules.
[0022] FIG. 10B illustrates another exemplary arrangement of base and dependent words in an embodiment of the invention.
[0023] FIG. 11A illustrates a method of playing a game in an embodiment of the invention using “STICKY” rules.
[0024] FIG. 11B illustrates an exemplary arrangement of connected words in an embodiment of the invention.
[0025] FIG. 12 illustrates a method of playing a game in an embodiment of the invention using “FRIENDLY” rules.
[0026] FIG. 13 illustrates a method of playing a game in an embodiment of the invention using “GREEDY” rules.
[0027] FIG. 14 illustrates a method of playing a game in an embodiment of the invention using “BRILLIANT” rules.
[0028] FIG. 15 illustrates a method of playing a game in an embodiment of the invention using “CRAFTY” rules.
[0029] FIG. 16 illustrates a method of playing a game in an embodiment of the invention using “SOPHISTICATED” rules.
[0030] FIG. 17 illustrates a method of playing a game in an embodiment of the invention using “SILLY” rules.
[0031] FIG. 18A illustrates a method of playing a game in an embodiment of the invention using “BACKWARDS” rules.
[0032] FIG. 18B illustrates an exemplary arrangement of words arranged in alphabetical order by last letter in an embodiment of the invention.
[0033] FIG. 19 illustrates a method of playing a game in an embodiment of the invention using “FANCY” rules.
[0034] FIG. 20 illustrates a method of playing a game in an embodiment of the invention using “CLAPPING” rules.
[0035] FIG. 21 illustrates a method of playing a game in an embodiment of the invention using “DIABOLICAL” rules.
[0036] FIG. 22 illustrates a method of playing a game in an embodiment of the invention using “HUGE” rules.
[0037] FIG. 23 d illustrates a method of playing a game in an embodiment of the invention using “SKINNY” rules.
[0038] FIG. 24 d illustrates a method of playing a game in an embodiment of the invention using “HUNGRY” rules.
[0039] FIG. 25 illustrates a method of playing a game in an embodiment of the invention using “TRIVIAL” rules.
[0040] FIG. 26 illustrates an exemplary arrangement of game pieces spelling a word using letters of the same color in an embodiment of the invention.
[0041] FIG. 27 illustrates an exemplary arrangement of game pieces spelling a word using letters of the same font in an embodiment of the invention.
[0042] FIG. 28 illustrates tennis balls which may be used as game pieces in an embodiment of the invention.
[0043] FIG. 29 illustrates a mat used to hold tennis balls from FIG. 1 .
[0044] FIG. 30 illustrates tennis balls from FIG. 1 arranged on a mat from FIG. 2 spelling words.
DETAILED DESCRIPTION OF THE INVENTION
[0045] FIG. 1 illustrates an exemplary embodiment of a selection of game pieces 100 in an embodiment of the invention. In some embodiments the game pieces 100 may be three dimensional pieces having four or more sides 102 . In some embodiments each game piece 100 may be a cube having six sides, as shown in FIG. 1 . In alternate embodiments each game piece 100 may have a non-cubical shape, such as a tetrahedron, octahedron, dodecahedron, cylinder, prism, or have any other desired shape. In other embodiments the game pieces 100 may be cards, tiles, or any other type of game piece. Each side 102 of each game piece 100 may display a letter of the alphabet 104 . In some embodiments each side 102 of each game piece 100 may display a different letter 104 . In other embodiments some sides 102 of a game piece 100 may display the same letter 104 as another side 102 of the same game piece 100 or a different game piece 100 . The selection of letters 104 for each game piece 100 may be random and/or varied such that at least some game pieces 100 have a different selection of letters 104 than other game pieces 100 . In alternate embodiments the game pieces 100 may be spheres or other ovoid shapes, and a plurality of letters 104 may be displayed at various points on the exterior of the game piece 100 .
[0046] In some embodiments one or more letters 104 and/or sides 102 on each game piece 100 may have different styles, such as different colors, fonts, and/or other characteristics. By way of a non-limiting example, a cube shaped game piece 100 may have two sides 102 with red letters 104 , two sides 102 with green letters 104 , and two sides 102 with blue letters 104 . In alternative embodiments all letters 104 and/or sides 102 may have the same style.
[0047] FIG. 2 illustrates an exemplary embodiment of a card 106 . Each card 106 may display one or more categories 108 on a face of the card. In some embodiments each card 106 may display a single category 108 . In other embodiments each card 106 may display a plurality of categories 108 , as shown in FIG. 2 . In some of these embodiments the plurality of categories 108 may be sorted and/or selected by difficulty, color, number, category type, and/or any other criteria. In some embodiments the difficulty of the various categories 108 may be color coded. By way of a non-limiting example, in some embodiments a card 106 may display five categories 108 , with a “beginner” category 108 in orange, an “easy” category 108 in purple, a “medium” category 108 in blue, an “advanced” category 108 in green, and a “tricky” category 108 in black. In some embodiments categories 108 may be words such as nouns, adjectives, names, or any other type of word. By way of a non-limiting example, FIG. 2 illustrates a card 106 with the categories: “Black Things,” “Sports Equipment,” “Things on a Map,” “Appliances,” and “Counties in this State.” In alternative embodiments categories 108 may be questions, pictures, colors, shapes, numbers, or any other type of category.
[0048] FIG. 3 illustrates an embodiment of a playing surface 110 . The playing surface 110 may have one or more designated spaces 112 . In some embodiments one or more of the designated spaces 112 may be an indentation shaped such that one or more of the game pieces 100 may be inserted into the indentation. In other embodiments the designated spaces 112 may be outlined areas, apertures, slots, or any other space or region.
[0049] Game pieces 100 , cards 106 , and/or playing surfaces 110 may be used together to play a game. In some embodiments the game pieces 100 , cards 106 , and/or playing surfaces 110 may be physical components. In alternate embodiments the game may be played as a video game, computer program, mobile application, internet game, social network game, or any other type of electronic game. In some of these embodiments the game pieces 100 , cards 106 , and/or playing surfaces 110 may be digital representations. In alternate embodiments some components may be physical and other components may be electronic.
[0050] The game may be played by one or more players. In some embodiments a player may play with or against other players and/or computer opponents. In other embodiments players may be grouped into teams that may play with or against one another. In alternate embodiments a single player may play the game to attempt to get a high score or achieve other objectives.
[0051] In some embodiments a plurality of game pieces may be provided to each player or team. In other embodiments each player or team may draw from a pool of game pieces. In some embodiments a plurality of cards may be provided in a deck. In other embodiments one or more cards may be provided to each player or team. In some embodiments there may be one playing surface 110 for each player or team. In other embodiments all players or teams may use the same playing surface 110 . In alternate embodiments the playing surface 110 may be absent, and players or teams may play the game on a table, floor, or any other surface.
[0052] In some embodiments the game may be played by having each player or team select and/or move game pieces 100 with sides 102 that display letters 104 that spell out a word that fits a selected category 108 on a drawn card 106 . In some embodiments the game and/or individual rounds may have a time limit. In these embodiments a timer 114 may be provided, as shown in FIG. 4 . The timer 114 may be a clock, sand timer, buzzer, or other timing device. In some embodiments players may attempt to spell out the most words using their game pieces 100 during a predetermined time period and/or number of rounds. In other embodiments game pieces 100 may be discarded as they are used, with the winning player being the player who discards the most game pieces 100 during a predetermined time period and/or number of rounds, or is the first player to discard all of his or her game pieces 100 . In still other embodiments other scoring systems and/or methods of determining a winner may be used.
[0053] Several possible embodiments comprising different sets of rules for playing the game are described below. Each of the sets of rules described below has been given a title, however the titles are for reference only and are not intended to be limiting. Each set of rules is intended to be non-limiting, as in some embodiments elements of one set of rules may be combined or replaced with elements of another set of rules to play the game.
“Basic” Rules
[0054] FIG. 5 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may have 40 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to spell one or more words that fit into one or more categories 108 on the card. In some embodiments the players may position the game pieces on a surface such that the letters on the side 102 facing upward spell out the intended word. By way of a non-limiting example, in FIG. 1 a player has positioned game pieces 100 to spell “RIVER,” which fits into the “Things on a Map” category 108 shown in FIG. 2 . In some embodiments players may spell one word for each category 108 on the card 106 . In some embodiments each word may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may have at least three letters.
[0055] Players may earn a predetermined number of points for each word they spell correctly that fits into a category 108 on the card 106 . In some embodiments other players may verify that words are correctly spelled and fit a category 108 before points are awarded. In some embodiments a dictionary may be consulted if players are unclear on whether a word is spelled correctly. In some embodiments players may vote on whether to accept another player's word if a player raises a question of whether the word meets fits within a category 108 . Players may play the game in this manner to earn enough points to meet or exceed a predetermined winning score. In some embodiments multiple rounds of selecting a card 106 and spelling words may be played in order to reach a predetermined winning score. By way of a non-limiting example, in some embodiments each correctly spelled word that meets a category 108 may be worth one point, and the winning score may be set at fifteen points, such that multiple rounds of selecting cards 106 with five categories 108 each and spelling words may be needed before a player reaches the winning score.
[0056] In some embodiments there may be a predetermined time limit during which players attempt to spell words that meet categories 108 on a drawn card 106 , after which points are tallied and a new card 106 is drawn from the deck to begin a new round if no player has reached the winning score. By way of a non-limiting example, the timer 114 may count down a time limit of two minutes per round. In some embodiments players may re-use game pieces 100 that were used in previous rounds for each new round.
“Simple” Rules
[0057] FIG. 6 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. The cards 106 may have numbered or color coded categories 108 , and the players may choose which number or color category 108 to use. A player may take a card 106 from the deck and read and/or display the category 108 on the card 106 corresponding to the selected number or color to the other players. The players may then attempt to use letters 104 on their game pieces 100 to spell as many words as possible that fit into that category 108 during a predetermined time limit marked by the timer 114 . By way of a non-limiting example, the timer 114 may count down a time limit of two minutes per round. In some embodiments each word may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may have at least three letters. Each correctly spelled word may earn each player a predetermined amount of points for that round, after which a new card 106 is selected and new words are spelled with the same game pieces 100 . The players may play a predetermined number of rounds, with the winner being the player with the most points after the final round.
“Vanishing” Rules
[0058] FIG. 7 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. Each card 106 in the deck may have numbered or color coded categories 108 . The players may agree on which number or color category 108 will be used. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to spell a word that fits into the category 108 of the number or color they selected. In some embodiments each word may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may have at least three letters.
[0059] When the first player that spells a word that fits the category 108 of the color the player selected, that spelling player may yell out the word and play stops. The word may be verified by the other players as being accurately spelled and appropriate for the category 108 . If the word is not spelled correctly or is not appropriate for the category 108 , play may resume and players may continue to attempt to spell words with their game pieces 100 . After a spelled word has been verified as accurate and appropriate, one or more game pieces 100 may be discarded by the spelling player depending on the length of the spelled word. In some embodiments the other players may add game pieces 100 if the spelled word was longer than a minimum number of letters 104 . By way of a non-limiting example, in some embodiments: for words with three or four letters 104 , the spelling player may discard one game piece 100 ; for words with five letters 104 , the spelling player may discard two game pieces 100 ; for words with six letters 104 , the spelling player may discard two game pieces 100 and the other players may each add one game piece 100 ; for words with seven letters 104 , the spelling player may discard three game pieces 100 and the other players may each add two game pieces 100 ; and for words with eight or more letters 104 , the spelling player may discard five game pieces 100 and the other players may each add two game pieces 100 .
[0060] In some embodiments discarded game pieces 100 may be discarded from the beginning of the spelled word. By way of a non-limiting example, if a player spells the word “THROW,” the player may discard the two game pieces 100 at the front of the word: the game pieces 100 used for the letters “T” and “H.” After game pieces 100 have been discarded and/or added, a new card 106 may be drawn and players may attempt to spell a word fitting into the category 108 of their selected color with their remaining game pieces 100 .
[0061] In some embodiments a player may exchange one or more of his or her game pieces 100 between rounds. In alternate embodiments a player may exchange all of his or her game pieces 100 between rounds. In some embodiments exchanging game pieces 100 may be performed when the player has less than a predetermined number of game pieces 100 remaining. By way of a non-limiting example, in some embodiments a player may exchange all of his or her game pieces 100 when the player has eight or fewer game pieces 100 remaining.
[0062] In some embodiments the winning player may be the first player with less than a predetermined number of game pieces 100 remaining. By way of a non-limiting example, the winner may be the first player with fewer than five game pieces remaining 100.
“Messy” Rules
[0063] FIG. 8 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. Each card 106 in the deck may have numbered or color coded categories 108 . The players may agree on which number or color category 108 will be used. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to spell as many words as possible that fit into the category 108 of the number or color they selected during a predetermined time limit marked by the timer 114 . By way of a non-limiting example, the timer 114 may count down a time limit of two minutes per round. In some embodiments each word may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may have at least three letters.
[0064] At the end of each round, spelled words may be verified by the other players as being accurately spelled and appropriate for category 108 . After a spelled word has been verified as accurate and appropriate, one or more game pieces 100 may be discarded by the spelling player depending on the length of the spelled word. By way of a non-limiting example, in some embodiments: for words with three, four, or five letters 104 , the spelling player may discard one game piece 100 ; for words with six or more letters 104 , the spelling player may discard two game pieces 100 . In some embodiments discarded game pieces 100 may be discarded from the beginning of the spelled word. By way of a non-limiting example, if a player spells the word “THROW,” the player may discard the game piece 100 at the front of the word: the game piece 100 used for the letter “T.” After the round has been completed and game pieces 100 have been discarded, the players may draw a new card 106 and play a new round.
[0065] In some embodiments a player may exchange one or more of his or her game pieces 100 between rounds. In alternate embodiments a player may exchange all of his or her game pieces 100 between rounds. In some embodiments exchanging game pieces 100 may be performed when the player has less than a predetermined number of game pieces 100 remaining. By way of a non-limiting example, in some embodiments a player may exchange all of his or her game pieces 100 when the player has eight or fewer game pieces 100 remaining.
[0066] In some embodiments the winning player may be the first player with less than a predetermined number of game pieces 100 remaining. By way of a non-limiting example, the winner may be the first player with fewer than five game pieces remaining 100.
“Stacked” Rules
[0067] FIG. 9A illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. Each card 106 in the deck may have numbered or color coded categories 108 . The players may agree on which number or color category 108 will be used. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to create an arrangement of words during a predetermined time limit marked by the timer 114 . By way of a non-limiting example, the timer 114 may count down a time limit of three minutes per round. In some embodiments each word may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may have at least three letters.
[0068] The players may attempt to create an arrangement comprising a base word and dependent words that re-use the letters of the base word, such that the first letter of each dependent word is one of the letters of the base word. In some embodiments the base word may fit the selected category, while the base words may be any word. By way of a non-limiting example, for a category 108 that reads “States,” a player may use game pieces 100 to spell the base word “OREGON” and six dependent words that begin with the letters “O,” “R,” “E”, “G,” “O,” and “N” respectively, as shown in FIG. 9B .
[0069] In some embodiments the game pieces 100 of the base word may be positioned vertically when viewed from above, such that dependent words may extend horizontally to the right from the game pieces 100 of the base word. In alternate embodiments the game pieces 100 of the base word may be positioned horizontally when viewed from above, and the dependent words may extend vertically below the game pieces 100 of the base word.
[0070] In some embodiments the winner of the game may be the player that spelled a base word with the highest number of letters, as long as each letter of the base word also has a dependent word with more than a predetermined number of letters. By way of a non-limiting example, a player that plays the arrangement of game pieces shown in FIG. 9B may beat a player that plays the arrangement of game pieces shown in FIG. 9C because the base word “OREGON” in has more letters than the base word “OHIO.” In the event that two or more players spell base words with the same number of letters, the player who used the greatest number of game pieces 100 in his or her arrangement may prevail.
“Shrinking” Rules
[0071] FIG. 10A illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 30 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. Each card 106 in the deck may have numbered or color coded categories 108 . The players may agree on which number or color category 108 will be used. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to create an arrangement of words. In some embodiments each word may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may have at least three letters.
[0072] The players may attempt to create an arrangement comprising a base word and dependent words that re-use the letters of the base word, such that the first letter of each dependent word is one of the letters of the base word. In some embodiments the base word may fit the selected category, while the base words may be any word. By way of a non-limiting example, for a category 108 that reads “Months,” a player may use game pieces 100 to spell the base word “JULY” and four dependent words that begin with the letters “J,” “U,” “L”, and “Y” respectively, as shown in FIG. 10B .
[0073] In some embodiments the game pieces 100 of the base word may be positioned vertically when viewed from above, such that dependent words may extend horizontally to the right from the game pieces 100 of the base word. In alternate embodiments the game pieces 100 of the base word may be positioned horizontally when viewed from above, and the dependent words may extend vertically below the game pieces 100 of the base word.
[0074] The first player to complete an arrangement of a base word and dependent words all meeting a predetermined minimum length may shout out the base word the player spelled and play may stop. The spelled base word may be verified by the other players as being accurately spelled and appropriate for the category 108 . After the spelled base word has been verified as accurate and appropriate, the spelling player may discard the game pieces 100 used in the shortest dependent word. By way of a non-limiting example, if the first player to complete an arrangement of a base word and dependent words spells the base word “JULY” as shown in FIG. 10B , that player may discard the game pieces 100 used in the dependent word “LIP.” After the round has been completed and game pieces 100 have been discarded, the players may draw a new card 106 and play a new round.
[0075] In some embodiments the winning player may be the first player with less than a predetermined number of game pieces 100 remaining. By way of a non-limiting example, the winner may be the first player with fewer than twelve game pieces remaining 100.
“Sticky” Rules
[0076] FIG. 11A illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to create an arrangement of words during a predetermined time limit marked by the timer 114 . By way of a non-limiting example, the timer 114 may count down a time limit of four minutes per round. In some embodiments each word may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may have at least three letters.
[0077] The words may each fit one of the categories 108 on the card 106 . The words may be connected to one another by one or more letters, such that at least letter of one word is re-used as a letter of a separate word. The connected words may be arranged vertically and horizontally when viewed from above. By way of a non-limiting example, the arrangement of words shown in FIG. 11B comprises words connected horizontally and vertically by at least one letter.
[0078] In some embodiments the winner of the game and/or round may be the player who uses the most game pieces 100 in an arrangement of connected, correctly spelled words that each fit into a category 108 on the drawn card 106 within the predetermined time limit.
“Friendly” Rules
[0079] FIG. 12 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to spell one or more words with the same number of letters that fit into one or more categories 108 on the card during a predetermined time limit marked by the timer 114 . By way of a non-limiting example, the timer 114 may count down a time limit of three minutes per round. In some embodiments each word may be longer than a predetermined number of letters and have the same number of letters. By way of a non-limiting example, in some embodiments each word may need to be at least three letters, and a player may choose to spell words all having four letters. In some embodiments the winner of the game and/or round may be the player that spells the greatest number of words of the same length within the predetermined time limit. By way of a non-limiting example, a player that spells four words each with three letters may beat a player that spells three words each with five letters.
“Greedy” Rules
[0080] FIG. 13 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with five game pieces 100 . A plurality of auxiliary game pieces 100 may be provided in a pool that is accessible by all players. A deck of cards 106 may also be provided that is accessible by all players. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to spell one or more words that fit into one or more categories 108 on the card 100 . In some embodiments the words may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may have at least three letters. When more than one word is spelled, the words may be connected to one another by one or more letters, such that at least letter of one word is re-used as a letter of a separate word. The connected words may be arranged vertically and horizontally when viewed from above. Once a word has been spelled by a player, the player may break up the word and re-use its game pieces 100 for new or longer words at any later point, as long as all words in the arrangement remain connected.
[0081] When a player has zero game pieces 100 remaining after spelling one or more words, that player may add a predetermined number of game pieces 100 from the plurality of auxiliary game pieces 100 . By way of a non-limiting example, in some embodiments when a player runs out of game pieces 100 after spelling words, the player may add three game pieces 100 . After the player has added new game pieces 100 , the player may continue attempting to spell words that fit any of the categories 108 on the card 106 . If the players agree that no player may spell any more words that fit any of the categories 108 on the card 106 , the players may draw a new card 106 and attempt to spell words that fit any of the categories 108 on the new card 106 .
[0082] In some embodiments the winner of the game and/or round may be the first player to acquire more than a predetermined number of game pieces and use them all to spell words that fit into the categories 108 on the drawn cards 106 . By way of a non-limiting example, the winning player may be the first player to acquire and use 20 game pieces 100 , with no game pieces 100 remaining.
“Brilliant” Rules
[0083] FIG. 14 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to spell words that fit into any one category 108 on the card 106 . In some embodiments each word may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may have at least three letters.
[0084] After spelling words, players may place their spelled words into alphabetical order. In some embodiments the first player to spell more than a predetermined number of words that fit the same category 108 and place the spelled words into alphabetical order may earn a predetermined number of points, and the players may begin a new round by drawing a new card 106 . The winner may be the first player to meet a minimum number of points. By way of a non-limiting example, the first player during a round who spells four words that each fit the same category 108 and places those four spelled words into alphabetical order may earn one point, and the winner of the game may be the first player to earn five points.
“Crafty” Rules
[0085] FIG. 15 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may individually select which category to use. The players may then attempt to use letters 104 on their game pieces 100 to spell words that fit into their selected category 108 on the card 106 . In some embodiments each word may be longer than a predetermined number of letters and have the same number of letters. By way of a non-limiting example, in some embodiments each word may need to be at least three letters, and a player may choose to spell words all having four letters.
[0086] In some embodiments the first player to spell more than a predetermined number of equally long words that fit the same category 108 may earn a predetermined number of points, and the players may begin a new round by drawing a new card 106 . The winner may be the first player to meet a minimum number of points. By way of a non-limiting example, the first player during a round who spells four words of the same length that each fit the same category 108 may earn one point, and the winner of the game may be the first player to earn five points.
“Sophisticated” Rules
[0087] FIG. 16 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to spell words that fit into any one category 108 on the card 106 . In some embodiments each word may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may need to be at least three letters.
[0088] The spelled words may each fit into the same category, and may be of increasing length, such that no word has the same number of letters. By way of a non-limiting example, a player may select the category “Colors,” and the player may attempt to spell five words of increasing length that fit the category, such as “Red,” “Blue,” “Green,” “Yellow,” and “Fuchsia.” In some embodiments the player may place the words in order from shortest to longest.
[0089] In some embodiments the first player to spell more than the predetermined number of words of increasing length that fit the same category 108 and places them in order may earn a predetermined number of points, and the players may begin a new round by drawing a new card 106 . The winner may be the first player to meet a minimum number of points. By way of a non-limiting example, the first player during a round who spells five words of increasing length that each fit the same category 108 may earn one point, and the winner of the game may be the first player to earn five points.
“Silly” Rules
[0090] FIG. 17 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to spell words that fit into one of the categories 108 on the card 106 . In some embodiments each word may be longer than a predetermined number of letters and have the same number of letters. By way of a non-limiting example, in some embodiments each word may need to be at least three letters, and a player may choose to spell words all having four letters.
[0091] The words may each fit the same category 108 on the card 106 . The words may be connected to one another by one or more letters, such that at least letter of one word is re-used as a letter of a separate word. The connected words may be arranged vertically and horizontally when viewed from above.
[0092] In some embodiments the first player to spell more than a predetermined number of connected words of the same length that fit the same category 108 may earn a predetermined number of points, and the players may begin a new round by drawing a new card 106 . The winner may be the first player to meet a minimum number of points. By way of a non-limiting example, the first player during a round who spells five connected words of the same length that each fit the same category 108 may earn one point, and the winner of the game may be the first player to earn five points.
“Backwards” Rules
[0093] FIG. 18A illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to spell words that fit into one of the categories 108 on the card 106 . In some embodiments each word may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may need to be at least three letters.
[0094] The spelled words may each fit the same category 108 . After the words are spelled, they may be placed in alphabetical order based on the last letter of each word. By way of a non-limiting example, the last letters of the words fitting the category “Food” in FIG. 18B are in alphabetical order from top to bottom. The winner may be the first player to spell more than a predetermined number of words and place them in alphabetical order by last letter. By way of a non-limiting example, the winner may be the first player to spell five words that all fit the same category and arrange those five words in alphabetical order by last letter.
“Fancy” Rules
[0095] FIG. 19 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to spell words that fit into each different category 108 on the card 106 . Each word may have either the same number of syllables, vowels, or letters. In some embodiments each word may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may need to be at least three letters.
[0096] In some embodiments the first player to spell more than a predetermined number of words having either the same number of syllables, vowels, or letters that each fit into a different category 108 on the card 106 may earn a predetermined number of points, and the players may begin a new round by drawing a new card 106 . The winner may be the first player to meet a minimum number of points. By way of a non-limiting example, the first player during a round who spells five words of the same number of syllables, vowels, or letters that each fit into a different category 108 may earn one point, and the winner of the game may be the first player to earn five points.
“Clapping” Rules
[0097] FIG. 20 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to spell words that fit into a single category 108 on the card 106 . Each word may have the same number of syllables. In some embodiments each word may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may need to be at least three letters.
[0098] In some embodiments the first player to spell more than a predetermined number of words having the same number of syllables that each fit into the same category 108 on the card 106 may earn a predetermined number of points, and the players may begin a new round by drawing a new card 106 . The winner may be the first player to meet a minimum number of points. By way of a non-limiting example, the first player during a round who spells four words of the same number of syllables that each fit into the same category 108 may earn one point, and the winner of the game may be the first player to earn five points.
“Diabolical” Rules
[0099] FIG. 21 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to spell as many words as possible that fit into different categories 108 during a predetermined time limit marked by the timer 114 . By way of a non-limiting example, the timer 114 may count down a time limit of three minutes per round. Each word may have a different number of vowels or letters. In some embodiments each word may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may have at least three letters.
[0100] In some embodiments if a player spells a word for each category 108 on the card 106 before the time limit expires, and each word has a different number of vowels or letters, that player may be declared the winner. If no player has completed a word for each category when the time limit expires, the player with the most correctly spelled words in different categories with different numbers of vowels or letters may be declared the winner.
“Huge” Rules
[0101] FIG. 22 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . The players may then attempt to use letters 104 on their game pieces 100 to spell as many words as possible during a predetermined time limit marked by the timer 114 . By way of a non-limiting example, the timer 114 may count down a time limit of three minutes per round. In some embodiments each word may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may have at least three letters.
[0102] In some embodiments each correctly spelled word may earn points depending on the length of the word. By way of a non-limiting example, in some embodiments: words with three letters may be worth one point; words with four letters may be worth two points; words with five letters may be worth three points; words with six letters may be worth four points; words with seven letters may be worth five points; words with eight letters may be worth six points; words with nine letters may be worth seven points; words with ten letters may be worth ten points; and words with eleven or more letters may be worth fifteen points. The winner of a game and/or round may be the player with the most points.
“Skinny” Rules
[0103] FIG. 23 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 20 game pieces 100 . A deck of cards 106 may also be provided that is accessible by all players. Each card 106 in the deck may have numbered or color coded categories 108 . In some embodiments the players may agree on which two numbered or colored categories 108 will be used. In other embodiments any number of numbered or colored categories may be agreed upon. A player may take a card 106 from the deck and read and/or display the categories 108 on the card 106 to the other players. The players may then attempt to use letters 104 on their game pieces 100 to spell words for each of the selected categories. In some embodiments each word may be longer than a predetermined number of letters. By way of a non-limiting example, in some embodiments each word may have at least three letters.
[0104] When a player believes he or she has spelled a word for each of the selected categories, play may stop. The words may be verified by the other players as being accurately spelled and appropriate for the categories 108 . If one or more of the words are not spelled correctly or are not appropriate for the categories 108 , each of the other players may transfer a game piece 100 to the player who spelled the incorrect word, play may resume and players may continue to attempt to spell words with their game pieces 100 . If both words are verified as accurate and appropriate, the player who played the words may transfer one game piece 100 to each of the other players and a new card 106 may be drawn to begin a new round.
[0105] In some embodiments the winning player may be the first player with less than a predetermined number of game pieces 100 remaining. By way of a non-limiting example, the winner may be the first player with fewer than thirteen game pieces 100 remaining.
“Hungry” Rules
[0106] FIG. 24 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 21 game pieces 100 . A plurality of auxiliary game pieces 100 may be provided in a pool that is accessible by all players. The players may then attempt to use letters 104 on their game pieces 100 to spell as many connected words as possible during a predetermined time limit marked by the timer 114 . By way of a non-limiting example, the timer 114 may count down a time limit of three minutes per round. In some embodiments each word may have the same predetermined number of letters. By way of a non-limiting example, in some embodiments each word may have four letters.
[0107] The words may be connected to one another by one or more letters, such that at least letter of one word is re-used as a letter of a separate word. The connected words may be arranged vertically and horizontally when viewed from above.
[0108] At any time during the time limit, players may choose to draw a predetermined number of new game pieces 100 from the plurality of auxiliary game pieces 100 . By way of a non-limiting example, a player may choose to draw seven additional game pieces 100 from the plurality of auxiliary game pieces 100 .
[0109] At the end of the time limit, each player may count the number of correctly spelled connected words that each have the predetermined number of letters, and count the number of unused game pieces 100 . Each player's score may be the amount of game pieces 100 used in the spelled words subtracted by the number of unused game pieces 100 . By way of a non-limiting example, a player who began with 21 game pieces and added seven additional game pieces during the time limit may have spelled six connected words of four letters each and may have used 19 of the player's total 28 game pieces, with nine unused game pieces remaining. That player may subtract the nine unused game pieces from the 19 used game pieces, for a total score of ten. The winner of the round and/or game may be the player with the highest score.
“Trivial” Rules
[0110] FIG. 25 illustrates a method of playing the game according to this embodiment of the rules. In this embodiment, a predetermined number of game pieces 100 may be provided to each player or team. By way of a non-limiting example, in some embodiments each player may begin with 40 game pieces 100 . In some embodiments one or more players may generate a list of questions. In alternate embodiments a deck of cards 106 may also be provided that is accessible by all players, and the one or more categories 108 on each card 106 may be questions. Questions may be asked and/or displayed from the generated list and/or cards 106 . The players may attempt to use letters 104 on their game pieces 100 to spell words that answer the questions. In some embodiments questions may be asked and/or displayed one at a time.
[0111] In some embodiments the first player to spell a word that answers the current question may earn a predetermined number of points, and the players may begin a new round by asking and/or displaying a new question. The winner may be the first player to meet a minimum number of points. By way of a non-limiting example, if the question is “What is the capital of Oregon?” the first player to spell “SALEM” may earn a point, and the winner of the game may be the first player to earn ten points.
MODIFICATIONS
[0112] The foregoing sets of rules are purely exemplary, and the rule sets and/or scoring systems may be modified and/or combined to create further ways of playing the game. Most rule sets specify providing the same number of game pieces to each player, but in some games governed by alternative rue sets players may compete for game pieces to get as many as they can before words are spelled out. In some embodiments one or more elements of one set of rules may be combined or replaced with elements of another set of rules to play the game. By way of non-limiting examples, players may play games with multiple rounds of the same rules, play a single round of any rule set, play multiple rounds with or without a time limit, play with the same or different categories for each player, play with a different number of points to determine the winner, play with a different beginning number of game pieces, or play with any other desired modification.
[0113] In some embodiments the game may be even further modified by specifying which letters on which game pieces are valid to play. By way of non-limiting examples, in some embodiments game pieces may have different colors and/or have sides and/or letters with varying colors and/or fonts. In some of these embodiments a player may play game pieces and/or letters on those game pieces with one or more specific fonts and/or colors. By way of non-limiting examples, in the exemplary arrangement shown in FIG. 26 all the letters 104 that spell “BLUE” may be of the same color, and in the exemplary arrangement shown in FIG. 27 all the letters 104 that spell “FONT” may be in the same font. In other embodiments all words may have matching fonts and/or colors. In some embodiments the color of fonts and/or colors may match the color of a selected category 106 . In still alternate embodiments players may earn bonus points for matching fonts and/or colors. By way of a non-limiting example, in some embodiments a player may earn one point for each spelled word, but earn an extra point for any spelled words that comprises game pieces with matching fonts and/or colors.
[0114] In another aspect of the invention the scale of a game may be expanded, and such a game may be, for example, provided for play outdoors, in an open environment. In such a game it may be desirable to have game pieces that are much larger than game pieces thus far described in embodiments of the invention described above.
[0115] In one aspect of the invention tennis balls have been adopted and configured as game pieces. FIG. 28 illustrates eight tennis balls 2801 having characters lettered thereon. In this example balls 2801 have letters placed according to natural divisions and regions following seams of the tennis ball, but this is not a limitation in the invention. Characters might be of any size and placement, and also of any color, font and size. It is required in the invention, however, that one character on each ball used in a game be clearly intended as an object of purposeful placement of the ball bearing the characters.
[0116] FIG. 29 is a perspective illustration of a mat 2901 in an embodiment of the invention. Mat 2901 has through openings 2902 arranged in a Cartesian coordinate system with rows and columns. In this example the arrangement is five by nine, providing forty-five through openings. It is necessary that the thickness of mat 2901 be provided such that if a ball of FIG. 1 is placed over one of the through openings, the ball will be supported by contact with the circular periphery of the opening, and the ball will not rest on a support surface upon which the mat may rest. The thickness to just support a tennis ball off a support under the mat is a minimum thickness for a mat in this embodiment, but the thickness may be greater than this minimum thickness. In some embodiments the thickness of the mat may be equal to the minimum thickness, and instead of openings, spherical indentions of the same diameter as a tennis ball may be provided in the arrangement on the mat. An advantage in this embodiment is that more of the surface of a tennis ball will be engaged by surface of the mat, and the balls may be held more securely.
[0117] FIG. 3 is a perspective view of a mat 2901 with an arrangement of through-openings as described above, with ten balls 2801 placed on openings in the mat such that balls placed spell two words, the words being “spell” and “words”. It should be noted that the intention here is to place the balls so that the intended letters (characters) face upward, upward being vertical relative to the horizontal placement of the mat on a support surface.
[0118] Lettered balls 2801 as game pieces placed a mat 2901 may be used to play any of the games described above, and may be serviceable for new types of games in this invention, where tennis balls with characters may be involved in games that have rules as described in many embodiments above, but also additional components, such as, for example, instances of throwing, batting and retrieving the lettered ball during the playing of a word game. Balls may be retrieved, for example, from a basket or other container at random, thrown against a wall, caught by a player, and then, according to what character faces upward when the ball is caught, become the first letter of a word to be formed according to an agreed-to category of words in the game. A player, then deciding on a word in the category starting with the first letter determined, may by rule be required to throw balls at random and catch them rebounding until the second and subsequent letters may be revealed by catch position and place on the ma to form the word intended.
[0119] Many athletic word games may be thus composed with rules to accommodate lettered tennis balls as described above, in many instances using rules of the games described above, or a mixture of described rules, and additional rules specific to a game played with tennis balls. Games and lettered tennis balls will be used by teachers, trainers, coaches and facilitators who want to combine physical activity with word/math games. Such balls can be used to teach juggling, dribbling, kicking, throwing, catching and a variety of other athletic skills, and then they can be used for more cognitive challenges using the letters or numerals on the balls. An example of such a challenge might be that there are 2 teams and everyone starts with a ball. Everyone needs to dribble their ball across a basketball court and make a basket. If they make a basket then their team will get to use that ball when it is time to spell. This could also be done with kicking the balls into a goal or hitting the balls over a net. After the competing teams have each had a chance to win their balls, the facilitator would then direct them to spell using those letters. They might be given specific words/numbers to build or they might just be directed to spell as many words as they can. They might be given questions and they need to assemble the correct answer using the balls. For example, What is the capital of Oregon? or What is 12 times 23? Such a product is needed because it creates an easy way to combine fun, physical activity and exercise with academic or cognitive challenges. There are a many games that involve spelling or math but these balls will give people the ability to play athletic games that also involve math and language arts.
[0120] Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the invention as described and hereinafter claimed is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.
|
A word game has a plurality of tennis balls bearing alpha-numeric characters, spaced apart uniformly on the spherical surface of the tennis balls, a support structure having a thickness, parallel upper and lower surfaces, and an arrangement of indentions configured to support individual tennis balls in a manner to primarily display one alphanumeric character on each ball placed, a mechanism enabling selection of one or more categories for words in a specific game, and a rule set for the specific game, in which athletic activities with the tennis balls may be a part of the rules, wherein the athletic activities may server to acquire balls by players or teams, or to define specific used of balls and characters on the balls in the game.
| 0
|
[0001] The entire contents of a document cited in this specification are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the technical field of forming silicon nitride films by plasma-enhanced chemical vapor deposition (CVD). The invention more specifically relates to a silicon nitride film-forming method capable of film formation at a high film deposition rate through inductively coupled plasma-enhanced chemical vapor deposition.
[0003] Silicon nitride films are employed as water vapor barrier films in various devices and optical elements requiring moisture resistance, and protective films (passivation films) and insulating films in semiconductor devices.
[0004] Plasma-enhanced CVD is used in methods of forming silicon nitride films.
[0005] A known technique of film formation by plasma-enhanced CVD is capacitively coupled plasma-enhanced chemical vapor deposition (hereinafter abbreviated as “CCP-CVD”), which is a technique involving applying a radio frequency voltage to two opposing electrodes to generate plasma between the electrodes, thus forming a film.
[0006] CCP-CVD has the following advantages: The structure is simple; and a gas material is supplied from the electrodes, which enables gas to be uniformly supplied to the whole film-forming area even in the case where the electrodes have an increased surface area (the gas is easily made uniform).
[0007] On the other hand, CCP-CVD suffers from a plasma electron density of as low as about 1×10 8 to about 1×10 10 electrons/cm 3 and has difficulties in improving the film deposition rate. In addition, because the electrodes are present in the plasma-generating region, film deposition continued for an extended period of time causes adhesion and deposition of a film to the electrodes as well, which may hinder proper film deposition.
[0008] Under the circumstances, in equipment where film deposition is continuously carried out as an elongated polymer film or other material is transported in a longitudinal direction with a view to, for example, producing water vapor barrier films in large quantities, the polymer film serving as a substrate cannot travel at an improved speed, which may often not ensure high productivity. Film deposition to the electrodes also limits the length of the polymer film serving as a substrate.
[0009] What is more, CCP-CVD requires a high pressure of usually about several tens of Pa to about several hundred Pa to maintain plasma, and in cases where film deposition is continuously carried out in a plurality of film deposition spaces (film deposition chambers) connected to each other, has a deteriorated film quality due to undesired incorporation of a gas in any of the film deposition chambers.
[0010] In addition to the above-described CCP-CVD, plasma-enhanced CVD also includes a known technique called inductively coupled plasma-enhanced chemical vapor deposition (hereinafter abbreviated as “ICP-CVD”).
[0011] ICP-CVD is a technique which involves supplying radio frequency power to an (induction) coil to form an induced magnetic field and an induced electric field, and generating plasma based on the induced electric field to form a film on a substrate.
[0012] ICP-CVD is a technique in which radio frequency power is supplied to a coil to form an induced electric field to thereby generate plasma and therefore requires no counter electrode which is essential in plasma formation by means of CCP-CVD. Plasma having a density of as high as at least 1×10 11 electrons/cm 3 can also be easily generated. In addition, plasma can be generated at a lower pressure and a lower temperature compared with plasma formation by means of CCP-CVD.
[0013] Upon manufacture of semiconductor devices, silicon nitride films are formed by ICP-CVD.
[0014] For example, JP 2005-79254 A describes that a silicon nitride film has been conventionally formed through ICP-CVD by using a gas material including silane gas and ammonia gas and adjusting the substrate temperature and the radio frequency power to 350° C. or higher and 6 W/sccm or more, respectively.
[0015] JP 2005-79254 A proposes a silicon nitride film-forming method which aimed at preventing a decline in film quality due to an increased hydrogen content in the film as having been seen in the above-mentioned conventional silicon nitride film-forming method and according to which a silicon nitride film is formed through ICP-CVD at a substrate temperature of 50 to 300° C. by supplying a gas material including silane gas and nitrogen gas in such a manner that the flow rate (supply flow rate) of the nitrogen gas is at least ten times that of the silane gas and by applying a radio frequency power of at least 3 W/sccm with respect to the total gas flow rate.
[0016] It is also described that, in this silicon nitride film-forming method, an inert gas serving as an excitation gas is supplied at a flow rate corresponding to up to 20% of the total flow rate of the silane gas and the nitrogen gas to improve the film deposition rate.
SUMMARY OF THE INVENTION
[0017] The above-mentioned method of forming (depositing) a silicon nitride film is capable of film deposition at a relatively low temperature while reducing the hydrogen content in the film. However, because the nitrogen gas used as the gas material has a low activity, this silicon nitride film-forming method is low in film deposition rate.
[0018] A high enough film deposition rate is not achieved even by using highly reactive ammonia gas as the gas material.
[0019] Therefore, as described above, equipment where film deposition is continuously carried out as an elongated substrate such as a polymer film is transported in a longitudinal direction requires slowing down the travel speed of the substrate, which hampers efficient production.
[0020] The present invention has been made to solve the aforementioned conventional problems and it is an object of the present invention to provide a silicon nitride film-forming method which is capable of forming a silicon nitride film through ICP-CVD at a high film deposition rate.
[0021] In order to achieve the above object, the present invention provides a silicon nitride film-forming method comprising the steps of: supplying a gas material including silane gas, ammonia gas and nitrogen gas in such a manner that a flow rate of the nitrogen gas is 0.2 to 20 times a total flow rate of the silane gas and the ammonia gas; and carrying out inductively coupled plasma-enhanced chemical vapor deposition to form a silicon nitride film.
[0022] The silicon nitride film is preferably formed at a substrate temperature of 0 to 150° C. The silicon nitride film is preferably formed on an organic material. The silicon nitride film is preferably formed on a substrate having a base material made of a polymer film.
[0023] According to the present invention having the features described above, a silicon nitride film is formed through ICP-CVD by using a gas material including silane gas, ammonia gas and nitrogen gas in such a manner that the flow rate of the nitrogen gas is 0.2 to 20 times and preferably 1 to 5 times the total flow rate of the silane gas and the ammonia gas.
[0024] Compared with the formation of a silicon nitride film using a gas material including silane gas and ammonia gas and also compared with the formation of a silicon nitride film using silane gas and nitrogen gas (and optionally a rare gas), the film deposition rate in forming a silicon nitride film can be considerably improved to enable water vapor barrier films and semiconductor devices to be produced with high productivity and high efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a chart showing the relation between the amount of nitrogen gas introduced and the plasma emission in forming a silicon nitride film using silane gas and ammonia gas;
[0026] FIG. 2 is an enlarged view of FIG. 1 at wavelengths of around 336 to 340 nm;
[0027] FIG. 3 is an enlarged view of FIG. 1 at wavelengths of around 488 nm;
[0028] FIG. 4 is a graph showing the relation between the amount of nitrogen gas supplied and the film deposition rate in Examples of the invention; and
[0029] FIG. 5 is a graph showing the relation between the amount of nitrogen gas introduced and the film deposition rate in Examples of the invention provided that the film deposition rate at the nitrogen gas flow rate of 0 sccm is taken as 100%.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] On the pages that follow, the silicon nitride film-forming method of the present invention is described in detail with reference to the accompanying drawings.
[0031] According to the silicon nitride film-forming method of the invention, a silicon nitride film is formed (deposited) through ICP-CVD by using a gas material including not only silane gas and ammonia gas but also nitrogen gas in such a manner that the flow rate (supply flow rate) of the nitrogen gas is 0.2 to 20 times the total flow rate (total quantity of flow) of the silane gas and the ammonia gas.
[0032] As described above, silicon nitride films are employed as water vapor barrier films in various devices and optical elements requiring moisture resistance, and protective films (passivation films) and insulating films in semiconductor devices.
[0033] With a view to producing water vapor barrier films or other films on a large scale with high productivity, a production method is implemented which involves continuously letting out an elongated substrate from a roll into which the substrate is wound, continuously forming a film on the elongated substrate traveling in a longitudinal direction and taking up the substrate having the film formed thereon. In order to improve the productivity and production efficiency in such a production method, it is necessary to improve the travel speed of the substrate through efficient film deposition, in other words, a very high film deposition rate is required.
[0034] Accordingly, the inventor of the invention has made intensive studies on the method of improving the film deposition rate in forming a silicon nitride film.
[0035] As a result, it has been found that the film deposition rate can be considerably improved by using not only silane gas and ammonia gas which are used for the gas material of the silicon nitride film but also nitrogen gas in such an amount that the flow rate of the nitrogen gas is 0.2 to 20 times the total flow rate of the silane gas and the ammonia gas and forming a silicon nitride film through ICP-CVD. The present invention has been thus completed.
[0036] A method as described in JP 2005-79254 A in which a gas material including silane gas and nitrogen gas is used to form a film on a substrate through ICP-CVD is known as a silicon nitride film-forming method.
[0037] However, the method using nitrogen gas as the gas material cannot achieve formation of a silicon nitride film at a high film deposition rate, because the activity of nitrogen is very low as is well known.
[0038] In this regard, JP 2005-79254 A describes that the film deposition rate can be improved by adding a rare gas in the process of forming a silicon nitride film through ICP-CVD using silane gas and nitrogen gas. Usually, an inert gas is very often added in film formation through ICP-CVD in order to stabilize discharge (maintain a high plasma density) and improve film thickness distribution, but in an application requiring a high film deposition rate, it is still difficult to ensure a high enough film deposition rate by adding a rare gas in formation of a silicon nitride film through ICP-CVD using a gas material including silane gas and nitrogen gas.
[0039] On the other hand, a silicon nitride film-forming method in which a gas material including silane gas and ammonia gas is used to form a film on a substrate through ICP-CVD is also known as described in JP 2005-79254 A.
[0040] This method can achieve film deposition at a high film deposition rate compared with the formation of a silicon nitride film using a gas material including silane gas and nitrogen gas, because the ammonia gas used in the method is much higher in activity than the nitrogen gas.
[0041] In the above-described ICP-CVD method in which silane gas and ammonia gas are used to form a silicon nitride film at such a high film deposition rate, the present invention additionally supplies nitrogen gas in such an amount that the flow rate of the nitrogen gas is 0.2 to 20 times the total flow rate of the silane gas and the ammonia gas to thereby achieve formation of a silicon nitride film at a higher film deposition rate.
[0042] As already described above and also described in JP 2005-79254 A, nitrogen gas is used as the gas material that serves as a nitrogen source in forming a silicon nitride film through ICP-CVD using silane as a silicon source. As is also well known, the activity of nitrogen gas is much lower than that of ammonia gas.
[0043] Therefore, according to a general way of thinking, nitrogen gas introduced in a silicon nitride film-forming system which uses a gas material including silane gas and ammonia gas is involved in the reaction, that is, film deposition. As a result, film formation with the less active nitrogen gas impedes film formation with the highly active ammonia gas. In addition, the less active nitrogen gas consequently dilutes the highly active ammonia gas, leading to reduction of the film deposition rate, although the nitrogen gas contributes to film deposition.
[0044] However, the inventor of the present invention has made an intensive study and as a result found that introduction of nitrogen gas in the process of forming a silicon nitride film using a gas material including silane gas and ammonia gas increases the amount of NH radicals which are active species contributing to the formation of the silicon nitride film, thus improving the film deposition rate. The present invention has been thus completed.
[0045] FIG. 1 shows variations in plasma emission intensity spectrum per unit time of 0.02 s in forming silicon nitride films through ICP-CVD using for the gas material silane gas and ammonia gas at flow rates of 50 sccm and 150 sccm, respectively, and also nitrogen gas at varying flow rates of 0 sccm, 100 sccm, 300 sccm, and 500 sccm.
[0046] The other conditions for film deposition are as described in Examples to be referred to later in the specification.
[0047] As shown in FIG. 1 , introduction of nitrogen gas in the process of forming a silicon nitride film through ICP-CVD using a gas material including silane gas and ammonia gas changes the state of plasma emission, that is, amounts of existing radicals and ions, and their ratios. The plasma emission also varies with the amount of nitrogen gas introduced.
[0048] Plasma emission of NH radicals contributing to the deposition of a silicon nitride film is observed at wavelengths of around 336 to 340 nm. FIG. 2 is an enlarged view of FIG. 1 at wavelengths of around 336 to 340 nm. FIG. 3 is an enlarged view of FIG. 1 at wavelengths of around 488 nm where plasma emission of H radicals is observed.
[0049] As is seen from FIG. 2 , introduction of nitrogen gas allows the plasma emission intensity of NH radicals to increase, that is, an increased amount of NH radicals are produced.
[0050] Both of N radical emission and NH radical emission are observed at wavelengths of around 336 to 340 nm. However, at wavelengths of around 488 nm in FIG. 3 where H radical emission is observed, the larger the amount of nitrogen gas introduced is, the lower the H radical emission intensity is. In other words, the amount of H radicals decreases. The intensity variations at wavelengths of around 336 to 340 nm due to introduction of nitrogen gas show that introduction of nitrogen gas did not simply increase the amount of N radicals but caused an increased amount of NH radicals to be produced, thus increasing the emission intensity. In other words, it can be confirmed that an increased amount of NH radicals are produced by the introduction of nitrogen gas in the process of forming a silicon nitride film through ICP-CVD using silane gas and ammonia gas. In addition, the larger the amount of nitrogen gas is, the more the amount of NH radicals produced is increased. The increase of the amount of NH radicals enables the film deposition rate to be improved in forming a silicon nitride film.
[0051] In addition, definite detection from the measurement of the plasma emission intensity spectrum is not possible, but it can be adequately presumed from the variations in the plasma emission intensity spectrum that the amount of NH-type radicals other than NH radicals such as NH 2 radicals that contribute to forming a silicon nitride film also varies. The film deposition rate in forming a silicon nitride film is improved presumably because of the increase of the amount of NH radicals and overall action of the introduced nitrogen gas on the NH-type radicals.
[0052] In other words, the film deposition rate can be improved to an unexpectedly high level as is shown in Examples to be referred to below, by making use of ICP-CVD in forming a silicon nitride film and by introducing a gas material including not only silane gas and ammonia gas but also nitrogen that is essentially deemed to impede film deposition.
[0053] As described above, in the silicon nitride film-forming method of the invention, the nitrogen gas (N 2 ) is used at the flow rate 0.2 to 20 times the total flow rate of the silane gas (SiH 4 ) and the ammonia gas (NH 3 ).
[0054] At a nitrogen gas flow rate of less than 0.2 times the total flow rate of the silane gas and the ammonia gas, the amount of the nitrogen gas is too small to fully improve the film deposition rate.
[0055] On the other hand, at a nitrogen gas flow fate of more than 20 times the total flow rate of the silane gas and the ammonia gas, the pressure is excessively increased to impair the uniformity in film thickness distribution. If the pressure is kept constant, the ratio of silane gas and ammonia gas which are not involved in the reaction and are therefore discharged is too increased to achieve the effects of the invention including an improved film deposition rate.
[0056] The flow rate of the nitrogen gas is preferably 1 to 5 times the total flow rate of the silane gas and the ammonia gas.
[0057] By setting the flow rate of the nitrogen gas to not less than the total flow rate of the silane gas and the ammonia gas, the film deposition rate can be advantageously improved in a consistent manner owing to the introduction of the nitrogen gas. In addition, by setting the flow rate of the nitrogen gas to up to 5 times the total flow rate of the silane gas and the ammonia gas, more preferable results are obtained in terms of, for example, uniformity in film thickness distribution.
[0058] In the method of the invention to form a silicon nitride film, the total flow rate of the silane gas and the ammonia gas is not particularly limited but may be appropriately determined according to the required film deposition rate and film thickness.
[0059] According to the study made by the inventor of the invention, the total flow rate of the silane gas and the ammonia gas is preferably from 1 to 10,000 sccm and more preferably from 100 to 5,000 sccm.
[0060] By adjusting the total flow rate of the silane gas and the ammonia gas within the above-defined range, preferable results are obtained in terms of, for example, productivity and discharge stability.
[0061] The ratio of the flow rate of the ammonia gas to that of the silane gas is also not limited to any particular value, but may be appropriately set according to the composition (compositional ratio) of the silicon nitride film to be formed.
[0062] According to the study made by the inventor of the invention, the ammonia gas and the silane gas are preferably used at a flow rate ratio of the ammonia gas to the silane gas of from 1/1 to 10/1 and more preferably from 2/1 to 6/1.
[0063] By setting the flow rate ratio between the ammonia gas and the silane gas to not less than 1 (not less than 1/1), the ammonia gas can furnish a suitable amount of nitrogen to produce silicon nitride. At a flow rate ratio of not less than 2/1, a sufficient amount of nitrogen can be obtained more consistently. On the other hand, at a flow rate ratio between the ammonia gas and the silane gas of not more than 10 (not more than 10/1), the amount of the nitrogen gas with respect to that of the ammonia gas can be properly adjusted to consistently achieve the effect of improving the film deposition rate. At a flow rate ratio of particularly not more than 6/1, the amount of the nitrogen gas with respect to that of the ammonia gas can be properly adjusted to more advantageously achieve the effect of improving the film deposition rate.
[0064] Therefore, by adjusting the flow rate ratio between the ammonia gas and the silane gas within the above-defined range, the effect of the invention that the film deposition rate is improved in forming a silicon nitride film through ICP-CVD can be more advantageously achieved, and preferable results are also obtained in terms of the composition of the silicon nitride film formed.
[0065] In the method of the invention to form a silicon nitride film, the radio frequency power to be supplied for film deposition (hereinafter abbreviated as “RF power” which refers to electromagnetic wave energy applied to the film deposition system (film deposition chamber) is also not limited to any particular value but may be appropriately determined according to the required film deposition rate and film thickness.
[0066] According to the study made by the inventor of the invention, the RF power supplied for film deposition is preferably from 0.5 to 30 W/sccm and more preferably from 1 to 10 W/sccm with respect to the total flow rate of the gas material.
[0067] By adjusting the RF power within the above-defined range, preferable results are obtained in terms of, for example, discharge stability and reduced damage to the substrate.
[0068] In the method of forming a silicon nitride film according to the invention, the film deposition pressure is also not limited to any particular value but may be appropriately determined according to the required film deposition rate and film thickness as well as the flow rate of the gas material.
[0069] According to the study made by the inventor of the invention, the film deposition pressure is preferably in a range of from 0.5 to 20 Pa.
[0070] By adjusting the film deposition pressure within the above-defined range, the effect of the invention that the film deposition rate is improved in forming a silicon nitride film through ICP-CVD can be more advantageously achieved. What is more, preferable results are also obtained in terms of, for example, discharge stability and reduced damage to the substrate.
[0071] In the method of forming a silicon nitride film according to the present invention, the film deposition rate is also not limited to any particular value but may be determined as appropriate for the required productivity or other factors. According to the forming method of the present invention, the effect of improving the film deposition rate is achieved at any order of film deposition rate.
[0072] According to the study made by the inventor of the invention, the effect of improving the film deposition rate can be more advantageously achieved in a range of preferably from 1 to 3,000 nm/min and more preferably from 10 to 1,000 nm/min.
[0073] A silicon nitride film is formed by the silicon nitride film-forming method of the invention preferably at a low temperature and more preferably at a substrate temperature of as low as 0° C. to 150° C.
[0074] As described above, according to the present invention, a silicon nitride film can be formed at a very high film deposition rate.
[0075] Accordingly, deposition of a silicon nitride film can be completed before the substrate has an elevated temperature. For example, in an apparatus in which film deposition is continuously carried out as the above-described elongated substrate is transported in the longitudinal direction, a film can be produced with high efficiency and high productivity as the substrate is transported at a high speed. In other words, according to the present invention, the effect of the invention that a silicon nitride film can be formed at a very high film deposition rate through film formation at a substrate temperature ranging from 0 to 150° C. can be more advantageously achieved to thereby produce, with high productivity, a water vapor barrier film (moisture barrier film) on a less heat resistant substrate such as a polymer film that has been unattainable in the conventional silicon nitride film-forming methods.
[0076] What is more, the nitride film-forming method of the present invention that is carried out in the above-defined substrate temperature range enables considerable reduction of costs for the substrate cooling function provided in the ICP-CVD film deposition apparatus.
[0077] According to the silicon nitride film-forming method of the present invention, there is no particular limitation on the substrate (film deposition substrate) on which a silicon nitride film is to be formed, and any substrate on which a silicon nitride film can be formed is available.
[0078] Considering that the effect of the invention can be advantageously achieved owing to the high film deposition rate, that is, silicon nitride films can be formed with high productivity even at a low film deposition temperature, a silicon nitride film is preferably formed on a substrate having an organic layer (organic substance layer) such as a polymer layer (resin layer) formed thereon, more preferably on a substrate having an organic layer on which the film is to be deposited, and even more preferably on a substrate made of a polymer film (resin film).
[0079] A silicon nitride film may be formed (film deposition may be carried out) by implementing the silicon nitride film-forming method of the invention basically in the same manner as in a conventional ICP-CVD process except that the gas material including silane gas, ammonia gas and nitrogen gas is used and the flow rate of the nitrogen gas is adjusted in the above-defined predetermined range.
[0080] Therefore, the present invention avoids the necessity of using a special film deposition device and may be carried out by using a common ICP-CVD film deposition device in which RF power is supplied to an (induction) coil to form an induced magnetic field and therefore an induced electric field, and the gas material is introduced in the area of the induced electric field to generate plasma, thus forming a film on the substrate. Any known CVD devices (film deposition devices) to which an ICP-CVD process is applied are all available. However, as described above, film deposition is preferably carried out at a substrate temperature of as low as 0° C. to 150° C. and therefore a film deposition device having a function of substrate cooling is preferably used.
[0081] While the method of forming a silicon nitride film according to the present invention has been described above in detail, the present invention is by no means limited to the foregoing embodiments and it should be understood that various improvements and modifications may of course be made without departing from the scope and spirit of the invention.
EXAMPLES
[0082] The present invention is described below in further detail with reference to specific examples of the invention.
Example 1
[0083] A common CVD device based on an ICP-CVD process was used to form a silicon nitride film on a substrate.
[0084] The substrate used was a polyester film with a thickness of 188 μm (polyethylene terephthalate film “Luminice” manufactured by Toray Advanced Film Co., Ltd.).
[0085] The substrate was set at a predetermined position within a vacuum chamber, and the vacuum chamber was closed.
[0086] Then, the vacuum chamber was evacuated to reduce the internal pressure. When the internal pressure had reached 7×10 −4 Pa, silane gas, ammonia gas and nitrogen gas were introduced into the vacuum chamber. The silane gas and the ammonia gas were introduced at flow rates of 50 sccm and 150 sccm, respectively (total flow rate: 200 sccm).
[0087] Evacuation of the vacuum chamber was adjusted so that the vacuum chamber had an internal pressure of 3 Pa.
[0088] Then, 2 kW RF power was supplied to an induction coil and a silicon nitride film was formed on the surface of the substrate by ICP-CVD. During the film formation, the substrate temperature was controlled with a temperature adjusting means disposed at a substrate holder so that the substrate had a temperature of 70° C.
[0089] Silicon nitride films were formed at different nitrogen gas flow rates of 0 sccm, 100 sccm (the flow rate of the nitrogen gas being half the total flow rate of the silane gas and the ammonia gas), 300 sccm (1.5 times), and 500 sccm (2.5 times), and the film deposition rate was determined for the respective nitrogen gas flow rates.
[0090] The results are shown in FIG. 4 .
[0091] FIG. 5 shows the film deposition rate [%] in each nitrogen gas flow rate with respect to the nitrogen gas flow rate of 0 sccm taken as 100%.
Example 2
[0092] Example 1 was repeated except that the silane gas and the ammonia gas were introduced at flow rates of 15 sccm and 45 sccm, respectively (at a total flow rate of 60 sccm) to thereby determine the relation between the nitrogen gas flow rate and the film deposition rate.
[0093] It should be noted that the nitrogen gas was introduced at flow rates of 0 sccm and 100 sccm (the nitrogen gas flow rate being about 1.67 times the total flow rate of the silane gas and the ammonia gas), respectively.
[0094] The flow rate is shown in FIG. 4 and the film deposition rate at a nitrogen gas flow rate of 100 sccm with respect to the nitrogen gas flow rate of 0 sccm taken as 100% is shown in FIG. 5 .
[0095] As is seen from FIGS. 4 and 5 , by forming a silicon nitride film through ICP-CVD using the gas material including the silane gas, ammonia gas and nitrogen gas, the film deposition rate can be considerably improved compared with cases where no nitrogen gas is used.
[0096] In the case where the total flow rate of the silane gas and ammonia gas is 200 sccm, for example, the film deposition rate can be considerably improved to about 1.25 times by adding the nitrogen gas in an amount half the total flow rate of the silane gas and ammonia gas. The film deposition rate can be improved to about 1.5 times or more by adding the nitrogen gas in an amount equal to or larger than the total flow rate of the silane gas and ammonia gas.
[0097] In the case where the total flow rate of the silane gas and ammonia gas is 60 sccm, the film deposition rate can be increased to about twice by adding the nitrogen gas in an amount about 1.67 times the total flow rate of the silane gas and ammonia gas.
[0098] The above results clearly show the beneficial effects of the present invention.
|
The silicon nitride film-forming method includes a step of supplying a gas material including silane gas, ammonia gas and nitrogen gas in such a manner that a flow rate of the nitrogen gas is 0.2 to 20 times a total flow rate of the silane gas and the ammonia gas, and a step of carrying out inductively coupled plasma-enhanced chemical vapor deposition to form a silicon nitride film. This method is capable of forming a silicon nitride film at a high film deposition rate.
| 2
|
The invention relates to a device for the stuffer box crimping of a synthetic multifilament yarn.
The disclosure in German Patent Application 101 32 148.1 of Jul. 3, 2001 and PCT/EP02/07161 of Jun. 28, 2002 are incorporated herein by reference.
BACKGROUND OF INVENTION
An example of a device for the stuffer box crimping of a multifilament yarn is disclosed in EP 0 554 642 A1 and corresponding U.S. Pat. No. 5,351,374. The device comprises a conveying nozzle and a stuffer box arranged downstream from the conveying nozzle. The yarn is conveyed by means of the conveying nozzle into the stuffer box, compressed to a yarn plug and thereby stuffer box crimped. The conveying nozzle is loaded with a conveying medium, preferably a hot gas, which conveys the yarn within the yarn channel to the stuffer box. The yarn plug is formed inside the stuffer box. In doing so, the multifilament yarn deposits itself in loops on the surface of the yarn plug and is compressed by the conveying medium, which can discharge above the yarn plug out of the stuffer box. To do so, the chamber wall of the stuffer box comprises several slot-shaped openings on the perimeter through which the conveying medium can escape. In order to obtain uniform crimping of the yarn, plug formation must result with very high uniformity in the stuffer box. Thus, the friction forces caused by the relative motion of the yarn plug in the stuffer box have a substantial impact on the texturizing process. A counterbalance of forces exists between the conveying effect, or the dynamic pressure effect of the conveying medium flowing from the yarn channel of the conveying nozzle, and the braking action resulting from the friction forces on the yarn plug. Adjusting the conveying pressure, or adjusting additional suction of the conveying medium, essentially determines the conveying effect. In contrast, the braking action resulting from the friction between the yarn plug and the chamber wall essentially depends on the condition of the chamber wall.
In the device disclosed in EP 0 554 642 A1, only a slight number of friction surfaces exist due to the slot-shaped openings especially in the section with the gas-permeable wall. Therefore, wear marks are unavoidable in prolonged operation, which results in a change in the braking action. If the braking action decreases sufficiently, the yarn plug will be conveyed out of the stuffer box due to small frictional forces. The texturizing process then fails. On the other hand, as frictional forces increase, the yarn plug is no longer or no longer uniformly conveyed out of the stuffer box. Non-uniform stuffer box crimping occurs when a stick-slip effect begins in the stuffer box. These effects cannot be controlled with a dynamic medium opposing the conveying medium.
In contrast, one task of the present invention is to further improve a stuffer box crimping device for synthetic multifilament yarn in such a manner that uniform crimping is ensured in the yarn, even during very prolonged operation.
SUMMARY OF INVENTION
According to this invention, the task is solved by a device for compressing a synthetic, multifilament yarn, the device including a conveying nozzle and a stuffer box. The conveying nozzle includes a yarn channel for guiding and conveying the yarn. The stuffer box is arranged at the end of the yarn channel to form and collect a yarn plug. The stuffer box includes a yarn inlet, a plug outlet, and at least a section with a gas-permeable chamber wall between the yarn inlet and the plug outlet. The gas-permeable chamber wall includes a friction surface made of wear-resistant material on an inner side facing the yarn plug.
The friction surface of the section may be a coating applied to the surface of the gas-permeable chamber wall. Alternatively, the gas-permeable chamber wall is a ceramic material that forms the friction surface on the surface of chamber wall.
The gas-permeable chamber wall may be formed as a cylindrical body with elongated slots evenly distributed along the circumference. Alternatively, the gas-permeable chamber wall may be formed by a plurality of blades arranged in a ring-shape with little separation distance from each other.
The stuffer box may include an additional section downstream from the section with the gas-permeable chamber wall. The additional section includes an enclosed chamber wall. The enclosed chamber wall includes a contact surface made of wear-resistant material on the inner side facing the yarn plug.
As with the section, the friction surface of the additional section may be a coating applied to the surface of the enclosed chamber wall. Alternatively, the enclosed chamber wall is a ceramic material that forms the friction surface on the surface of chamber wall.
Further, the contact surfaces contacted by the yarn within the conveying nozzle may be at least partially formed from a wear-resistant material. The wear-resistant material may be in the form of a coating or a ceramic material.
The conveying nozzle may include a guide insert forming an inlet of the yarn channel. The guide insert includes an intake channel arranged as an extension of the yarn channel. Also, the conveying nozzle may include a second guide insert forming the outlet of the yarn channel. As with the guide insert, the second guide insert may be manufactured from a ceramic material or coated on its surface. Further, the conveying nozzle may include a third guide insert forming the air inlet into the yarn channel. The third guide insert forms a guide channel arranged as an extension of the yarn channel. The third guide insert forms an outlet channel arranged as an extension of the yarn channel. The guide inserts may be manufactured from a ceramic material or coated on its surface.
The third guide insert may further include an insert forming the inlet of the guide channel. The insert forms an intake channel arranged as an extension of guide channel. The inserts may be manufactured from a ceramic material or coated on its surface.
Any one of a conveying device, cooling device, and a conveying device in combination with a cooling device may be arranged downstream from the stuffer box in the yarn's direction of travel. The conveying device and the cooling device may include a coating on the contact surfaces contacted by the yarn plug.
The invention is based on the knowledge that depositing of the yarn on the yarn plug surface by self-shaping loops and coils significantly influences crimp uniformity. In order to maintain the yarn's point of impact on the yarn plug surface at an essentially unchanging height, the balance of forces between the conveying effect and the brake action at the yarn plug resulting from the friction must be held constant. This can be essentially achieved by the device according to this invention in that the gas-permeable chamber wall comprises a friction surface made of wear-resistant material on the inner side facing the yarn plug. Thereby, a change in the friction forces is not possible even in extended operation. Thus, the invention has the advantage that plug formation is solely controlled by controlling the conveying medium by, for example, means of pressure control.
The wear-resistant material on the surface of the chamber wall can be constructed essentially from two variants. In an initial especially preferred embodiment of the invention, the friction surface is formed by a coating applied to the chamber wall surface. This coating could consist, for example, of a ceramic material, a chrome oxide or a carbon coating. The possibility also exists to manufacture the chamber wall from aluminum in order to then form anti-wear protection by means of a hard oxide coating.
In another especially preferred embodiment of the invention, the friction surface is formed by a chamber wall manufactured from a ceramic material. To this end, the chamber wall can be manufactured out of ceramic materials such as zircon oxide, aluminum oxide or a combination of both.
The use of ceramic coatings, or ceramic materials, also achieves a corrosion-resistant gas-permeable wall and decreased fallibility to fouling. In particular, deposits caused by preparation residue may be avoided. Even after a maintenance period, the same friction specifications are achieved when operating the device as prior to shutting down the facility.
Regardless whether a coating or solid-ceramic is used to form the friction surface, the gas-permeable chamber wall can be designed as a cylindrical body with evenly distributed elongated slots along its circumference.
However, an especially preferred embodiment has a gas-permeable chamber wall with a plurality of blades that are arranged in a ring-shape with clearance from each other. Thus, it was observed in the use of ceramic blades that decreasing the friction coefficient subjects the yarn to less of a thermal and mechanical load.
In order to avoid wear inside the stuffer box on all sides contacting the yarn plug, an additional section with an enclosed chamber wall may be provided. In accordance with a preferred embodiment of this invention, the stuffer box includes an additional section with an enclosed chamber wall. The additional section is downstream from the section with the gas-permeable chamber wall. The enclosed chamber wall includes a contact surface comprised of a wear-resistant material on the inner side facing the yarn plug.
The contact surface could be formed by a coating applied to the surface of the chamber wall or by a chamber wall manufactured from ceramic material.
It was observed that when using a conveying nozzle with ceramic sides at least on parts of the surface contacting the yarn, that the yarn tension reduction in the conveying nozzle was reduced by the friction of the yarn on the side. In accordance with a preferred embodiment, the contact surfaces contacted by the yarn within the conveying nozzle are at least partially formed from a wear-resistant material in the form of a coating or a ceramic material. Thus, higher yarn tension can be achieved with the same conveying pressure, which results in higher operational uniformity of the texturizing process. On the other hand, yarn tension can be achieved with a lower pressure, whereby a lower conveying pressure results in less consumption of the conveying medium. The contact surface's wear-resistant material inside the conveying nozzle can be formed of coatings or ceramic base materials. Thus, the conveying nozzle can be preferentially manufactured entirely out of ceramics.
In another embodiment variant of the invention, the inlet of the yarn channel is formed by means of a guide insert in the conveying nozzle. The guide insert, which can be manufactured from a ceramic material or carry a coating on its surface, forms an intake channel as an extension of the yarn channel. Wear, in particular, at the yarn's entry into the conveying nozzle is thereby avoided. Using ceramic materials or ceramic coatings also enables a very low friction guidance of the yarn.
The conveying nozzle could also comprise a guide insert forming the yarn channel's outlet, which is also manufactured from a ceramic material or carries a coating on its surface. The yarn thereby leaves the conveying nozzle through the guide insert's outlet channel.
To convey the yarn, a conveying medium, preferentially hot air or a hot gas, is supplied. In order not to have any scouring in the yarn channel even at very high flow speeds, that may even lie in the range of the speed of sound, the air inlet into the yarn channel is formed by means of a guide insert, according to a preferred embodiment of the invention. Next to the air inlet, the guide insert comprises a guide channel that is arranged as an extension of the yarn channel. The guide insert is also made of a ceramic material or carries a coating on its surface.
Since the conveying medium flowing into the yarn channel results in a sudden dynamic load for the yarn, in a preferred embodiment of the invention, the third guide insert includes an additional insert forming the inlet of the guide channel. The additional insert forms an intake channel arranged as an extension of the guide channel. Also, the additional insert is either manufactured from a ceramic material or coated on its surface. The third guide insert in the area of the air inlet includes the additional insert in the inlet of the guide channel. In this manner, yarn guidance is stabilized and disturbances affecting the yarn are avoided.
To guide and condition the yarn plug, a cooling device is arranged downstream from the stuffer box at the plug outlet. In some cases a conveying device is provided between the cooling device and the stuffer box to guide the yarn plug. In order to avoid premature fouling and adhesion of preparation residue, in a preferred embodiment according to the present invention, the conveying device and the cooling device comprise a coating on the contact surfaces contacted by the yarn plug.
The invention is further described by means of several embodiments depicted in the attached illustrations.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 schematically depicts an initial embodiment of the device in accordance with this invention in a cross-sectional view;
FIG. 2 schematically depicts an additional embodiment of the device in accordance with this invention in a sectional cross-section;
FIG. 3.1 schematically depicts an embodiment of a conveying nozzle in a cross-sectional, exploded view; and
FIG. 3.2 schematically depicts an embodiment of a conveying nozzle in a cross-sectional view.
DETAILED DESCRIPTION
FIG. 1 schematically depicts a cross-sectional view of an initial embodiment of the device in accordance with this invention. The device consists of conveying nozzle 1 and stuffer box 2 arranged downstream from conveying nozzle 1 . Conveying nozzle 1 comprises yarn channel 3 that forms inlet 21 on one end and outlet 24 on the opposite end. Conveying nozzle 1 is connected to a pressure source (not depicted) by means of feed line 17 . Feed line 17 is connected to yarn channel 3 by air inlet 16 and pressure chamber 39 . Air inlet 16 is formed by several boreholes that supply a conveying medium in yarn travel direction, marked by an arrow, to yarn channel 3 . Yarn channel 3 merges into yarn channel 31 of stuffer box 2 by means of outlet 24 .
Stuffer box 2 is formed by section 7 . 1 facing conveying nozzle 1 having yarn inlet 5 , and section 7 . 2 , arranged downstream from section 7 . 1 , having a plug outlet 6 . In section 7 . 1 , plug channel 31 is formed by a gas-permeable chamber wall 8 . Gas-permeable chamber wall 8 comprises a multiplicity of blades 9 that are arranged in a ring in close proximity to each other. Blades 9 are held by blade holders 10 . 1 on the upper end of section 7 . 1 and by holder 10 . 2 on the lower end of section 7 . 1 . Blades 9 and holders 10 . 1 and 10 . 2 are arranged in housing 11 , whereby housing 11 is enclosed to the outside and connected to suction 12 by opening 32 .
On the side facing yarn plug 13 , blades 9 each comprise friction surface 14 . Blades 9 are made of a ceramic material so that friction surfaces 14 consist of a wear-resistant material.
Enclosed chamber wall 15 is provided below the gas-permeable chamber wall 8 , which forms plug channel 33 . Plug channel 33 is designed to have a larger diameter than the plug channel 31 in the area of the gas-permeable chamber wall 8 . At its end, plug channel 33 forms plug outlet 6 .
The embodiment of the device in accordance with this invention and depicted in FIG. 1 is shown with a yarn course in order to clarify the device's function. Thus, yarn 4 is transported through conveying nozzle 1 into yarn channel 3 by means of a conveying medium supplied via air inlet 16 . Yarn 4 thereby enters into yarn channel 3 through inlet 21 . Hot air or a hot gas are preferentially used as conveying medium. The conveying medium flowing at high speed conveys yarn 4 at high speed to stuffer box 2 . In doing so, yarn plug 13 develops in plug channel 31 . Yarn 4 , comprised of a plurality of filaments, is deposited on the surface of yarn plug 13 in such a manner that the filaments form loops and coils. The conveying medium is suctioned off between and past blades 9 through opening 32 . Yarn plug 13 forming in plug channel 31 abuts on friction surfaces 14 of blades 9 . The friction forces and the conveying pressure of the conveying medium acting on yarn plug 13 are essentially counterbalanced so that the yarn plug height within the yarn channel 31 remains essentially the same. Since blades 9 are manufactured from a ceramic material, the counterbalancing forces acting on yarn plug 13 are essentially maintained by constant pressure of the conveying medium. After leaving plug channel 31 , yarn plug 13 enters into plug channel 33 that is formed by enclosed chamber wall 15 . Enclosed chamber wall 15 that could be constructed from a tube, for example, serves to feed yarn plug 13 to a downstream placed cooling device not depicted here. Plug channel 33 is designed larger than plug channel 31 so that only slight friction forces act on yarn plug 13 . Anti-wear protection is therefore unnecessary.
FIG. 2 schematically depicts an additional embodiment in a cross-sectional view. The embodiment is essentially identical in its design to the previous embodiment according to FIG. 1 , so that hereafter only the essential differences will be pointed out. For clarity's sake, components having identical functions are identically labeled.
For additional acceleration of the conveying medium in yarn channel 3 , conveying nozzle 1 comprises its smallest diameter directly downstream from air inlet 16 . The conveying medium is thereby accelerated to a supersonic flow velocity. Yarn channel 3 merges into plug channel 31 that is formed by cylindrical body 18 . cylindrical body 18 is arranged in the first section 7 . 1 of stuffer box 2 . Cylindrical body 18 has distributed on its circumference several elongated slots 34 , whereby plug channel 31 is connected to the annulus 35 which is formed between the housing 11 and cylindrical body 18 . The annulus 35 is connected to suction 12 via the opening 32 in the housing 11 . On the side facing yarn plug 13 , cylindrical body 18 has a coating 19 which forms a friction surface 14 to guide a yarn plug. The coating 19 preferably consists of a ceramic material. However, metallic hard chrome layers or carbon compounds are also possible. Thus, cylindrical body 18 may also be manufactured from an aluminum material, which receives an aluminum oxide coating forming friction surface 14 . Elongated slots 34 extend at least over a portion of cylindrical body 18 . Elongated slots 34 extend at least over a portion of cylindrical body 18 .
The second section 7 . 2 of the stuffer box is formed by enclosed chamber wall 15 that comprises plug channel 33 . Plug channel 33 forms at its end plug outlet 6 . On the side facing yarn plug 13 , enclosed chamber wall 15 comprises contact surface 20 that also carries wear-resistant coating 35 .
Formed out of two opposing rollers, conveying device 29 is attached directly to stuffer box 2 at plug outlet 6 . Conveying device 29 guides the yarn plug 13 to a cooling device 30 arranged downstream from conveying device 29 . Cooling device 30 could be constructed from a cooling barrel on whose circumference the yarn plug is cooled. Both conveying device 29 and cooling device 30 are furnished with a coating on their contact surfaces 37 and 38 .
The function of the embodiment depicted in FIG. 2 is essentially identical to the previous embodiment according to FIG. 1 , so that depicting the yarn course was not repeated. However, yarn plug development can be also influenced by conveying device 29 .
FIGS. 3.1 and 3 . 2 schematically depict an embodiment of a conveying nozzle in a cross-sectional view as it might be used for example in the embodiment according to FIG. 1 or the embodiment according to FIG. 2 . The conveying nozzle is thus depicted in FIG. 3.1 in a disassembled state and in FIG. 3.2 in an assembled state. The following description applies for both illustrations, unless express reference is made to one of the illustrations.
Conveying nozzle 1 comprises in the areas of inlet 21 , air inlet 16 , outlet 24 , and grooves 36 . 1 , 36 . 2 , and 36 . 3 respectively.
Grooves 36 . 1 , 36 . 2 , and 36 . 3 are connected to each other by means of yarn channel 3 . Pressure chamber 39 is designed in conveying nozzle 1 between grooves 36 . 1 and 36 . 2 . Groove 36 . 1 in the intake section of conveying nozzle 1 serves to receive guide insert 22 . 1 . Guide insert 22 . 1 forms an intake channel 23 that is arranged as an extension of yarn channel 3 . Guide insert 22 . 1 is preferentially manufactured from ceramic material. However, it is also possible that guide insert 22 . 1 carries a coating in the area of the intake channel 23 .
Guide insert 22 . 2 is inserted into groove 36 . 2 . Guide insert 22 . 2 forms air inlet 16 through which the conveying medium is fed from pressure chamber 39 into guide channel 26 of guide insert 22 . 2 . Guide channel 26 of guide insert 22 . 2 is arranged as an extension of yarn channel 3 . Insert 27 , which forms intake channel 28 , is provided on the inlet side of guide insert 22 . 2 . Intake channel 28 has a smaller diameter than guide channel 26 located downstream. Insert 27 and guide insert 22 . 2 may also be preferentially manufactured from a ceramic material or furnished with a coating.
Guide insert 22 . 3 is embedded in groove 36 . 3 on the outlet side of conveying nozzle 1 . Guide insert 22 . 3 forms outlet channel 25 that is arranged as an extension of yarn channel 3 and forms outlet 24 of conveying nozzle 1 . Guide insert 22 . 3 is also preferentially manufactured from a ceramic material.
The conveying nozzle depicted in FIGS. 3.1 and 3 . 2 consists of a wear-resistant material especially in the contact and friction areas heavily stressed by the yarn so that stable and uniform yarn guidance as well as yarn conveying are achieved. In addition, the friction coefficients between the yarn and the contact or friction points are substantially decreased.
In the device depicted in FIGS. 1 to 3 , one should note that conveying nozzle 1 and stuffer box 2 are each preferentially formed out of two halves that are frictionally connected with each other during operation. However, it is also possible to basically provide one-piece conveying nozzles and stuffer boxes with corresponding ceramic inserts or coatings. Regardless of the device's design type, the possibility also exists, however, to manufacture each of the devices' yarn-contacting areas from solid ceramics or a coated aluminum material. The device according to this invention thereby distinguishes itself especially by a high degree of wear-protection and thus stable friction behavior and non-sensitivity to yarn conditioning, as well as a substantial lengthening of the cleaning cycles due to the resistance to fouling. Using a device in accordance with this invention, the service life was increased 3- to 5-fold. When using the device in accordance with this invention, which was furnished with ceramic materials or ceramic material coatings, crimping of the yarn could be kept uniform over a substantially longer period than compared to conventional crimping devices. A significantly higher degree of production safety is thereby achieved.
Reference List
1 Conveying nozzle
2 Stuffer box
3 Yarn channel
4 Yarn
5 Yarn inlet
6 Plug outlet
7 Section
8 Gas-permeable chamber wall
9 Blade
10 Blade holder
11 Housing
12 Suction
13 Yarn plug
14 Friction surface
15 Enclosed chamber wall
16 Air inlet
17 Feed line
18 Cylindrical body
19 Coating
20 Contact surface
21 Inlet
22 Guide insert
23 Intake channel
24 Outlet
25 Outlet channel
26 Guide channel
27 Insert
28 Intake channel
29 Conveyance device
30 Cooling device
31 Plug channel
32 Opening
33 Plug channel
34 Elongated slot
35 Annulus
36 Groove
37 Contact surface
38 Contact surface
39 Pressure chamber
The disclosure in German Patent Application 101 32 148.1 of Jul. 3, 2001 and PCT/EP02/07161 of Jun. 28, 2002 are incorporated herein by reference. The German Patent Application and the PCT Application describe the invention described hereinabove and claimed in the claims appended hereinbelow and provided the basis for a claim of priority for the instant application.
While the invention has been illustrated and described as an embodiment of a device for compression crimping, it is not intended to be limited to the details shown, since various modifications and 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.
|
The invention relates to a device for the compression crimping of a synthetic multifilament yarn, said device comprising a transport nozzle and a compression chamber. Said transport nozzle comprises a yarn channel by which means a yarn is guided to a compression chamber. Said compression chamber forms a section having a gas-permeable chamber wall, between a yarn inlet and an enmeshment outlet. According to the invention, the gas-permeable chamber wall comprises a friction surface consisting of material which is resistant to wear, on the inner side facing the yarn enmeshment. The constancy of the braking action produced by the friction on the yarn enmeshment can thus be significantly improved.
| 3
|
BACKGROUND OF THE INVENTION
This invention relates to winged implements in which the wings are biased by a hydraulic downpressure circuit to pivot toward the ground during operation to provide force onto the ground working tools so that they better penetrate hard ground to the set working depth.
An earlier form of downpressure system shown in Flexi-coil's U.S. Pat. No. 5,687,798 uses PRRV (pressure reducing-relieving valve) as controls in the downpressure circuit. A related system is shown in Flexi-coil's patent application (U.S. Ser. No. 08/891,204, corresponding to Canadian 2,210,238.
Recent tractor designs include hydraulic systems on the tractors that are CCLS (closed center load sensing) systems. These systems attempt to maintain a set flow volume through each of the tractor valves, when open. This volume can be set by the operator. The tractor hydraulic pump is controlled such that it will increase the system pressure until the flow volume at each of the open valves is satisfied. This system allows for efficiency to be gained from previous systems in which the pump volume output was reduced only after full pressure capability had been reached. Circuits connected to the tractor that have PRRV controls, will only accept flow when the PRRV senses a requirement for flow in the circuit connected downstream of the valve. A tractor having CCLS controls will attempt to deliver flow in any case, and the tractor pump will raise the pressure to the system maximum. This not only diminishes the efficiency of downpressure circuit which is causing the problem, but also diminishes the efficiency of any of the circuits being operated because the tractor control system introduces pressure drops at each valve to maintain only the set flow.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a downpressure circuit for an agricultural implement having ground working devices mounted thereon.
It is another object of this invention to reduce negative effects caused by agricultural implements having downpressure circuits on CCLS tractor hydraulic systems.
It is a feature of this invention that the efficiency losses on CCLS tractor hydraulic systems that may be introduced by connecting other downpressure circuits are reduced.
This invention relates to an agricultural implement including a frame having a pair of tool-carrying wings pivotally mounted thereon for pivotal movement between raised transport positions and lowered ground-working positions, each said wing having a hydraulic wing actuator connected thereto which is extendable and retractable for effecting said pivotal motion, and a hydraulic wing actuator circuit connected to each of said wing actuators, which circuit, when connected to a tractor hydraulic system, enables said wing actuators to apply down pressure to said wings when the wings are in the lowered working positions, and hydraulic pressure control valve means for controlling the down pressure exerted by said wing actuators.
In one preferred feature of the invention said pressure control valve means comprises at least one pressure relief valve.
In one form of the invention a hydraulic top link actuator is secured to said implement frame and adapted to be interposed between said implement frame and another vehicle to apply down pressure to the implement frame.
As a further feature of the invention said hydraulic top link actuator is preferably connected to a portion of the wing actuator circuit.
In another form of the invention a pair of said relief valves are provided to enable the down pressures exerted by said wing actuators and top link actuator to be controlled separately.
The agricultural implement typically includes an implement lift hydraulic circuit adapted to be connected to a lifting system for the implement. Advantageously, the system may include a valve to disable the down pressure action of the top link actuator when the implement lift circuit is activated to raise the implement.
The agricultural implement may preferably include a valve responsive to wing position to disable the pressure relief valve associated with the wing actuators when the wings are raised upwardly beyond the working positions.
As a further preferred feature the agricultural implement includes a flow divider in said wing actuator circuit to allow the connection of another branch circuit to the same tractor control to maintain constant flow to each branch regardless of varying pressure in either branch or between branches.
These and other objects, features and advantages are accomplished according to the invention by providing an agricultural implement including a frame having a pair of tool-carrying wings pivotally mounted thereon for pivotal movement between raised transport positions and lowered ground-working positions. Each wing has a hydraulic wing actuator connected thereto which is extendable and retractible for effecting the pivotal motion. A hydraulic wing actuator circuit is connected to each of the wing actuators, which circuit, when connected to a tractor hydraulic system, enables the wing actuators to apply down pressure to said wings when the wings are in the lowered working positions. A hydraulic pressure control valve system controls the down pressure exerted by the wing actuators.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of a winged implement in which the actuator and downpressure system are incorporated;
FIGS. 1A and 1B show in diagrammatic fashion the manner in which the implement is attached to the three point hitch of an aircart;
FIG. 2 shows a simple wing lift circuit, i.e. without down pressure capability, with the actuator connected to the implement lift circuit;
FIG. 3 shows a wing lift circuit with down pressure control in combination with the actuator system; and
FIG. 4 shows a further hydraulic circuit with additional top link down pressure and wherein the wing down pressure and top link down pressure are controlled separately.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a first embodiment of the implement has wing sections 10 and 12 pivotally attached via joints 14 and 16 to a frame middle section 18 for carrying suitable ground working tools (not shown), which joints each have an axis that is oriented generally horizontal in the working position so that the wing sections are allowed pivotal movement over uneven ground. In the headland position shown in FIG. 1, the wing sections 10 and 12 are supported generally horizontally over the ground, suspended from the middle section 18 by their joints and by hydraulic wing actuators 20 . No other means is supporting the wings in this position. When lowered to a working position, gauge wheels 22 support each wing above the ground. The gauge wheels 22 can be adjusted to set the working height above the ground for each wing section. The wing can thereby float (pivot freely) to follow ground contours, or it may be biased toward the ground, and the gauge wheel 22 will limit the downward motion. Downward biasing may be required in soil conditions in which ground engaging tools do not penetrate to the desired depth as set by the gauge wheel and the gauge wheel and wing section is suspended off the ground by the ground tools.
Points 24 and 26 for attachment to a three-point hitch are provided on the middle section 18 for towing and for controlling the height of the middle section. (Alternately the invention would work on implements having ground wheel means to support the middle section, with a floating or fixed hitch for towing). The hitch of the implement shown is particularly suited for connection to the three-point hitch of an aircart having double acting lower link actuators. Most three-point hitches on tractors or other implements provide only lifting action by the lower links and allow free upward movement of the links. The lower links of the aircart can be maintained in a fixed position. The implement middle section 18 is pivotally attached to the aircart lower links by connections at points 24 and 26 allowing the implement movement about a horizontal transverse axis 28 .
A hydraulic top link 30 is pivotally connected at one end to the aircart (offset from the axis of the lower links), and at the second end is pivotally connected to the implement middle section 18 at a point offset from the horizontal axis 28 . An intermediate link 32 , is connected between the second end of the top link and the implement middle section by pivotal connections on both ends. The implement is allowed free downward pivotal movement about the horizontal axis 28 (limited by the length of the actuator and link 32 , and by rear support assembly 40 ) but upward pivotal movement is limited by an abutment 36 along the intermediate link 32 . The implement middle section 18 abuts the intermediate link at abutment 36 and the top link 30 reacts to the upward pivotal movement.
FIGS. 1A and 1B help to illustrate the above and they show the implement connected to an aircart by the preferred 3 point hitch with hydraulic top link 30 and intermediate link 32 in both working and raised positions. This shows how there is freedom of pivoting in the raised position, even though the top link 30 may be locked out, and therefore rigid. The intermediate link 32 is drawn away from the abutment 36 , not by the top link but by the system geometry and during the raising action from the lower links 38 and rear support assembly 40 . Rear support assembly 40 is well known per se and each includes a castored ground wheel 42 connected by linkages 44 to frame middle section 18 . Actuator 46 effects movement of the linkages 44 during raising and lowering in a well known fashion.
Alternately a rigid top link (not shown) may be connected directly between the aircart and the implement, as in a conventional three point hitch. This is used on implements not having rear support assembly 40 , so the rotation of the frame middle section 18 about the horizontal axis 28 is controlled, maintaining a generally constant relative orientation between the implement and the aircart as the implement is raised or lowered.
When a rear lift support assembly 40 is provided on the implement, a compressible top link is required so that the implement is allowed pivotal movement about axis 28 . This may be a spring connected directly to the implement or via an abutting intermediate link 32 . In the preferred embodiment the required compressible link is a hydraulic top link operated by a biasing pressure and an intermediate link is also provided to create freedom to pivot in the transport position when hydraulic flow to the top link is blocked.
The top link 30 is locked out of the circuit by valve 48 (FIG. 4) when the implement is raised (by rear lift means and lower arms of hitch) and the link 32 pivots away from the frame middle section so it no longer abuts the frame. The geometry between the lower links 38 and top link 30 causes this action. This allows pivoting of the implement relative to the aircart about horizontal axis 28 when in transit over uneven ground.
Referring further to the embodiment of FIG. 1, the headland actuator system includes a headlands cylinder 50 , having its opposite ends pivotally attached to elongated center links 52 and 54 . The outer ends of links 52 and 54 are secured by pins 56 , 58 to the inner ends of the wing actuators 20 and these pins are disposed for movement in slots 60 and 62 formed in the upper ends of spaced towers 64 , 66 fixed to the frame middle section 18 . The headlands cylinder 50 is stabilized by means of stabilizing links 68 , 70 having upper ends connected at opposing ends of the cylinder 50 and their lower ends pivoted to the middle section 18 of the implement frame. Thus, as cylinder 50 is extended and retracted, the inner ends of the wing actuators 20 are caused to travel along the paths defined by slots 60 , 62 between the inner and outer extremities of these slots. (In an alternative arrangement an extra long headlands actuator could be used with its opposing ends being directly connected to the inner ends of the wing actuators 20 and eliminating the need for links 52 to 70 described above).
In operation without down pressure, (FIG. 2) the wing lift circuit CD can be set to float mode in the tractor when the implement wings 10 and 12 have been lowered from their transport position. After the implement is lowered to the ground, continued flow into line B builds pressure to further operate the implement lift actuators until the depth stop (not shown) is reached. During this period pressure in line B causes pilot-to-open check valve 72 to open to allow flow from the rod end of the cylinder 50 , and the headlands system is extended by pressure in line B. This forces the ends of the wing actuators 20 to the outer ends of slots 60 and 62 for extra downward pivotal range of the wings 10 and 12 .
The actuators 20 are held at the outer ends of slots 60 and 62 during operation in the working position. When raising the implement at headlands the cylinder 50 is retracted. This limits droop of the wings when the middle section 18 is raised by applying pressure to line A. The implement is typically raised just enough for working tools to clear the ground for turning at the field headlands. The pilot-to-open check 72 prevents fluid from escaping from the cylinder 50 to the rear or front lift actuators which may be extended only to an intermediate position at headlands. The check valve 72 also limits the droop of the wings 10 and 12 until the implement is lowered to the ground and line B is pressurized, repeating the cycle above.
To raise the wings to transport position, the implement is first raised. Pressure is applied to line A, retracting the cylinder 50 and at the same time operating the three point hitch actuators (and rear lift actuators if present) which raise the middle section 18 . After the middle section 18 is raised, pressure is applied to line D and the wing actuators 20 rotate wings 10 and 12 to a generally vertical position for transport. The ends of the wing actuators 20 are held at the inner ends of slots 60 and 62 by the cylinder 50 . In this held position the headlands actuator motion is completely restricted so that motion of one wing may not be transmitted to the opposite wing through the linkage system when the wings are being raised. Otherwise the wings could freely toggle side to side in the vertical position until they came to rest against some other abutment. Alternately the slots 60 and 62 could be replaced by links pivotally connected to the middle section 18 and end of the wing actuator providing the link's rotation is limited by stops corresponding to the inner ends of the slots of the present embodiment.
In operation with down pressure, (see the hydraulic circuits of FIGS. 3 or 4 ) the operation of the headlands system is the same. The wing lift circuit may be set to down pressure mode by setting the valve in the tractor to pressurize line C. The down pressure circuit to the wings may be connected in combination with the hydraulic top link 30 , or may act alone as in the case of a rigid top link.
A hydraulic top link not connected to a down pressure circuit is known in the prior art for adjusting the angle of an implement relative to a tractor, and remains fixed as a rigid link during operation.
Ball valve 74 (FIGS. 3 or 4 ) is closed when wings 10 and 12 are raised to the transport position. This allows full tractor pressure to be applied to wing actuators 20 to lower the wings which generally rest past an overcenter position in transport (generally vertical). The ball valve 74 is controlled by a cam or link mechanism so that it is open when the wing position is lower than about 15 degrees up from horizontal as described in the above-noted U. S. patent.
Referring to FIGS. 3 and 4, wing down pressure is controlled by relief valve 76 , which limits the pressure in line C 2 . This relief valve allows fluid to return through line D when pressure in line C 2 exceeds the setting. An optional top link actuator may also be connected to line C 2 via line C′, and pressure to both the wing actuators and the top link actuator may be controlled by valve 76 .
With particular reference to FIG. 4, valve 80 is provided when connecting a hydraulic biasing top link to lockout the top link biasing function when the implement is being raised. When the implement is lowered to the set working height there is no pressure in line A or to pilot A′, and valve 80 will open with any pressure at C 4 or C 1 to allow the top link to extend or retract with the biasing function.
A second relief valve 82 (FIG. 4) may be added to the circuit to control the top link pressure separately. This valve may be set at pressures greater than that of relief valve 76 to create a differential pressure between lines C 2 and C′.
The valve 82 allows pressure in C′ to build higher, before continuing into line C 2 , where relief valve 76 will control the pressure in that part of the circuit.
This type of down pressure circuit described above which uses relief valves or pressure regulating valves rather than PRRV (pressure reducing-relieving valve) controls is preferred when connecting to tractors having CCLS (closed center-load sensing) controls. The tractor valve controlling this circuit is preferably set to deliver 3 gpm, which generally satisfies the rate at which the various actuators respond to uneven ground. This set flow will continuously pass through circuit CD during operation of down pressure, and be used as required by the actuators when they extend or retract as they provide bias to force the middle section 18 and/or wing sections 10 and 12 toward the ground.
A flow divider 84 can be used to separate equal portions of flow when a second circuit is connected to the same control valve. In this case the tractor valve may be set to 6 gpm. A 50/50 divider will split 3 gpm to each circuit regardless of the pressure at which either circuit is operation. In the embodiment shown in FIG. 4, the second circuit operates hydraulic drives for metering seed or other materials for planting. A check valve 86 in the second circuit blocks reverse flow to the second circuit so that full pressure may be applied to the wing actuators when raising the wings. Depending on the ratio of flow required by the branch circuits, a flow divider with a different split ratio could be used. Or a priority flow divider could be used which sets a fixed flow to one branch and delivers any excess flow to the other. Other multiple number of branch circuits is conceivable by using primary and secondary flow dividers and so on.
Preferred embodiments of the invention have been described and illustrated by way of example. Those skilled in the art will realize that various modifications and changes may be made while still remaining within the spirit and scope of the invention. Hence the invention is not to be limited to the embodiments as described but, rather, the invention encompasses the full range of equivalencies as defined by the appended claims.
|
An agricultural implement includes a frame having a pair of tool-carrying wings pivotally mounted thereon for pivotal movement between raised transport positions and lowered ground-working positions. Each wing has a hydraulic wing actuator connected thereto which is extendable and retractible for effecting the pivotal motion. A hydraulic wing actuator circuit is connected to each of the wing actuators, which circuit, when connected to a tractor hydraulic system, enables the wing actuators to apply down pressure to said wings when the wings are in the lowered working positions. A hydraulic pressure control valve system controls the down pressure exerted by the wing actuators.
| 0
|
FIELD OF THE INVENTION
The invention relates to Multilink Point-to-Point Protocol (MLPPP) and is particularly concerned with maintaining synchronization between an active MLPPP receiver and transmitter side of a switch, and the hot-standby MLPPP receiver and transmitter of the same switch.
BACKGROUND OF THE INVENTION
As described in US patent application publication number 2007/0253446 and incorporated herein by reference; multilink protocols are well known in the art and have been standardized for both point-to-point protocol (MLPPP, also referred to as MP) and Frame Relay protocol (MLFR, also referred to as MFR), among others. Multilink protocols combine multiple physical or logical links and use them together as if they were one high-performance link. MLPPP is described in RFC 1717, which has been updated by RFC 1990. MLFR is described by specifications FRF.15 and FRF.16. (Note: If not otherwise stated herein, it is to be assumed that all patents, patent applications, patent publications and other publications (including web-based publications) mentioned and cited herein are hereby fully incorporated by reference herein as if set forth in their entirety herein.)
MLPPP and the MLFR Protocols function by fragmenting datagrams or frames and sending the fragments over different physical or logical links. Datagrams or frames received from any of the network layer protocols are first encapsulated into a modified version of the regular PPP (Point-to-Point Protocol) or FR (Frame Relay) frame. A decision is then made about how to transmit the datagram or frame over the multiple links. Each fragment is encapsulated and sent over one of the links.
On a receiving end, the fragments received from all of the links are reassembled into the original PPP or FR frame. That frame is then processed like any other PPP or FR frame, by inspecting the Protocol field and passing the frame to the appropriate network layer protocol.
The fragmenting of data in multilink protocols introduces a number of complexities that the protocols must be equipped to handle. For example, since fragments are being sent roughly concurrently, they must be identified by a sequence number to enable reassembly. Control information for identifying the first and last fragments must also be incorporated in the fragment headers. A special frame format is used for the fragments to carry this information.
One possible remedy for this would be to utilize the solution disclosed in U.S. Pat. No. 6,912,197 wherein the active and standby processors exchange messages to synchronize fragment numbers. The active processor sends periodic updates to the standby processor with a sequence number. On an activity switch, the newly active processor calculates a new sequence number as a sum of the number received from the previously active processor plus a jump number. The jump number is calculated as a maximum number of fragments that can be transmitted in a timeframe between the previous update and the switchover time.
There may be at least two drawbacks of this solution. The first is the burden of sending periodic messages between the processors. There may be hundreds and thousands of MLPPP groups supported on the switch processor. Sending periodic messages for all of them may be resource consuming. Another other drawback is that the jump count may vary since the fragment rate is not predictable. It will almost always be greater than the number expected by the receiver. The receiver at the other end of the network may have to unnecessarily wait for missing fragments that will never come in. This creates a delay in the fragment flow since the receiver must wait for “missing” fragments until a timeout expires.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved method and system for active and hot-standby receiver/transmitter portions of a switch.
According to an aspect of the present invention there is provided a method for synchronizing the transmit frame fragment sequence numbers of active and standby transmitters on line cards in a switch supporting multilink protocol having active and standby sides. The method has the steps of first, initializing a standby transmit sequence number for the standby transmitter to an initial value; and subsequently incrementing the standby transmit sequence number with each transmit frame fragment handled by the standby transmitter. This is followed by the step of associating the standby transmit sequence number with respective receive sequence numbers received by the switch and determining an association of transmit frame fragment sequence numbers used by the active transmitter for respective receive sequence numbers received by the switch. Then, calculating an offset to the standby transmit sequence number based upon the difference between the standby transmit sequence number associated to a specific receive sequence number and an active transmit frame fragment sequence number associated to the same specific receive sequence number. Finally, applying said offset to the standby transmit sequence number to bring the standby transmit sequence number in synchronization with the transmit sequence numbers of the active side.
Advantageously, the determining step further may further have the step of querying of the active side by the standby side in respect of transmit frame fragment sequence numbers associated to receive frame fragment sequence numbers.
Also advantageously, the query step may specify a specific receive frame fragment sequence number or a plurality of specific receive frame fragment sequence numbers for the active side to provide an association to.
Under some configurations there is the additional step of extrapolating a specific receive frame fragment sequence number based at least in part upon the receive frame fragment sequence numbers received by the standby side. This additional step may also take into account the rate at which receive frame fragments are being received.
Advantageously, the query step may be repeated in the event that no association is received by the standby side from the active side. This repetition may be initiated after a specified quantity of time has elapsed without an association being received.
According to another embodiment of the invention, there is provided a system for synchronizing the transmit frame fragment sequence numbers of active and standby transmitters on line cards in a switch supporting multilink protocol having active and standby sides. The system provides for the initializing a standby transmit sequence number for the standby transmitter to an initial value; and subsequently incrementing the standby transmit sequence number with each transmit frame fragment handled by the standby transmitter. This is followed by associating the standby transmit sequence number with respective receive sequence numbers received by the switch and determining an association of transmit frame fragment sequence numbers used by the active transmitter for respective receive sequence numbers received by the switch. Then, a calculation of an offset to the standby transmit sequence number based upon the difference between said standby transmit sequence number associated to a specific receive sequence number and an active transmit frame fragment sequence number associated to the same specific receive sequence number is performed. Finally, the system applies the offset to the standby transmit sequence number to bring the standby transmit sequence number in synchronization with the transmit sequence numbers of the active side.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be further understood from the following detailed description of embodiments of the invention, with reference to the drawings in which:
FIG. 1 illustrates an active and hot-standby receiver and transmitter in a switch supporting MLPPP in accordance with an embodiment of the present invention; and
FIG. 2 illustrates timing diagram showing message frame fragment streams with sequence numbers originating and terminating at active and standby sides.
DETAILED DESCRIPTION
In order to provide reliable operation, modern communication switches provide replacement of operating devices with redundant devices in order to secure continued operation. These redundant or “standby” devices may be switched into operation manually, or more commonly automatically, in the event of a failure.
For minimum service disruption, standby devices operating in a “hot” standby mode operate to “shadow” the operation of the active device they are intended to replace. In the hot-standby mode data traffic handling, signaling, and other aspects of switching operation are being handled in the hot-standby device as much as possible, short of actually disrupting normal operation.
Switching systems where the active receiver and the standby receiver are capable of receiving the same flow of MLPPP fragments are well known in the art. An example of such a system is Alcatel-Lucent's 7670 RSP switch. Both the active receiver and the standby receiver receive fragment frames with the same fragment sequence numbers. For seamless standby transmitter cutover in the case of active side failure, there must be some form of synchronization of the transmit sequence number such that the standby transmitter commences transmitting frame fragments with the same sequence number as the active transmitter would have should it not have failed.
In many implementations the active and standby frame processors are located on different physical line cards within the switching equipment. This synchronization of transmit frame fragment sequence numbers is complicated by having to effect the synchronization across the interconnection between the physical line cards. Signaling channels and bandwidth associated with the synchronization would preferably be kept to a minimum.
In operation, every transmit fragment frame sequence number that is transmitted from the switch will occur concurrent to a respective receive fragment frame sequence number. The transmit fragment frame sequence number may be associated to the receive fragment frame sequence number in the transmitter.
Referring to FIG. 1 , there may be seen switch 100 having a connection to a data network 150 via input ports 102 a and 102 b , and via output ports 104 a and 104 b.
In FIG. 1 , active side 110 has an active receiver 112 and an active transmitter 116 . Operating within active receiver 112 is MLPPP Receive Module 114 which has a storage element containing a receive frame fragment sequence number RxNUM 115 . Operating within active transmitter 116 is MLPPP Transmit Module 118 which has a storage element containing a transmit frame fragment sequence number ActiveTxNum 119 .
Likewise, hot-standby side 120 has a standby receiver 122 and a standby transmitter 126 . Operating within standby receiver 122 is MLPPP Receive Module 124 which has a storage element containing a receive frame fragment sequence number RxNUM 125 . Operating within standby transmitter 126 is MLPPP Transmit Module 128 which has a storage element containing a transmit frame fragment sequence number StandbyTxNum 129 .
The ports 102 a , 102 b , 104 a , and 104 b are representative of connections to data network 150 and may be separate physical elements. These ports are associated for redundancy purposes by configuration management. Disconnect 140 inhibits standby transmitter 126 message frame fragments from output port 104 b from reaching network 150 . In the event of a failure in which the hot-standby side 120 replaces the active side 110 in operation, disconnect 140 would operate to connect output port 104 b to network 150 , thereby allowing the hot-standby side 120 to become the active side.
In operation, the standby transmitter learns a transmit frame fragment's sequence number used by the active transmitter after the active transmitter associates a transmit frame fragment with a specific receive frame fragment. Upon startup the standby side has an initial transmit frame fragment sequence number. As it operates in parallel to the active side it will assign incremental transmit frame fragment sequence numbers to outgoing (but blocked by disconnect 140 ) transmit message frame fragments. Since the hot-standby side 120 receives receive frame fragments, it is able to associate its transmit frame fragment sequence numbers to the incoming receive frame fragment sequence numbers. However, the initial sequence of transmit message frame fragment sequence numbers from the hot-standby side 120 will not match the active side 110 sequence of transmit message frame sequence numbers as the startup of hot-standby side 120 may occur at any point in time relative to the ongoing operation of active side 110 . Should the hot-standby side be informed of the association between receive frame fragment sequence numbers and transmit frame fragment sequence numbers in use by the active side, then it would be able to adjust its transmit frame fragment sequence number by incrementing it by an appropriate amount.
Referring to FIG. 2 there may be seen message frame fragments stream 270 having receive message frame fragments 271 received by the active receiver 112 and standby receiver 122 . Also depicted are a transmit message frame fragments stream 280 generated by the active transmitter 116 having transmit message frame fragments 281 ; and a transmit message frame fragments stream 290 having transmit message frame fragments 291 generated by the standby transmitter 126 . Within the respective message streams may be seen message frame fragments bearing sequence numbers.
By way of example, suppose at some point in the past the ActiveTxNum was 123 when it received a receive fragment frame with RxNum of 1000 as indicated by reference 282 . Also suppose that on the standby side the StandbyTxNum was 23 when it received the same receive fragment frame with the RxNum of 1000 as indicated by reference 292 . Suppose, that after the standby has simulated transmission of 50 fragments (since it received RxNum of 1000), it subsequently learns that the ActiveTxNum was 123 at the time of RxNum 1000 reception. Not knowing the ActiveTxNum, the standby would use a transmit sequence number of 74 (23+50+1) for the next transmit fragment frame sequence number. Instead, having the association used by the active side, the standby calculates the next transmit fragment frame sequence number as follows:
calculates the delta between ActiveTxNum and StandbyTxNum, e.g. 123−23 is 100 as indicated at reference 285 ; and adds this to the would be transmit fragment frame sequence number of 74, e.g. 100+74 is 174.
Therefore, the next number to be used by the standby would be 174 and not 74. Since the active and the standby transmit the same fragments at the same rate, this operation provides that the active and the transmit fragment frame sequence numbers will be the same, and this will guarantee a seamless switchover in the future. After the delta or offset is applied, the transmit frame fragments sequence numbers will be synchronized as indicated at reference 295 .
The method described above assumes that the standby side can learn ActiveTxNum associated with a particular receive frame fragment. One method of learning this association is as follows.
When the standby side starts up and commences receiving fragments, it looks up the sequence number in the fragment received. Based on received number, the standby side extrapolates receive frame fragment sequence numbers that it expects to receive within some next time interval. This time interval can range from seconds to minutes, dependent upon the implementation of the startup procedure and the quantity of switch message traffic present.
Referring back to FIG. 1 , the standby side then sends a message via message channel 130 to the active side requesting the active side record its transmit frame fragment sequence numbers when receiving fragments with the specified receive frame fragment numbers. Upon reception of the receive frame fragments having at least one of the specified sequence numbers, the active side records the associated transmit frame fragment sequence number. The active side then forwards the at least one associated number via a message channel 132 to the standby side.
During the same period of time, the standby side records the transmit frame message fragment sequence number it produces at the time that the specified receive frame fragment sequence numbers are received.
On receiving the ActiveTxNum numbers, the standby side calculates the delta or offset in respect to its association and adjusts the StandbyTxNum as per the method described above.
If the active side did not receive the request in time to record the association with the specified sequence numbers, it can inform the standby side that the specified numbers have already transpired. In a preferred mode of operation a plurality of numbers is specified by the standby side so that the active side has an increased likelihood of receiving the request in sufficient time to record the association. This approach avoids having to extrapolate a receive fragment sequence number that is too far in the future to allow a reasonably rapid synchronization of active and standby sides to occur.
If, after some time interval, the standby side has not received an association response from the active side, the extrapolation and request process may be repeated until at least one association is received by the standby side.
Therefore, what has been disclosed is a method and system for MLPPP sequence number synchronization between the active and hot-standby side transmitters in a switch supporting multilink protocols.
Numerous modifications, variations and adaptations may be made to the embodiment of the invention described above without departing from the scope of the invention, which is defined in the claims.
|
A method and system for MLPPP sequence number synchronization between the active and standby side transmitters is disclosed. The MLPPP sequence number synchronization system includes a method for the standby side to associate transmit frame fragment numbers used by the active side to those generated by the transmitter on the standby side. The association is used to produce an offset which is used to synchronize the active and standby transmitters. The MLPPP sequence number synchronization system is particularly useful for overcoming the drawbacks of high bandwidth signaling between active and standby sides of switches known in the art.
| 7
|
FIELD OF THE INVENTION
The present invention is directed to an improved gate latch and is especially concerned with an improvement in a bi-directional self-latching gate latch.
BACKGROUND OF THE INVENTION
Gate latches have been in common use for untold years. Such latches come in various functional types. Those that allow the gate to swing only in, those that allow the gate to swing only out and those that allow it to swing in either direction. Latches may be operable to open the gate from one or the other or both sides.
Most desirable in the modern gate latch is an automatic latching. That is, it should positively latch upon the gate swinging into its closed or shut position. It is also highly desirable in a gate latch that provisions be made for locking the gate and latch. This is especially advantageous and may often be required under local law, for example in gates helping to enclose outdoor swimming pools or other areas where access by children could be dangerous.
One example of a bi-directional gate latch is U.S. Pat. No. 1,177,487 issued to J. A. Clements in 1916. That latch is automatic and bi-directional. It may not, however, be locked. It is also of the type, shared by many gate latches, which may be opened by an intelligent dog or other pet or by a small child. Further, latches such as the Clements latch, are complex and difficult to manufacture and install and would be expensive to manufacture and difficult to mount.
The present invention provides a gate latch that is automatic and lockable and which overcomes one or more of the disadvantages of prior latches and yet achieves many of the desired features for gate latches. The gate latch of the present invention further may be easily and economically manufactured, installed and used.
SUMMARY OF THE INVENTION
A gate latch constructed in accordance with the present invention comprises a catch assembly including a base having means for mounting it to one or the other of a gate or a gate post. As an example, conventional "C" clamps may be used for such mounting. The base has mounted to it a pair of catch members, each of which is mounted for vertical limited movement between a home position and an open position. The catch members define between them, when in their home positions, a gap for receiving the strike. A strike assembly is also provided with means for mounting it to the other one of the post or gate. The strike assembly includes a strike sized and shaped to, when strike and catch assemblies are properly installed and the gate is closed, move upward one or the other of the catch members and to fit in and be releasably captivated in the gap. A latch handle is connected to each of the catch members and may be manually operated to move either or both of them from their home position to their open position to release the strike. Further provided on the base are means for receiving a locking member such that when inserted it prevents the movement of the catch members.
In accordance with an additional feature of this invention, the base and each catch member defines means for receiving a locking member for substantially locking one or both of the catch members in their home positions. This allows the gate latch to be either one that allows the gate when unlatched to swing only in, or only out or both.
In accordance with another feature of the invention, a simple locking member is provided such that both catch members are secured in their home positions and a padlock may be used to more securely lock the gate with the padlock position selectively to the inside or the outside of the gate.
The invention, together with the advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings, in the several figures of which, like reference numerals identify like elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a catch assembly constructed in accordance with the present invention.
FIG. 2 is an elevational view of the assembly of FIG. 1, with a strike shown in section in one of its operational positions and with moved parts shown in phantom lines;
FIG. 3 is a side elevational view of the assembly of FIGS. 1 and 2 mounted on a fragmentally depicted gate;
FIG. 4 is a top view of a portion of the assembly of FIGS. 1-3;
FIG. 5 is a perspective view of the assembly of FIG. 1 and strike assembly, mounted as in FIG. 3, with a locking member and padlock installed;
FIG. 6 is a view similar to that of FIG. 2 showing the assembly of FIGS. 1-5 converted to being a one-way opening gate latch.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is depicted a catch assembly 10 constructed in accordance with the present invention. The catch assembly 10 includes a base 12 having means, a conventional "C" clamp 14, for mounting it to a gate post or gate.
The base 12 has a pair of sleeves 16 projecting on both sides for receiving in a loose fit a pair of vertically arranged catch plate members 18. The catch members 18 have a central vertically oriented slot 20. A rivet 22 is provided through each of the sleeves 16 and through the slot 20. The rivet 22 is received in the slot 20 in a loose fit and serves as a guide member for the catch member 18. The catch members 18 are thus held parallel to each other in the sleeves 16 by the rivet 22 acting as a guide member such that they can move vertically upward from a home position in which they are shown in FIG. 1 for a limited distance. A handle 24 spans across the top of the catch members 18 and is pivotally secured to each of them by rivet 26.
The base 12 is provided with an opening or hole 28 through its upper portion. The opening 28 is just above the home position of the handle 24, as better shown in FIG. 2. As can be seen in that figure, the range of movement of one catch member 18 is between the position shown in solid lines and that depicted in phantom lines. The bottom surfaces 19 of the catch members 18 are formed at an angle so as to allow a strike 30 to drive either one of them upward as it moves horizontally from either side of the assembly 10. The catch members 18 are mounted in a spaced apart array with a gap 32 between them when they are both in their home positions (solid lines of FIG. 2) into which the strike 30 may easily fit and be held by the catch members 18. The loose fit of the catch members and handle 24 allows gravity to pull each of the catch members 18 back to its home position as soon as the strike 30 enters the gap and after release of the handle by the user. The holes formed in the catch members 18 for receiving the rivets 26 are preferably made slightly elongated in the horizontal direction to accomodate the increased distance between the rivets from the position shown in solid lines in FIG. 2 to the moved position shown in phantom lines in that figure.
Installed, as shown in FIG. 3, the full locking gate latch 100 preferably has the assembly 10 mounted to a fence post 40 by means of "C" clamps 14 and 44 and nuts and bolts 46. (A similar nut and bolt arrangement, [FIGS. 3 and 5] is provided on the other side of the "C" clamps 14 and 44.) The strike assembly 50 comprises the strike 30 secured, as by welding, to means for affixing it to the frame of a gate 60. Such means are in this preferred embodiment the "C" clamp 32 which is secured by nuts and bolts 34 to a second "C" clamp 36 such that both clamps 32, 36 are about an outer vertical member of the gate 60.
As shown best in FIG. 4, the handle 24 is preferably formed of a rectilinear elongated flat piece of metal and lies in a vertical plane with its ends 25 turned to lie in a horizontal plane. These ends 25 provide a good thumb or finger lifting surface and are preferably bent back toward the fence post so as to present a minimum obstruction to someone passing through the gate. As also indicated in FIG. 4 the fit between the catch member 18 and sleeves 16 is loose so as to allow water, ice, sleet, etc., to easily fall or drain through and not bind up the catch member 18.
Referring to FIG. 5, there is depicted the catch assembly as in FIG. 1 installed as in FIG. 2 and locked by means of a special locking member 70 and padlock 80. The member 70 comprises a rod with a hook end 72 sized to just fit through the hole 28 and overlay and overlap on the other side of the handle member 24. When so installed it prevents the handle 24 and the catch members 18 from leaving their home positions. The lock member 70 is sized so as to extend to the exposed area of the slot 20 which extends below the sleeve 16. The slot 20 is sized so as to expose an opening large enough to receive the shackle 82 of the padlock 80 and the member 70 includes an eye 74 to similarly receive the shackle 82. Note should be made of the fact that this arrangement makes it easy to open the gate from one side but difficult to reach the padlock from the other side. There are many applications where this result is desired, for example, to prevent attempted picking of the padlock from the outside of the fence and gate. Alternatively, the padlock could be passed through the hole 28 directly in which case it would be equally accessible from either side. The member 70, (or a similar pin) can also be used through the hole 28 without a lock 80 when it is desired to just lock the latch against pets or small children who could not easily remove it.
In FIG. 6 is illustrated the manner of adapting the latch 100 so as to have the gate open in only one direction (in or out). This is done by providing a ring 90 or other stop member that like the shackle 82 passes through the exposed opening of one slot 20 below the sleeve 16. In this case only the opposite catch member 18 can be raised (from either side of the gate by using the handle 24) as shown in phantom lines. With this arrangement the gate can be locked by a pin or shackle through either the hole 28 or the slot 20 of the movable catch member 18.
It should be noted that a pin or ring such as the ring 90 can be positioned in the exposed slot 20 of either or both catch member 18 when it is in its open position (i.e. in the opening indicated by 20' in FIG. 6) should it be desired to temporarily keep the latch assembly 100 from latching.
It should now be apparent that a locking latch assembly 100 has been described that is quite versatile. The assembly 100 may serve a two way opening gate or convert a gate so as to open only "in" or only "out". The latch assembly may be locked by a pin or padlock such that the padlock is readily accessible to both sides of the gate or to only one or the other side by using the locking member 70.
The latch assembly 100 is easily and economically manufactured. As depicted, the sleeve 16 and strike member 30 are identical in configuration. Similarly, the catch members 18 are of identical configuration. This yields benefits as it reduces the number of different configurated parts that are necessary to make. These parts, as well as the handle 24 are readily cut or stamped from flat steel and easily formed by simple tools and jigs. Further, the unit 30-32 is a pre-existing part used in the commercially available STA-KLOS gate closer marketed by Ingot Products, Inc. Thus a further advantage of the current invention is that it can employ pre-existing parts and thus reduce the number of separate new parts necessary to be manufactured and inventoried.
The assembly 10 has only three moving parts which are secured to the base 12 and each other by four simple rivets. The mounting means for the strike 30 and base 12 may be conventional "C" clamps as are commonly used for gate and fence hardware. The locking member 70 and ring 90 may be formed of wire stock.
A prototype of the invention was constructed and tested and demonstrated to work well.
For purposes of illustration and not for purposes of limitation the following presently preferred dimensions and materials are specified. Of course, as is well known to those in this art, many other sizes and materials as well as variations in arrangement can be employed and, indeed, the present inventor may, for reasons of economy and other reasons decide in the future to vary from these particulars. However, as presently contemplated the preferred embodiment would employ catch members 18, handle 24, sleeves 16 and strike 30 made of one-eighths inch thick flat steel. The sleeves and strike are preferred to be about 1 inch high and one and seven-sixteenths inch wide with nine thirty seconds inch diameter holes. The catch members 18 would be about four and one half inches in height one and one quarter inches wide with slot 20 about three-eighths inch by one and three-sixteenths inch in overall size. Its hole for receiving the rivet 26 is preferably about thirteen thirty-seconds by eleven thirty-seconds inches in overall size. Its bottom surface 19 is preferably formed at an angle of 60 degrees to the vertical. The handle is preferably about seven and three-eighths inches long and also formed of one inch wide by one-eighth inch stock with one-quarter inch diameter holes for receiving rivets 26. The base 12 is preferably formed of three-fourths by five-eighth inch steel stock with hole 28 being nine thirty-seconds inches in diameter and counter sunk. The locking member 70 was formed of one-quarter inch thick steel rod and was about three and five-eighth inches in overall length with its eyelet having a three-eighth inch inside diameter. The rivets 26 are preferably flat head shoulder rivets 9/32×1/4 inch, CRS semi-tubular and the rivets 22 are preferably 5/16 inch CRS semi-tubular.
This arrangement produces a strong gate latch that is lockable and versatile of an overall size that is convenient to install and use. The parts shown constitute a kit from which the professional as well as the do-it-yourself can easily and quickly assemble and install a lockable gate latch.
While only one particular embodiment of the invention has been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention 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 the invention.
|
A positive gate latch having a striker bar and two vertical catch members held in place by two sleeves secured to a base. When the catch members are down, the striker bar (often referred to as a gate tongue) cannot move in either direction. The catch members are attached to an operating bar, allowing passage when activated from either direction. The gate latch may be locked in three separate positions, allowing passage in only one direction or may be locked allowing no passage in either direction. The latch is designed primarily for use on tubular structures, such as chain link fence.
| 8
|
This application is a continuation of copending application Ser. No. 07/149,374, filed Jan. 28, 1988, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to drill bits, and more particularly to rotary drill bits with diamond cutting elements used in the drilling of bore holes in earth formations.
Earth boring diamond drill bits may typically include an integral bit body which may be of steel faced with an abrasion-resistant material such as tungsten carbide or may itself be fabricated of a hard metal matrix material such as tungsten carbide. A plurality of diamond cutting elements are mounted along the exterior face of the bit body. Each diamond cutter typically may be mounted on a stud the other end of which is mounted in a recess in the exterior face of the bit body, or the cutter mount may be integrally cast with the matrix of the bit body.
The cutting elements are positioned along the leading edges of the bit body so that as the bit body is rotated in its intended direction of use, the cutting elements engage and drill the earth formation. In use, tremendous forces are exerted on the cutting elements, particularly against the face thereof in the forward to rear direction as the bit is rotated. Additionally, the bit and cutting elements are subjected to substantial abrasive forces. In some instances, impact, lateral, and/or abrasive forces have caused drill bit failure and cutter loss.
A significant problem encountered when drilling in certain earth formations such as shales, clay, and other water reactive, sticky formations known as "gumbo" has been the tendency of such bits to become clogged during operation. In dealing with such earth formations, bits have been designed with relatively large cutters with strong hydraulics in the proximity of the cutters to remove the cuttings from the cutter faces with a high volume, high velocity, hydraulic fluid flow.
As synthetic diamond technology has advanced, it is now possible to provide large diamond disc cutters up to two inches in diameter for use on bits. These very large cutters have been helpful in drilling in "gumbo" formations. However, the large diameter of the cutting elements has caused problems in providing secure attachment thereof to the exterior face of the rotary drill bits. To accommodate such large diameter cutters, drill bits have been fabricated with outwardly extending shoulders or protrusions on which the cutters may be mounted. However, this leaves a relatively small structure beneath and behind the cutter faces to support the cutters. Additionally, blades, ridges and other structures having multiple cutters mounted thereon and extending significant distances from the main profile of the bit body are also becoming more common, presenting similar problems.
While tungsten carbide or other hard metal matrix bits are highly erosion resistant, such materials are relatively brittle and can crack upon being subjected to the impact forces encountered during drilling. Typically, such cracks have occurred proximate where the cutting element support structures join the matrix body. The shoulders or protrusions on the exterior of the drill bits to accommodate large diameter cutting exposes these areas of the bit to high impact and shear forces. Bits having large cutter elements thereon extending outwardly from the body of the bit are particularly susceptible to cracking and failure due to these high impact and shear forces. If the cutting elements are sheared from the drill bit body, the expensive diamonds on the cutter elements are lost, and the bit may cease to drill.
Accordingly, there is a need in the art for a drill bit having increased impact strength and resistance to cracking, particularly in areas supporting the cutter elements.
SUMMARY OF THE INVENTION
The present invention meets that need by providing a rotary drill bit in which the areas supporting the cutter elements are reinforced to provide those areas with increased impact strength. In accordance with one aspect of the present invention, a rotary drill bit is provided which includes a main body portion of a hard metal matrix material and at least one shoulder or protrusion formed of the same hard metal matrix material. The protrusion is integral with the main body portion of the bit and extends outwardly from the exterior surface of the bit. As used in this specification, the term protrusion encompasses protrusions, shoulders, blades, ridges, or other structures extending outwardly from the main profile of the bit body.
A cutting element is mounted on the protrusion and is angled as known in the art to accomplish drilling of an earth formation. There may be one or a plurality of individual cutter elements mounted on each protrusion. Means for reinforcing the protrusions are provided and extend between the main body portion of the bit and individual protrusions.
In a preferred embodiment, the reinforcing structure comprises a solid preformed arrangement positioned rearwardly of the cutting elements and extending at an acute angle with respect to the main body portion of the bit. The reinforcing structure may be in the form of one or more rods, bars, disks, or wires which are preferably of metal. While steel is the preferred composition for the reinforcing structure, other metals and metal alloys such as stainless steel, nickel alloys or molybdenum may be utilized.
The present invention also encompasses drill bits having a plurality of such protrusions and cutting elements and is particularly suited for use with rotary bits having relatively large diameter cutting elements. The portions of the matrix on which the elements are mounted are reinforced to provide the bit with greater impact strength and greater resistance to cracking and failure of the bit matrix. Accordingly, it is an object of the present invention to provide a rotary drill bit matrix having improved impact strength and resistance to cracking over prior bits. This, and other objects and advantages of the present invention, will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the rotary drill bit of the present invention;
FIG. 2 is a diagrammatic sectional view taken through one of the cutting elements along line 2--2 of FIG. 1 and illustrating the reinforcing structure; and
FIG. 3 is also a diagrammatic sectional view similar to FIG. 2 illustrating the reinforcing structure in a bit having a somewhat different structure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is illustrated in the drawings with reference to a typical construction of a rotary earth boring bit. In particular, the invention is illustrated and described with reference to the large compact cutter rotary bit described in greater detail in commonly assigned, copending U.S. application Ser. No. 906,169, filed Sept. 11, 1986. It will also be recognized by those skilled in the art that the configuration of the cutting elements along the exterior face of the matrix may be varied depending upon the desired use of the bit. Thus, the bit may be designed for either a flat, parabolic, or extended blade crown profile. The invention may also be useful in any hard metal matrix bit configuration which has one or more shoulders, ridges, blades, or other protrusions extending outwardly from the main body of the bit.
Referring now to FIG. 1, a rotary drill bit 10 of the type disclosed in the above referenced copending application includes an exterior generally cylindrical surface or gage 12 having a bit face 14 on its lowermost portion. Both gage 12 and bit face 14 are formed of the hard metal matrix material of the bit body, such as tungsten carbide. Defined within gage 12 are a plurality of junk slots 16 and 18. The junk slots are designed to facilitate the upward flow of the drilling fluid and cuttings away from the bit face 14. A number of fluid nozzles 20 are also located on bit face 14. Each of fluid nozzles 20 is designed to provide directed fluid flow to a specific cutting element 22. Each cutting element 22 comprises a tungsten carbide backing 25 having deposited thereon a thin synthetic diamond cutting face 23 which performs the cutting operation.
Cutting elements 22 are mounted on protrusions 24 which extend outwardly from the bit face 14. The cutting elements are secured in place by brazing or otherwise fixing them to the bit face in a conventional manner. For example, cutting elements 22 may be secured to the matrix and to tungsten carbide slug 26 cast into the trailing portion of sockets 28 (best shown in FIG. 2) on bit face 14 by brazing or other suitable means. In a preferred embodiment, the cutting faces 23 of cutting elements 22 are one inch in diameter or larger.
As shown, each cutter element 22 has an associated fluid nozzle 20 which provides a directed hydraulic flow of fluid to the face of the cutting element. This fluid flow applies a force to chips cut from the earth formation, loosening and removing the chips from the faces of the cutting elements. Additionally, bit 10 includes a plurality of gage cutting elements 30 which comprise smaller diameter diamonds which are mounted on the gage 12 of bit face 14. The gage cutters insure that the drill cuts a path of the desired diameter through the earth formation.
As shown in FIG. 2, positioned rearwardly of each cutting element 22 is reinforcing means 32 extending between the main body portion of drill bit 10 and protrusion or shoulder 24. As illustrated and previously noted, cutting element 22 includes a hard metal matrix backing 25 of tungsten carbide or the like, and is preferably substantially laterally symmetrical.
The backing 25, having cutting face 23 thereon, is brazed into socket 28 in the bit matrix. Backing 25 provides shock protection and load resistance to the cutting face 23. As shown in FIG. 2, the bit 10 rotates in the direction of the arrow and encounters impact forces on cutting face 23 as indicated by the arrow shown in phantom lines. Typically, the cutting element 22 will have a predetermined rake angle to the formation encountered depending upon placement of cutting element 22 and the bit profile and the desired operation of the bit, which depends upon the formations to be drilled.
Reinforcing means 32 may comprise a longitudinally extending element which takes the form of a rod, bar, disk, or wire. It may also comprise a plurality of such structures. In a preferred embodiment, reinforcing means 32 comprises a threaded rod of cylindrical steel stock, such as 1018 or 1020 steel. Preferably, the steel stock has no coatings on it and the stock is cleaned of any oxides prior to being used.
As can be seen, reinforcing means 32 is positioned rearwardly of cutting element 22 and extends between the main body of the bit and substantially the outermost extent of protrusion 24. Reinforcing means 32 is positioned at an acute angle with respect to the centerline of the main body of the bit when referenced with respect to the orientation of the drill string as shown in FIG. 1. At such an angle, the reinforcing means is pointed slightly toward cutting element 22. Reinforcing means 32 also extends at least partially behind cutting element 22 and is also preferably centered with respect to cutting element 22 so that impact forces will be focused thereon.
In the embodiment of the invention illustrated in FIG. 3, a somewhat differently configured bit has a protrusion 24, which may be a blade-shaped protrusion emanating from the center of a "fishtail" bit toward the gage of the bit. Cutting element 22 is mounted into socket 28 in the bit matrix. As shown, reinforcing rod 32 is positioned rearwardly of cutting element 22 and extends between the bit matrix and substantially the outermost extent of shoulder or protrusion 34. Reinforcing rod 32 is preferably angled so that it is roughly parallel or at a slight angle (as shown) to the surface of cutting element 22 (as shown). Reinforcing rod 32 is disposed in a substantially perpendicular orientation to the profile of the main body portion of the bit.
Rotary drill bits employing the present invention are generally made by powder metallurgical techniques which are known in the art. The bit is formed in a carbon mold having an internal configuration corresponding generally to the required surface shape of the bit body, including protrusions for mounting cutting elements. Thus, the areas where the junk slots are found on the finished bit body contain carbon or clay displacement material in the mold.
The areas in the mold which correspond to where the cutting elements are to be mounted after furnacing of the bit body are filled with a displacement material such as carbon discs of like size to the cutting elements having clay adjacent thereto so that the furnaced bit body has mounting sockets 28 formed therein. Reinforcing means 32 are positioned in the mold by embedding them in the clay displacement material placed at the outermost extent of the protrusion cavitities from the body mold cavity.
Reinforcing means 32 are positioned rearwardly of where the cutting elements 22 are to be mounted. Preferably, the reinforcing means 32 is a threaded steel rod which is desirable positioned to be perpendicular to the mold profile from which it protrudes. In other words, when viewed from the perspective of the finished bit, reinforcing means 32 extends from the main profile or surface of the bit in a perpendicular manner to the point on the profile from which it extends.
As is conventional, elements which will form the internal fluid passages and nozzles in the finished bit are also positioned in the mold at this time. A steel blank is also positioned in the mold at this time. A hard metal matrix material such as tungsten carbide is then added to the mold. A binder material, preferably a copper-based alloy, in the form of pellets or other small particles, is then poured over the matrix material. The filled mold is then placed in a furnace and heated to above the melting point of the binder, typically above about 1100 degrees C. The molten binder passes through the infiltrates the matrix material.
After cooling, the matrix and binder are consolidated into a solid body which is bonded to the steel blank. After further cooling, the bit body is removed from the mold. The steel blank is then welded or otherwise secured to an upper body or shank. Clay and other displacement material is removed at this time. Because reinforcing means 32 was embedded in the clay, the portion of the reinforcing means which extends from the bit body is machined off flush to the trailing edge of the protrusion.
Cutting elements 22 are then mounted to the bit body. As is conventional, cutting element 22 is mounted into socket 28 and backing 25 secured therein by brazing with a suitable metal brazing material. The gage cutting elements may also be mounted to the exterior of the bit body at this time.
In order that the invention may be more readily understood, reference is made to the following example, which is intended to illustrate the invention, but is not to be taken as limiting the scope thereof.
EXAMPLE
In order to demonstrate the reinforcing capabilities of the structure of the present invention an impact test was made. The test measured the resistance to fracture by impact forces of a matrix material reinforced by a steel rod such as the preferred reinforcing rods of the present invention.
Samples of matrix material were fabricated in a conventional manner by filling a cylindrical mold with tungsten carbide matrix material and a copper-based alloy binder. The mold was sized to produce a sample specimen six inches in length with a 1/2 inch diameter. The matrices were furnaced at 2150 degrees F. for 60 minutes. Previous testing established that such a sample, when subjected to an impact force with a Charpy Impact Tester, would fracture at an impact force of about 3.5 ftlb.
Sample specimen 1 included a 3/16 inch diameter mild 1018 steel rod positioned centrally within the specimen. Sample specimen 2 included a 3/16 inch diameter threaded mild 1018 steel rod positioned centrally within the specimen. Sample specimen 3 included a 1/8 inch diameter tool steel rod positioned centrally within the specimen. All steel rods were grit blasted prior to placement in the respective mold to remove any oxides.
All sample specimens were then cut in two to form two three inch long bars (labeled A and B below) and tested using a Charpy Impact Tester. The results are reported in Table I below.
TABLE I______________________________________Specimen # Impact Force Result______________________________________1A 25.0 ftlb incomplete break1B 23.5 ftlb break2A 11.0 ftlb break2B 11.7 ftlb break2A 4.75 ftlb break2B 5.75 ftlb break______________________________________
While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes in the methods and apparatus disclosed herein may be made without departing from the scope of the invention, which is defined in the appended claims. For example, multiple cutting elements may be mounted on each protrusion; half-circular or other shape cutting elements may be used; several reinforcing elements may be employed for a single protrusion; U or V-shaped reinforcing elements may be used either right side up or upside down; reinforcing elements of a variety of cross-sections, including but not limited to square, rectangular, triangular, elliptical, half-circular, etc., may be employed.
|
A rotary drill bit for boring earth formations is provided which includes a main body portion of a hard metal matrix material and at least one protrusion or shoulder formed of the same matrix material. On the protrusion is mounted a cutting element. Means for reinforcing the protrusion are provided and extend between the main body portion of the bit and the protrusion. The reinforcements add impact strength to the bit and increase the resistance of the bit to cracking in areas supporting the cutting element.
| 4
|
FIELD OF THE INVENTION
This invention pertains to covered clarifiers, and more particularly, the present invention pertains to a low profile retractable cover which is supported largely on the outside wall of a circular clarifier.
BACKGROUND OF THE INVENTION
The clarification of industrial effluent is normally effected by alternatively agitating and letting the effluent settle, and lifting floating scum from the surface of the effluent or scraping sediments at the bottom of the reservoir. The clarification process is often accompanied by a fermenting action and a generation of odorous bio-gases, and/or the release of volatile organic carbons. For environmental reasons, these gases must be collected and treated. Therefore, a clarification reservoir, or clarifier, is preferably covered and sealed to contain the off-gases. Also, a clarifier preferably has a piping system to transport the off-gases to a gas treatment plant.
An industrial clarifier is often circular in shape. The reservoir typically has a central column supporting a motor, a gearbox, and a bearing assembly carrying a surface-skimming boom, a bottom rake or both. These equipment must be accessible for inspection, repair or preventive maintenance. Therefore a first preferred feature of a clarifier cover consists in its ability to be opened, to inspect, repair or maintain the boom, the rake, the circumferential launder or other equipment inside the reservoir. A second preferred feature is that the cover must be adaptable to the integration of a catwalk to the central column, to allow access to the machinery on the central column at all times.
The covering of a clarifier is often associated with the implementation of environmental regulations. Therefore a cover is often installed on an existing clarifier which was not designed to support a cover structure. Therefore, the retrofit installation of a cover over an existing clarifier must be done in such a way that the cover does not apply a substantial load or side stress on the central column inside the clarifier.
Another preferred feature in a clarifier cover is that the enclosed volume above the level of the clarifier must be kept as small as possible to maintain the ventilation of the clarifier as efficient and as economically as possible.
Examples of various systems available for covering a reservoir are described in the following documents:
U.S. Pat. No. 3,130,488 issued on Apr. 28, 1964 to G. Lindström;
U.S. Pat. No. 3,683,427 issued on Aug. 15, 1972 to H. C. Burkholz et al.;
U.S. Pat. No. 4,136,408 issued on Jan. 30, 1979 to E. L. Dahlbeck et al.;
U.S. Pat. No. 4,400,927 issued on Aug. 30, 1983 to A. M. Wolde-Tinase;
U.S. Pat. No. 4,951,327 issued on Aug. 28, 1990 to V. J. Del Gorio, Sr.;
U.S. Pat. No. 5,381,634 issued on Jan. 17, 1995 to S. Pietrogrande et al;
U.S. Pat. No. 5,943,709 issued on Aug. 31, 1999 to H. Y. Chiu;
Although the cover structures of the prior art deserve undeniable merits, it is believed that a need still exists in the industry for a clarifier cover which has a low profile, which does not apply substantial load on the central column of a clarifier, which is easily openable for inspection, repair or maintenance of the equipment inside the clarifier and which is strong and durable and can accommodate a catwalk to the central column.
SUMMARY OF THE INVENTION
In the present invention, there is provided a retractable clarifier cover which has a low profile, which is particularly appropriate for a retrofit installation over an existing clarifier, and which has all the other aforesaid advantages.
In a first aspect of the present invention, there is provided a clarifier cover having a plurality of saddle brackets mounted on the circular outside wall of the clarifier and a central ring plate mounted on the central column of the clarifier. A support structure is affixed to the saddle brackets and to the central ring plate, and a flexible sheet cover is affixed to the support structure. The support structure has a shape defined by a low profile circular segment of revolution around the central ring plate.
The shape of the support structure is particularly advantageous for defining a relatively small volume of gas under the cover, whereby the ventilation of the clarifier is doable economically. The shape of the support structure is also advantageous for isolating the mechanical and electrical equipment that may be present atop the central column of the clarifier from the corrosive or inflammable gases which may be generated inside the clarifier by the content of the clarifier.
In accordance with another aspect of the present invention, there is provided a support structure for supporting a flexible sheet cover over a circular clarifier. The support structure comprises a plurality of spaced-apart saddle brackets disposed in a first circular array defining a first circle. There is also provided a plurality of ring trusses disposed in a second circular array and defining a second circle, concentric with and inside the first circle. The support structure also comprises a radial array of outer trusses each having an outside end mounted to one of the saddle brackets and an inside end mounted to the plurality of ring trusses. A series of inner trusses are individually affixed to and extend from the inside end of one of the outer trusses, toward the centre of the first circle.
In this structural arrangement, the outer trusses and the ring trusses constitute a self-supporting structure wherein the weight thereof rests on the saddle brackets. The inner trusses are affixed to the outer trusses in an overhung mode such that the loading applied to the central column of a clarifier by the cover structure is minimal or negligible.
In yet another aspect of the present invention, there is provided a retractable cover mounted over a circular clarifier. The retractable cover comprises a central ring plate mounted on the central column of the clarifier; a plurality of saddle brackets affixed to the outside wall of the clarifier, and a support structure affixed to the support brackets and to the central ring plate. The support structure is made of an array of triangular frame sectors, each having an apex over the central column and a base over the outside wall of the clarifier, and a flexible sheet sector affixed thereto. At least one of the flexible sheet sectors has a retractable section near the base of the corresponding triangular frame sector. This retractable section is removably affixed to one of the triangular frame sector and to the clarifier wall. The clarifier cover according to the present invention is thereby selectively openable for inspection, repair or maintenance of equipment inside the clarifier.
Other advantages and novel features of the present invention will become apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
Four embodiments of this invention are illustrated in the accompanying drawings, in which like numerals denote like parts throughout the several views, and in which:
FIG. 1 is a perspective view of a circular clarifier having a retractable cover according to the first preferred embodiment of the present invention mounted thereon;
FIG. 2 is a cross-section view of the support structure of the retractable cover according to the first preferred embodiment, as seen along a radius thereof;
FIG. 3 is a perspective view of one of the triangular frame sectors of the support structure;
FIG. 4 is an enlarged partial perspective view of an outer truss and a saddle bracket supporting an outer truss on the clarifier wall;
FIG. 5 is a partial perspective view of a connection between an outer truss and an inner truss and of a connection between an outer truss and a ring truss;
FIG. 6 is a perspective view of an alternate connection between an inner truss, an outer truss and ring trusses;
FIG. 7 is a perspective view of a ring plate for retaining the inner trusses of a support structure to the central column of a clarifier;
FIG. 8 a cross-section view through the ring plate, showing a preferred attachment of a flexible cover thereto;
FIG. 9 a top view of a clarifier with the outer trusses and the ring trusses installed thereon;
FIG. 10 is a cross-section view through the clarifier and the outer truss and ring truss assembly as seen along line 10 — 10 in FIG. 9 .
FIG. 11 is a top view of the support structure as optionally assembled on the ground, and in a condition to be hoisted over a clarifier;
FIG. 12 is a partial top view of a support structure having a catwalk incorporated therein;
FIG. 13 is an enlarged cross-section view of a slotted rail mounted over the trusses of the support structure for retaining the sides of a flexible sheet sector to the trusses, as seen along line 13 — 13 in FIG. 16;
FIG. 14 is an enlarged partial view of a flexible joint between adjacent winding roll segments on a flexible sheet sector;
FIG. 15 is an enlarged partial view of an end of a winding roll on a flexible sheet sector;
FIG. 16 is a partial perspective view of a clarifier and a retractable cover according to the first preferred embodiment of the present invention;
FIG. 17 is a partial cross-section view of a clarifier having a cover structure according to the first preferred embodiment mounted thereon, as seen along line 17 — 17 in FIG. 16;
FIG. 18 is an enlarged partial view of a typical keyhole slot incorporated in a winding roll and in a sheet-stretching pipe;
FIG. 19 is a perspective view of a preferred puller used for stretching the flexible sheet sectors over the support structure;
FIG. 20 is a partial cross-section view of a clarifier having a removable cover according to a second preferred embodiment mounted thereon;
FIG. 21 is a partial cross-section view of a clarifier having a removable cover according to a third preferred embodiment mounted thereon;
FIG. 22 is a cross-section view of an alternative arrangement for retaining the flexible sheet cover to the lower cord of a truss, as seen along line 22 in FIG. 21;
FIG. 23 is a cross-section of a slotted pipe affixed to one of the trusses of the claifier cover, illustrating a mounting arrangement using self-tapping screws;
FIG. 24 is a side view of the slotted pipe looking inside the slot thereof;
FIG. 25 is a partial cross-section view of a claifier cover according to a fourth preferred embodiment;
FIG. 26 is an enlarged partial view of the cornice and soffit of the clarifier cover according to the fourth preferred embodiment, as seen in the detail circle 26 in FIG. 25 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While this invention is susceptible of embodiments in many different forms, there are shown in the drawings and will be described in details herein four specific embodiments, with the understanding that the present disclosure is to be considered as an example of the principles of the invention and is not intended to limit the invention to the embodiments illustrated and described. The four embodiments do not differ substantially from one another but are nonetheless enclosed herein to better illustrate various manners of construction, installation and operation of the present invention
The first preferred retractable cover 30 has the shape of a circular segment of revolution or of a half-bagel. The retractable cover structure 30 is made of trusses and flexible sheet sectors stretched over or under the trusses. The trusses are supported principally on the outside wall 32 of the clarifier 34 , and are lightly anchored to the central column 36 inside the clarifier. Each flexible sheet sector 38 is made of a stretch-resistant nylon-based pliable sheet material. Each flexible sheet sector 38 is partially held to slotted rails 40 , mounted over the trusses. In the first preferred installation, each flexible sheet sector has along each side edge thereof a hem and a rod or oblong nodules enclosed in the hem (not shown) and engaged in the slotted rail 40 as it is customary with tarpaulin structures. The slotted rails 40 do not extend to the edge of the clarifier, such that one or more sheet sectors 38 are retractable away from the clarifier wall 32 as shown in FIG. 1 for the purpose of inspecting the launder 42 or other equipment inside the clarifier. The retractable section of a sheet sector 38 is openable by winding it on a winding roll 44 as illustrated in FIGS. 1 and 2. In FIG. 1, two sheet sectors have been omitted from the drawing for the purpose of illustrating the support structure of the cover.
When the cover is in a closed and sealed mode, each sheet sector 38 is held tight over the edge 46 of the clarifier 34 by a series of pullers 48 mounted in a structural angle 50 which is affixed to the clarifier wall 32 . A group of pullers 48 act upon the winding roll 44 of each sheet sector 38 .
The retractable cover 30 according to the first preferred embodiment is advantageous for its low height, shown by label 52 , between the maximum effluent level inside the clarifier and the inside surface of the flexible sheet 38 . The space inside the clarifier is therefore relatively small as compared to a conical or a dome-shaped structure for example. The air changes required to ensure a good ventilation of the clarifier is therefore also relatively small, and the equipment required to do this is relatively simple and inexpensive.
The circular segment of revolution or the half-bagel shape of the cover is also advantageous for isolating the equipment 54 mounted over the central column 36 of a circular clarifier, from the corrosive or inflammable gases which may be generated by the content of the clarifier.
Referring now specifically to FIG. 3, the support structure comprises outer trusses 60 , inner trusses 62 connected to the outer trusses, and ring trusses 64 extending laterally between the outer trusses 60 . There are also provided intermediate trusses 66 extending radially outwardly relative to the centre of the support structure, from a mid span of each ring truss 66 . The outer trusses 60 are supported on a series of saddle brackets 68 affixed to the outside wall 32 of the clarifier. The inner trusses 62 are supported primarily on the outer trusses 60 and are lightly anchored to a ring plate 70 affixed to the central column 36 of the clarifier.
FIGS. 4-8 illustrate various preferred connections between the trusses and the clarifier structure. The preferred saddle bracket 68 consists of an angle member with a pair of clevis plates 72 affixed to the upper portion thereof. Each outer truss 60 has a holed stem 74 adapted to connect to the clevis plates 72 with a bolt or a pin. This connection is referred to herein as the first clevis and stem connection 76 . The saddle bracket 68 is anchored to the clarifier wall through holes 78 in the upper portion thereof.
The ring plate 70 is affixed to the central column 36 by conventional means, and has a number of clevis brackets 80 to make respectively a second clevis and stem connection 82 with one of the inner trusses 62 , as shown in FIGS. 7 and 8.
Referring back to FIG. 5, each inner truss 62 is connected to an outer truss 60 by means of a pair of third clevis and stem connections 84 , only the upper one of the pair is illustrated in FIG. 5 . Each ring truss 64 is connected to an outer truss 60 by a pair of a fourth type of clevis and stem connections 86 . Alternatively, the trusses may be connected to each other by bolted connections 88 , as illustrated in FIG. 6, according to the preference of the manufacturer.
Some of the clevis brackets 80 may have a modified shape 90 , as illustrated in FIG. 7, to retain parallel trusses supporting a catwalk for example. The ring plate 70 also has a series of holes 92 therein to retain a clamping ring 94 , for holding the flexible sheet sectors 38 to the ring plate 70 , as illustrated in FIG. 8 .
Referring now to FIGS. 9 and 10, one of the most important feature of the present invention will be described. It will be appreciated that the assembly of the saddle brackets 68 , the outer trusses 60 , the intermediate trusses 66 and the ring trusses 64 constitute a self-supporting structure bearing entirely on the clarifier wall 32 . In this structural assembly, the ring trusses 64 constitutes a compression ring that holds the outer trusses 60 and the intermediate trusses 66 above the clarifier wall. The inner trusses 62 as illustrated in FIGS. 1-3 are supported to the outer trusses 60 in an overhung mode. Therefore, it will be appreciated that the inner trusses 62 apply a minimum load on the central column 36 of the clarifier.
During the installation of the support structure, the saddle brackets 68 are preferably shimmed up or down as needed to reduce any stresses that may be applied to the central column 36 . It is believed that the only load applied to the central column are generated by the deflection of the support structure under its own weight, under a snow load, a wind load, or by one or more imprecise connections between the trusses or along the side wall 32 . A proper design and installation of the support structure can be done to take these factors into consideration such that the actual loading on the central column of the clarifier is considered minimal or negligible. This feature is particularly appreciable to accommodate the retrofit installation of a cover structure over an existing clarifier wherein the strength of the central column is not known precisely.
Another important feature of the support structure according to the first preferred embodiment is that it can be assembled on the ground and lifted and transported over an existing clarifier with a crane. In these circumstances, an array of tie members 100 , as illustrated in FIG. 11, are installed between the outer trusses 60 , the intermediate trusses 66 and the ring trusses 64 . The entire support structure 102 can then be lifted up with hoisting cables attached at three or more locations to the connections of the outer trusses 60 with the ring trusses 64 for example.
When a catwalk 104 is installed in the cover structure 30 , the ring trusses 64 on both sides of the catwalk 104 are linked together by a stiffening beam 105 extending below or across the floor of the catwalk as illustrated in FIG. 12, in order to maintain the integrity of the structural ring defined by the ring trusses 64 .
Referring now to FIGS. 13-19 the attachment of a flexible sheet sector 38 over the support structure will be described. As mentioned earlier, each flexible sheet sector 38 is held to the outer trusses 60 and to the inner trusses 62 by means of slotted rails 40 affixed to the upper cord of the trusses. In a preferred installation over a clarifier having a launder portion 42 , the slotted rails 40 do not extend to the edge of the clarifier. The retractable section 106 of a flexible sheet sector 38 , is preferably immediately above the launder portion 42 and is held to the outer trusses 60 by rope lashings 108 through grommets (not shown) along both side edges of the retractable section 106 . The rope lashings 108 are tied to a pair of edge support plates 110 , affixed to the outer trusses 60 over the launder portion 42 .
The retractable section 106 is held in a closed mode over the edge 46 of the clarifier wall 32 by a series of pullers 48 mounted in a structural angle 50 affixed to the clarifier wall 32 , and pulling on a flexible winding roll 44 . For opening the retractable portion 106 of a flexible sheet sector 38 , the pullers 48 are disengaged from the winding roll 44 , and the winding roll 44 is turned upon itself for winding the flexible sheet 38 thereon as illustrated in FIGS. 1 and 2. For this purpose, one end of the winding roll 44 has a drive stem 112 for connection to a rotating brace tool or to other socket drive equipment.
In the preferred embodiments, the winding roll 44 is made in two or more segments 114 , 116 which are linked to each other by flexible torque-transmitting joints 118 . The flexible winding roll 44 is thereby workable between a straight mode for rolling a sheet sector 38 thereon, and a curved mode to better seal the cover sector 38 against the edge 46 of the circular clarifier wall 32 as illustrated in FIG. 16 . Although the preferred flexible roll 44 is illustrated herein with flexible torque-transmitting joints 118 it will be appreciated that it may also be made of a single section of flexible plastic pipe material for example.
Referring now specifically to FIGS. 18 and 19, the preferred puller 48 has a faceted stem 120 for engagement with a socket drive tool. The stem is affixed to a winding shaft 122 to which is also affixed a ratchet wheel 124 on which a pawl 126 is engaged. The puller 48 further has a cable 130 affixed to the winding shaft, and a knob 132 crimped on the end of that cable. In use, the knob 132 is inserted into a keyhole slot 134 in a winding roll 44 and pulled toward the puller to stretch the flexible sheet sector over the edge 46 of the clarifier wall.
The structural angle 50 retaining the pullers 48 to the clarifier wall constitutes a guard rail for preventing damage to the retractable cover 30 or to the winding roll 44 by machinery moving near the clarifier wall 32 .
Referring back particularly to FIGS. 16 and 17, another feature of the retractable cover 30 according to the first preferred embodiment is illustrated. The central portion of each flexible sheet sector 38 is held tightbetween adjacent inner trusses 62 and adjacent outer trusses 60 , and toward the clarifier wall 32 by winches, in a similar manner as described for the retractable section 106 . A pair of pipes 140 are held inside hems 142 which are affixed to the sheet sector 38 by stitches 144 or the like, adjacent the retractable section 106 . The pipes 140 are pulled toward the clarifier wall 32 by winches 146 , two of which are illustrated in FIGS. 16 and 17. The winches 146 are similar to the pullers 48 mounted on the clarifier wall 32 . The winches 146 are affixed to the upper cord 148 of the outer trusses 60 and to the upper cord of the intermediate trusses 66 . The winches 146 are detachably engaged with the pipes 140 by means of knobbed cables, as the one shown in FIG. 19
In FIG. 20, there is illustrated a partial cross-section view of a retractable cover structure 150 according to the second preferred embodiment of the present invention. In this second preferred embodiment, have a curved lower cord 154 . The slotted rails 40 are mounted under the lower cords 154 of the trusses, for holding the flexible sheet sectors 38 under the trusses 152 . An edge plate 110 and rope lashing 108 are also used to retain each side edge of a retractable section of a sheet sector 38 to the trusses 152 over the launder portion 42 of a clarifier. In this embodiment, the space 156 between the maximum level of the clarifier and the cover is relatively small and therefore also relatively easy to ventilate. Moreover, the trusses 152 are kept outside the corrosive fumes that may be generated in some installations by the content of the clarifier.
It will be appreciated that the clarifier cover may comprise an inner flexible sheet as illustrated in FIG. 20, as well as an outer flexible sheet as described in the first preferred embodiment. This arrangement constitutes a third preferred embodiment 160 of the present invention, and is partly illustrated in FIG. 21 . This arrangement is advantageous for combining the characteristics of the first and second preferred embodiments. The space 162 between the inner sheet and the outer sheet can be used as an air space to insulate the content of the clarifier against heat losses for example, or by circulating fresh air therein to prevent over-heating of the clarifier content from the sun's rays.
Where a flexible sheet sector 38 is hung under the trusses of a support structure, such as illustrated in FIGS. 20 and 21, and the structure of the clarifier cover is compatible to the joining of two or more flexible sheet sectors into a single sheet panel, an alternative to the slotted rail 40 may be used. Referring to FIG. 22, two or more flexible sheet sectors 38 may be joined to form a single sheet panel 164 that is hung to a slotted pipe 166 affixed to the lower cord 154 of a truss. In this mounting, a strip of fabric 168 is wrapped and sewn over a rope, a flexible cord, a rubber hose 170 or the like, and bent outwardly to form opposite flaps 172 . The flaps are bonded or otherwise affixed to the sheet panel 164 . The covered rope, cord or hose 170 is inserted in the slotted pipe 166 . The flexible sheet panel is thereby removable from the trusses if the need arises.
Where the material of the slotted pipe is different from the material of the truss and welding is not appropriate to affix the slotted pipe to the truss, the slotted pipe 166 may be affixed to the truss with self-tapping screws 174 , rivets or other similar fasteners, as shown in FIGS. 23 and 24. When a power tool is used to install the fasteners, the slot 176 may have an enlarged region 178 at each fastener to accommodate for the tip of the power tool.
As can be seen from the illustration in FIG. 23, the slotted pipe 166 can be affixed to the truss in any position, such as alongside one of the cord 154 of the truss. This arrangement is a preferred alternative to the slotted rail 40 , to retain the flexible sheet sectors to both handrails or to the floor joists of a catwalk 104 for example.
In a fourth preferred embodiment 180 of the present invention, the retractable section 182 of the cover is disposed along a vertical wall of a raised-roof clarifier cover. This arrangement is advantageous for obtaining access to large equipment near the perimeter of a clarifier, or to let an excavator or other machinery reach inside the cover support structure.
Referring now to FIGS. 25 and 26, the principal features of the clarifier cover according to the fourth preferred embodiment are illustrated therein. The flexible sheet sectors extending over the roof trusses 184 are held to the trusses in slotted rails 40 as previously explained. The retractable section 182 of the cover is detachably held to the wall columns 186 by rope lashings 108 extending through edge plates 110 also as previously described. The retractable section 182 is held in a closed mode by pullers 48 and is rollable upwardly over a winding roll 44 .
In this embodiment, a rounded cornice 190 is mounted to the roof trusses 184 and defines an eave 192 under the roof trusses 184 . In this embodiment, the roof portion 188 of the cover is not continuous with the retractable section 182 . The retractable section 182 is anchored to the rounded cornice 190 and hangs down along the wall columns 186 . The roof portion 188 extends down just enough to wrap around the rounded cornice 190 , and carries at its lower edge one or more lengths of roof-stretching pipe 194 . These lengths of roof-stretching pipe 194 and the roof portion 188 are pulled around the rounded cornice 190 by a series of pullers 146 mounted to the cover support structure. The pullers' cables 130 extend through the retractable section 182 and are attached to the lengths of pipe 194 , in keyhole slots through the pipe walls as previously explained.
The working of the pullers 146 causes the pipes 194 to simultaneously stretch the roof portion 188 and pull the upper portion of the retractable section 182 inside the eave 192 , to define a soft and a drip edge of that eave. This arrangement is advantageous for allowing rainwater 196 to drip away from the edge plates 110 , and falling snow to accumulate away from the wall columns 186 .
A removable cover according to one of the preferred embodiments mounted over a clarifier, has been found to be resistant, durable and sufficiently strong to permit one of more workers to walk thereon for the purpose of fixing it if the need arises.
As to other manners of construction, installation and operation of the present invention, the same should be apparent from the above description and accompanying drawings and accordingly further discussion relative to these aspects would be considered redundant and is not provided. It will also be appreciated that many changes and modifications may be made to the illustrated and described embodiments without departing from the essence of this invention. Therefore, the above description and illustrations should not be construed as limiting the scope of the invention which is defined by the appended claims.
|
The clarifier cover has a shape defined by a low profile circular segment of revolution around the central column of the clarifier, for maintaining the volume of gas thereunder minimum. In another aspect, the support structure of the cover is made of a plurality of ring trusses disposed in a circular array and defining a circle, concentric with the circular wall of the clarifier, and a radial array of outer trusses each having an outside end mounted to the wall of the clarifier and an inside end mounted to the plurality of ring trusses. A series of inner trusses are individually affixed in an overhung mode to one of the outer trusses, such that the loading applied to the central column of a clarifier by the cover structure is minimal or negligible. The trusses define an array of triangular frame sectors. A flexible sheet sector affixed to each frame sector, and at least one of the flexible sheet sectors has a retractable section which is removably affixed to one of the triangular frame sectors and to the clarifier wall.
| 8
|
BACKGROUND OF THE INVENTION
The present invention relates to the determination of the equivalence of two blocks of assignment statements, such as those used in computer programs. The invention provides a method and computer system for carrying out such a determination and also to a computer program product including a computer readable medium having recorded thereon a computer program for performing such determination.
An assignment statement assigns the value of an expression, the right-hand side of the statement, to a variable at the left-hand side of the statement The two sides of the statement are connected by an assignment operator, which in many programming languages (including C and C++) is the equals sign (=). Thus, an example of an assignment statement in a programming language such as C might be x=x+4. The interpretation of the assignment operator (=) in this statement is: take the current value of x (say, 3), add 4 to it and assign the result (7) to x as its new value. This operation is very different from the interpretation of the equal sign in algebra where the statement x=x+4 would be meaningless since in algebra it is used to express an equation and not an assignment. In some programming languages the assignment operator is given the symbol (:=) to avoid confusion between the assignment and equation.
The present invention has for its object, a technique which is specifically relevant to the determination of whether or not two blocks of assignment statements are equivalent. By way of example, such a technique is useful in realising intermediate steps in program verification, program proving, and compiler initiated optimisation of source code. Expressed mathematically, the objective is as follows:
Given, (1) a set of input variables {x 1 , x 2 , . . . x m } and a set of output variables {x k , x k +1, . . . x n } with an overlap of variables in the two sets given by the set {x k , x k+1 , . . . x m } if k≦m, and (2) two blocks of assignment statements B 1 and B 2 where B 1 comprises the set of assignments { 1 S 1 , 1 S 2 , . . . 1 S M } and B 2 comprises the set of assignments { 2 S 1 , 2 S 2 , . . . 2 S N }, determine if the two blocks B 1 and B 2 provide equivalent computations for the output variables.
The term equivalent computation here means that the values for the output variables {x k , x k+1 , . . . , x n } produced by B 1 are identical to those produced by B 2 given the input variables {x 1 , x 2 , . . . , x m } even if the sets { 1 S 1 , 1 S 2 , . . . 1 S M } and { 2 S 1 , 2 S 2 , . . . , 2 S N ) are not identical. For example, given the input variables {x 1 , x 2 , x 3 } and output variables {x 2 , x 3 , x 4 }, block B 1 might comprise the assignment statements:
x 5 =x 1
x 6 =3 *x 2
x 3 =x 1 +3 *x 2
x 1 =x 1 +x 2 +x 2
x 2 =2
x 1 =x 1
x 4 =x 5 +x 6
while block B 2 comprises the statements:
x 1 =x 1 +2 *x 2
x 3 =x 1 +x 2
x 4 =x 3
x 2 =2
Inspection will reveal that, in either case, the output variables {x 2 , x 3 , x 4 } will produce the same computed values.
SUMMARY OF THE INVENTION
The invention provides a computer implemented method for determining, in a computer environment, the equivalence, if any, of two blocks of assignment statements in a computer program, for use in compiler optimisation of source code, program verification, program proving, and like computing tasks, said method comprising the steps of:
(a) forming, for each block of assignment statements, a corresponding array, each array comprising a plurality of elements corresponding to respective ones of the statements and populating the elements with attributes of the statements including the expression at the right-hand side of the statement;
(b) processing, in each array, each assignment statement in turn, in the order from the last statement to the first, the processing comprising the inspection of each unprocessed assignment statement in turn, in the order from the last unprocessed assignment statement to the first, to determine if the variable appearing on the left-hand side of the unprocessed assignment statement appears on the right-hand side of the assignment statement being processed;
(c) during step (b), in each array, if the variable appearing on the left-hand side of the unprocessed assignment statement also appears on the right-hand side of the assignment statement being processed, replacing all occurrences of such variable on the right-hand side of the assignment statement being processed, non-recursively, by the right-hand side of the said unprocessed assignment statement;
(d) forming, from each array, a corresponding new block of assignment statements comprising the statements processed according to steps (b) and (c) less any statements which, after processing, is either an identity (the left and right sides of the statement are identical) or whose left-hand side variable is not one of the output variables;
(e) creating, from each new block of assignment statements, a corresponding new array, each array comprising a plurality of elements corresponding to respective ones of the statements and populating the elements with attributes of the statements including the expression at the right-hand side of the statement;
(f) sorting, in each new array, the array elements in alphabetical order using the output variable name as the key.
(g) comparing the arrays to detect the equivalence of two blocks of assignment statements.
The method, inter alia, successfully eliminates, from a block of assignment statements, all intermediate variables and statements which are identities and also those which are irrelevant to the computation of the output variables and brings the block to a form suitable for comparing two or more blocks of assignment statements.
The invention also provides an apparatus adapted to determine, in a computer environment, the equivalence, if any, of two blocks of assignment statements in a computer program, for use in compiler optimisation of source code, program verification, program proving, and like computing tasks, said apparatus comprising:
(a) forming means for forming, for each block of assignment statements, a corresponding array, each array comprising a plurality of elements corresponding to respective ones of the statements and populating the elements with attributes of the statements including the expression at the right-hand side of the statement;
(b) processing means for processing, in each array, each assignment statement in turn, in the order from the last statement to the first, the processing comprising the inspection of each unprocessed assignment statement in turn, in the order from the last unprocessed assignment statement to the first, to determine if the variable appearing on the left-hand side of the unprocessed assignment statement appears on the right-hand side of the assignment statement being processed;
(c) during step (b), in each array, if the variable appearing on the left-hand side of the unprocessed assignment statement also appears on the right-hand side of the assignment statement being processed, replacement means for replacing all occurrences of such variable on the right-hand side of the assignment statement being processed, non-recursively, by the right-hand side of the said unprocessed assignment statement;
(d) forming means for forming, from each array, a corresponding new block of assignment statements comprising the statements processed according to steps (b) and (c) less any statements which, after processing, is either an identity (the left and right sides of the statement are identical) or whose left-hand side variable is not one of the output variables;
(e) creation means for creating, from each new block of assignment statements, a corresponding new array, each array comprising a plurality of elements corresponding to respective ones of the statements and populating the elements with attributes of the statements including the expression at the right-hand side of the statement;
(f) sorting means for sorting, in each new array, the array, elements in alphabetical order using the output variable name as the key.
(g) comparison means for comparing the arrays to detect the equivalence of two blocks of assignment statements.
The invention further provides a computer program product including a computer readable medium having recorded thereon a computer program for determining, in a computer environment, the equivalence, if any, of two blocks of assignment statements in a computer program, for use in compiler optimisation of source code, program verification, program proving, and like computing tasks, said program comprising:
(a) forming process steps for forming, for each block of assignment statements, a corresponding array, each array comprising a plurality of elements corresponding to respective ones of the statements and populating the elements with attributes of the statements including the expression at the right-hand side of the statement;
(b) processing steps for processing, in each array, each assignment statement in turn, in the order from the last statement to the first, the processing comprising the inspection of each unprocessed assignment statement in turn, in the order from the last unprocessed assignment statement to the first, to determine if the variable appearing on the left-hand side of the unprocessed assignment statement appears on the right-hand side of the assignment statement being processed;
(c) during step (b), in each array, if the variable appearing on the left-hand side of the unprocessed assignment statement also appears on the right-hand side of the assignment statement being processed, replacement steps for replacing all occurrences of such variable on the right-hand side of the assignment statement being processed, non-recursively, by the right-hand side of the said unprocessed assignment statement;
(d) forming process steps for forming, from each array, a corresponding new block of assignment statements comprising the statements processed according to steps (b) and (c) less any statements which, after processing, is either an identity (the left and right sides of the statement are identical) or whose left-hand side variable is not one of the output variables;
(e) creation process steps for creating, from each new block of assignment statements, a corresponding new array, each array comprising a plurality of elements corresponding to respective ones of the statements and populating the elements with attributes of the statements including the expression at the right-hand side of the statement;
(f) sorting process steps for sorting, in each new array, the array elements in alphabetical order using the output variable name as the key.
(g) comparison process steps for comparing the arrays to detect the equivalence of two blocks of assignment statements.
The present invention relates to determining if two syntactically correct blocks of assignment statements in a computer program are equivalent or not. Equivalence among more than two blocks of assignment statements may be determined by pair-wise comparison of the blocks.
Among its applications are compiler initiated optimisation of source code, where it is desirable to recognise multiple occurrences of blocks of assignment statements producing identical output so tat such blocks can be evaluated once, and the result used in all the remaining instances.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, reference will be made, by way of example, to the accompanying drawings, in which:
FIG. 1 is a simplified diagram of a computer system; and
FIGS. 2 and 3 are flow-charts for explaining the method of the invention.
DETAILED DESCRIPTION
The invention includes a method for determining the equivalence of two blocks of assignment statements such as might be found in a computer program The method may be implemented as a program for a computer, and the program may be stored on a storage medium, for example a CD-ROM, to form a program product according to the invention. Alternatively, a program product according to the invention may comprise a program made available for downloading from another computer. The computer program can be loaded into or made available to a suitable computer to form a computer system of the invention. FIG. 1 shows one embodiment of such a computer system.
This embodiment comprises a so-called stand-alone computer, i.e. one that is not permanently linked to a network. It includes a display monitor 2 , a keyboard 3 , a microprocessor-based central processing unit 4 a hard-disc drive 5 and a random access memory 6 all coupled one to another by a connection bus. The keyboard 3 is operable for enabling the user to enter commands into the computer along with user data. As well as keyboard 3 , the computer may comprise, a mouse or tracker ball (not shown) for entering user commands especially if the computer is controlled by an operating system with a graphical user interface.
To load program instructions into the memory 6 and/or store them on the disc drive 5 so that the computer begins to operate or to become operable in accordance with the present invention, the computer 1 comprises a CD-ROM drive 8 for receiving a CD-ROM 9 .
The program instructions are stored on the CD-ROM 9 from which they are read by the drive 8 . However, as will be well understood by those skilled in the art, the instructions as read by the drive 8 may not be usable directly from the CD-ROM 9 . Instead, they may be loaded into the memory 6 and stored in the hard disc drive 5 and used by the computer 1 from there. Also, the instructions may need to be decompressed from the CD-ROM using appropriate decompression software on the CD-ROM or in the memory 6 and may, in any case, be received and stored by the computer 1 in a sequence different to that in which they are stored on the CD-ROM.
In addition to the CD-ROM drive 8 , or instead of it any other suitable input means could be provided, for, example a floppy-disc drive or a tape drive or a wireless communication device, such as an infrared receiver (none of these devices being shown).
The computer 1 also comprises a telephone modem 10 through which the computer is able temporarily to link up to the Internet via telephone line 11 , a modem 12 located at the premises of an Internet service provider (ISP), and the ISP's computer 13 . Also connected to the Internet are many remote computers, such as the computer 14 , from which information, software and other services are available for downloading to the computer 1 . Furthermore, the computer 1 does not have to be in a stand-alone environment. Instead, it could form part of a network (not shown) along with other computers to which it is connected on a permanent basis. It could also be permanently coupled to or have a temporary link to an intranet. An intranet is a group of data holding sites similar to Internet sites and arranged in the same way as the Internet but accessible only to particular users, for example the employees of a particular company. Instead of modem 10 , the computer 1 could have a digital hard-wired link to the ISP's computer 13 or the computer 1 could itself comprise a permanently connected Internet site whether or not acting as an ISP for other remote users. Instead of the invention being usable only through the local keyboard 3 , it may be available to remote users working through a temporary or permanent link to computer 1 acting as ISP or simply as an Internet site.
Thus, instead of being provided by a local device such as the CD-ROM drive 8 , the program instructions could be received or made available via the Internet from a remote computer such as the computer 14 . Alternatively, the instructions could be received or made available from a computer connected with computer 1 via a network such as an intranet.
To carry out the method of the invention, the computer 1 is loaded with a suitable operating system, a compiler including a section for carrying out the method, or simply a specific utility for carrying out that method, and a section of source code which, it is assumed, contains the two sets of assignment statements of which the equivalence is to be determined. The compiler/utility is supplied to computer 1 from a portable storage medium such as a series of floppy discs (not shown) or a CD-ROM or from another computer such as the computer 14 .
The method will now be described by reference to the three flow charts of FIGS. 2 , 3 and 4 . The numbered “steps” noted herein correspond to the step numbers of the flow charts.
Referring first to FIG. 2 , the two sets of assignment statements are identified in the relevant source code and then, to facilitate the analysis, each assignment statement is now reduced to a standardised format according to a predetermined set of rules as follows:
Step 1: Make Variable Names Compliant
Initially, it is assumed that the statement is syntactically correct and does not contain any blanks. In the preferred embodiment, variable names appearing in the statement may comprise only lower-case alphabet characters, the underscore character, and digits. Also, a variable name may not start with a digit or end with an underscore. If these construction rules are not met, then the affected variable names are mapped (aliased) to alternative, but distinct, names obeying the construction rules, and these new names used instead. The right-hand side expression of the statement is then subjected to the following steps 2 to 12.
Step 2: Remove Brackets
Brackets, if present, in the expression must be removed by carrying out the necessary operations needed to remove them, such as multiplying two parenthesised factors, discarding superfluous brackets, and so on.
Step 3: Insert Leading Operator if None Present
The expression is put in the following form:
<unitary operator><operand><operator><operand> . . . <operator><operand>
where the unitary operator is either +(plus) or −(minus), and each operator is one of +(plus), −(minus), * (multiplication) or/(division). In the event that an expression does not commence with a unitary operator, one is added, i.e. a unitary operator +(plus) is inserted at the start of the expression. For example:
a*b/c becomes +a* b/c
Step 4: Map Division by Variable to Multiplication by Reciprocal of Variable
Division by a variable, for example, the operator operand pair /x, is replaced by multiplication by the reciprocal of the variable, where the reciprocal of the variable is formed as a new variable by appending an underscore to the variable, i.e. /x is replaced by *x_in the case of the given example.
Step 5: Map Division by Constant to Multiplication by Reciprocal of Constant
Division by a constant, for example /5, is replaced by multiplication by the reciprocal of the constant, i.e., /5 is replaced by *0.2 in the case of the given example.
Step 6: Replace “+” and “−” by Strings “+1*” and “−1*”
Next all +(plus) operators are substituted with the string “+1*” so that “+” becomes “+1*”. Similarly, all − (minus) operators are substituted with the string “−1*” so that “−” becomes “−1*”. Thus, for example:
+x becomes +1*x
and
−x*y+z becomes −1*x*y+1*z
Step 7: Convert Constants to E-Format
Next the operands, which are constants (including the 1's introduced in the previous step) are converted into an e-format as follows:
“.[unsigned number]e[e-sign][unsigned exponent]”
where: [unsigned number] is an n-digit number comprising only digits and n is a predetermined fixed integer greater than 0; [e-sign] is the sign of the exponent and is one of > for plus or < for minus; and [unsigned exponent] is an m-digit number comprising only digits and m is a predetermined fixed integer greater than 0.
Thus, for example:
25=0.25*10 2 becomes 0.250000e>02
and
0.025=0.25*10 −1 becomes 0.250000e<01
where we have assumed n=6 and m=2. It is noted that any constant will be represented by a string of constant length m+n+3 characters in the e-format. Here e[e-sign] [unsigned exponent] represents the quantity 10 raised to the power [e-sign] [unsigned exponent], which must be multiplied to the number represented by. [unsigned number] to get the actual constant.
Now, the expression is free of the division operator and will contain at least one operand which is a constant Each term in this expression will therefore have the following form:
<unitary operator><operand><*><operand> . . . <*><operand>
where the unitary operator is either +(plus) or −(minus), and between two consecutive operands is the multiplication operator *. After the terms are identified, the [e-sign] of each constant is restored from < or > to − or + respectively.
Step 8: Sort Operands in Each Term
In each term the operands are sorted (rearranged) in ascending order according to their ASCII value. This rearrangement is entirely permissible because the multiplication operator is commutative, i.e. the exchange of operands does not affect the result.
It is noted that no other variable will be able to place itself in the rearrangement between any particular variable and its reciprocal if they are both present. For example, if the variable “a” and its reciprocal “a 13 ” are both present, they will be sorted so as to remain together as “*a*a_”.
Step 9: Eliminate Variable/Reciprocal Pairs
In the next step, all operator-operand sequences of the form “*a*a_” are eliminated from the term. For example, the expression a 3 /a 2 will appear as “*a*a*a*a_*a_”. After “*a*a_” has been eliminated from it, “*a*a*a_” will remain, from which “*a*a_” must, again, be eliminated That is, the elimination process must be continued till no further elimination is possible.
Step 10: Consolidate Constants in Each Term
After sorting, the operands which are constants will be bunched up at the beginning of the terms where they can be easily identified and replaced by a single constant Thus, for example:
+0.100000e+01*s*k*m*s — *0.500000e+00
after arranging the operands in ascending order becomes
+0.100000e+01*0.500000e+00*k*m*s*s —
and after eliminating the units s and s_and consolidating the constants, the term becomes
+0.500000e+00*k*m
At this stage a term will have the following form:
<unitary operator><constant><* ><operand> . . . <*><operand>
where each operand is a variable name, whose ASCII value is not lower than that of its preceding operand, if any. This is the reduced form of a term. In the reduced form, the non-constant part of a term is called a variable-group. For example, if the term in the reduced form is “+0.250000e+01*m*m*s”, then its variable-group is “*m*m*s”.
Step11: Consolidate Like Terms
In an expression, all those terms whose variable-groups match, are combined by modifying the constant in one of the terms, and eliminating the others.
Step 12: Sort Terms in the Expression
Finally, the reduced terms in the expression are rearranged in an ascending order according to the ASCII value of their respective variable-groups. In this final form, the expression is said to be in its reduced form Note, in particular, that no two terms in a reduced expression will have the same variable-group.
Having obtained the reduced right-hand side expressions, the method continues by carrying out certain array processing operations as will be described. For convenience, conventions and data structures similar to those used in the C/C++ programming language have been used in the following part of the description. However, the invention is not specific to the C/C++ programming languages.
To extract certain attributes of an assignment statement S, expressed as v=e, there is defined a data structure D with elements v, e, p, d, u, nVars, tag. Here v is the variable appearing on the left-hand side of the statement; e is the right-hand side expression; p is the list of the variables appearing in e; d is the sublist of variables from p, which have appeared on the left-hand side of an earlier assignment statement; u is the list of; as yet, undefined variables in e; nVars is the number of variables (defined or undefined) appearing in p, and tag has the value −1 if the assignment is an identity, 0 if e is a constant value, 1 if v does not appear in p, 2 if v appears in p. In the programming language C/C++, the data structure could be expressed as:
struct_EQ_ATTRIBS{
char *v;
//lhs variable
char *e;
//rhs expression
char *p;
//list of rhs variables in equation
char *d;
//list of rhs variables defined by one or more previous
//assignments
char *u;
//list of undefined variables in rhs expression
int n Vars;
//number of variables in p
int tag;
//equation tag; −1 (identity), 0 (rhs = const),
1 (non-recursive),
//2(recursive)
} D;
Further, there is created from a given block of assignment statements B, an array of the structure _EQ_ATTRIBS, D, expressed in a standard form. A property of this standard form is that, for a given input variables set, if two blocks of assignment statements B 1 and B 2 produce identical expressions for corresponding output variables for the output variables set, then they will also produce a common D.
Referring now to FIG. 3 in turn, the array processing operations comprise the following steps:
Step 13. If M is the total number of statements in B, create the empty array D of dimension M. Let the i-th element of D be given by D[i] = (v i , e i , p i , d i , u i , nVars i , tag i ).
Step 14. For every S i in B, determine its attributes. Let D[i] contain the attributes of S i . Note that a variable is undefined in S i if it does not appear in either the input variables set or as a left-hand side variable in any previous assignment statement. All such undefined variables ate placed in the element u i of D[i]. Then arrange the variables in the lists p i and d i in ascending order according to the ASCII value of the variables, placing only a comma between variables to separate them from each other. This is done to facilitate comparisons between similar entities by means of string comparison.
Step 15. For every S i in B, determine if it is an identity (its tag value will be −1). If it is an identity, mark the statement for elimination from B (say, by emptying the contents of D[i]).
Step 16. For every S i in B, check if it has one or more undefined variables.(i.e. its u i is non-empty). If such a statement is found, terminate the algorithm with the message that the block of statements B has one or more undefined variables along with the list of the undefined variables collected in u i , for each of the statements in B.
Step 17. Begin with the last statement S M in B and move up to the first statement S i . For every S i , check if its d i is non-empty. If it is non-empty define an index j. Begin with j =i−1(with j>1) and go backwards to j=1. For each v j appearing in S i , replace v j by its corresponding e j . Note that this is a string replacement and to carry it out with semantic correctness e j must be enclosed within the parentheses “( )”. That is, replace the string, which represents v, with the string “(e j )” where e j is the string representation of the right-hand side of S j . Further, after the replacement, ensure that if v j reappears in “(e j )”, it is left untouched (since it would belong to the left-hand side of a still earlier assignment statement). This is easily done, for example, by scanning from left to right the expression e i and after every replacement of v j moving the pointer to the right of ‘)’ of “(e j )”. This ensures that any v j appearing in the assignment now will be correctly replaced by its corresponding e j as we go up the index j towards 1. After operation with j=1 is completed, mark S i for deletion if it reduces to an identity after the replacements are completed, otherwise empty out p i , d i , u i , nVars i , tag i (if not already empty) since they are no longer relevant. Step 17 is a crucial step, and will need to be coded carefully. The right-hand sides of the statements remaining will contain only the input variables and those output variables, which have appeared on the left-hand side of a previous assignment statement.
Step 18. Renumber the statements in B, skipping all statements marked for deletion but otherwise maintaining their sequence. Let these be S i to S r . (Note: r≠M, if identities were found in steps 15 and 17. The number of identities found will be M−r). Define a current output variables list and copy the variables in the output variables set into it. Begin with j=r and move backwards to j=1. For every S j , check if its v j is in the current output variables list. If it is, retain the statement in B and delete the variable v. from the current output variables list. If it is not, mark the statement for deletion from B by emptying out its entries in D[j]. Note that at the end of this step all intermediate variables (i.e. variables, which are neither input variables nor output variables) would have been eliminated from B. So would also statements which do not contribute to the computation of the output variables set.
Step 19. If, at the end of step 18, the current output variables list is not empty, terminate the algorithm with the message that some output variables have not been calculated and list those variables (these will be the variables remaining in the current output variables list). Otherwise move to step 20.
Step 20. At this stage, the number of assignment statements left in B will be equal to the number of variables (n−k+1) in the output variables set. Destroy B. Recreate the assignment statements of a new B, in the sequence they appear in D (skipping those which were marked for deletion in step 18), by concatenating the strings v, e, and the character ‘=’ in the form ‘v=e’. Destroy D. Construct a new D for the (n−k+1) assignment statements.
Step 21. Rearrange the (n−k+1) data structures in D in alphabetical order using v as the key. This is the final standard form of D for the original set of the assignment statements.
If two blocks of assignment statements B 1 and B 2 each produces the same D, then their output variables will obviously produce the same values of execution.
The algorithm as described above eliminates, from a block of assignment statements, all intermediate variables and statements which are identities and also those which are irrelevant to the computation of the output variables. It retains only those statements, which assign final values to the output variables. Since the attributes of each of the statements (contents and it's hierarchical position in B) is preserved in the array D, each element D[i] is self-contained and can be read in any order. Therefore D can be sorted as a list and put into a desired standard form.
As an example of the operation of the algorithm, the first block of assignment statements mentioned in the background section of this specification are used, namely:
x 5 =x 1
x 6 =3* x 2
x 3 =x 1 +3* x 2
x 1 =x 1 +x 2 +x 2
x 2 =2
x 1 =x 1
x 4 =x 5 +x 6
To this, the steps of the algorithms are applied as shown below:
Each statement is reduced according to steps 1 to 12. For illustration, one statement, namely x 3 =x 1 +3*x 2 , will be reduced.
Step 1
To make variables compliant, they are mapped to x 3 , x 1 and x 2 respectively. The right-hand side of the statement, ie x 1 +3*x 2 is then subject to rules 2 to 12.
Step 2
There are no brackets.
Step 3
A leading operator is added to give +x 1 +3*x 2 .
Steps 4 and 5
There are no division operators.
Step 6
Plus and minus operators are replaced by “+1 *” and “−1*” to give +1 *x 1 +1*3*x 2 .
Step 7
Put constants in e-format
+0.100000 e> 01 *x 1 +0.100000 e> 01*0.300000 e> 01 * x 2
Thus, the expression has two terms +0.10000e>01*x 1 and +0.100000e>01*0.300000e>01*x 2 . Having identified the two terms, the e-signs of the constants are restored to give +0.10000e+01*x 1 and +0.100000e>+01 *0.300000e+01*x 2 .
Steps 8 to 10
The operands are already sorted in each term and there are no variable/reciprocal pairs. However, the constant operands of the second term can be consolidated to give +0.300000e+01*x 2 .
Steps 11 and 12
The variable groups of the respective terms do not match. In fact, each variable group contains just one variable, namely of x 1 and x 2 respectively. Thus, the reduced form of the statement is:
x 3=+0.100000 e +01 *x 1+0.300000 e +01 *x 2 .
Steps 13-15
Note that M=7. At the end of step 15 the array D has the following entries
D[ 1 ]={“x 5 ”, “+0.100000e+01,*x 1 ”, “x 1 ”, “”, “”, 1, 1}
D[ 2 ]={“x 6 ”, “+0.300000e+01*x 2 ”, “x 2 ”, “”,“”, 1, 1}
D[ 3 ]={“x 3 ”, “+0.100000e+01*x 1 +0.300000e+01*x 2 ”, “x 1 , x 2 ”, “”, “”, 2, 1}
D[ 4 ]={“x 1 ”, “+0.100000e+01*x 1 +0.200000e+01*x 2 , “x 1 , x 2 ”, “”, “”, 2, 1}
D[ 5 ]={“x 2 ”, “+0.200000e+01 ”, “”, “”, “”, 0, 0}
D[ 6 ]={“x 1 ”, “+0.100000e+01*x 1 ”, “x 1 ”, “x 1 ”, “”, 1, −1} (see note)
D[ 7 ]={“x 4 ”, “+0.100000e+01*x 5 +0.100000e+01*x 6 ”, “x 5 , x 6 ”, “x 5 , x 6 ”, “”, 2, 1}
Note that the contents of D[ 6 ] just prior to marking it for elimination are shown here for illustration. Since its tag =−1, it refers to an identity statement, which must be eliminated in a later step.
Step 16
No action since no undefined variables were found.
Step 17
At the end of step 17, the array D has the following entries:
D[ 1 ]={“x 5 ”, “+0.100000e+01*x 1 ”, “”, “”, “”, ,}
D[ 2 ]={“x 6 ”, “+0.300000e+01*x 2 ”, “”, “”, “”, ,}
D[ 3 ]={“x 3 ”, “+0.100000e+01*x 1 +0.300000e+01*x 2 ”, “”, “”, “”, ,}
D[ 4 ]={“x 1 ”, “+0.100000e+01*x 1 +0.200000e+01*x 2 ”, “”, “”, “”, ,}
D[ 5 ]={“x 2 ”, “+0.200000e+01”, “”, “”, “”, , }
D[ 6 ]={“”, “”, “”, “”, “”, , }
D[ 7 ]={“x 4 ”, “+0.100000e+01*x 1 +0.300000e+01*x 2 ”, “”, “”, “”, ,}
Notice that the intermediate variables x 5 , and x 6 have been eliminated from the right-hand sides of the statements. No new identities were found at the end of this step, and r=6.
Step 18
The current output variables list at the beginning of step 18 is “x 2 , x 3 , x 4 ”. At the end of step 18, the array D has the following entries:
D[ 1 ]={“”, “”, “”, “”, “”, ,}
D[ 2 ]={“”, “”, “”, “”, “”, ,}
D[ 3 ]={“x 3 ”, “+0.100000e+01*x 1 +0.300000e+01*x 2 ”, “”, “”, “”, }
D[ 4 ]={“”, “”, “”, “”, “”, ,}
D[ 5 ]={“x 2 ”, “+0.200000e+01”, “”, “”, “”, , }
D[ 6 ]={“x 4 ”, “+0.100000e+01*x 1 +0.300000e+01*x 2 ”, “”, “”, “”, ,}
and the current output variables list is empty. Notice that only the output variables x 2 , x 3 , x 4 appear on the left-hand side of the statements (the v i , element of D[i]), and the right-hand sides (the e i element of D[i]) contain only defined input and output variables.
Step 19
The current output variables list is found to be empty. Move to step 20.
Step 20
The number of statements left in B are 3 (same as the number of output variables) corresponding to x 2 , x 3 , x 4 . Reconstruct them to produce the new B.
S[ 1 ]=“x 3 =+0.100000e+01*x 1 +0.300000e+01*x 2 ”
S[ 2 ]=“x 2 =+0.200000e+01”
S[ 3 ]=“x 4 =+0.100000e+01*x 1 +0.300000e+01*x 2 ”
The new D is given by
D[ 1 ]={“x 3 ”, “+0.100000e+01*x 1 +0.300000e+01*x 2 ”, “x 1 , x 2 ”, “x 2 ”, “”, 2, 1}
D[ 2 ]={“x 2 ”, “+0.200000e+01”, “”, “”, “”, 0, 0}
D[ 3 ]={“x 4 ”, “+0.100000e+01*x 1 +0.300000e+01*x 2 ”, “x 1 , x 2 ”, “x 2 ”, “”, 2, 1}
Step 21
The rearranged (sorted on v) D is given by
D[ 1 ]={“x 2 ”, “+0.200000e+01”, “”, “”, “”, 0, 0}
D[ 2 ]={“x 3 ”, “+0.100000e+01*x 1 +0.300000e+01*x 2 ”, “x 1 , x 2 ”, “x 2 ”, “”, 2, 1}
D[ 3 ]={“x 3 ”, +0.100000e+01*x 1 +0.300000e+01*x 2 ”, “x 1 , x 2 ”, “x 2 ”, “”, 2, 1]
Step 22
After repeating steps 1 to 21 for the second block of statements, namely,
x 1 =x 1 +2 *x 2
x 3 =x 1 +x 2
x 4 =x 3
x 2 =2
A final D for the second block is found to be
D[ 1 ]={“x 2 ”, “+0.200000e+01”, “”, “”, “”, 0, 0}
D[ 2 ]={“x 3 ”, “+0.100000e+01*x 1 +0.300000e+01*x 2 ”, “x 1 , x 2 ”, “x 2 ”, “”, 2, 1}
D[ 3 ]={“x 4 ”, “+0.100000e+01*x 1 +0.300000e+01*x 2 ”, “x 1 , x 2 ”, “x 2 ”, “”, 2, 1}
The two final arrays D are compared and, as may be seen are identical.
The algorithm described here provides a means for determining if two blocks of assignment statements are equivalent or not. The applications of such an algorithm are, among others, in program verification, program proving, and compiler initiated optimization of source code.
It will be emphasised that the invention is not limited to the specific embodiment described above but includes modifications and developments within the purview of those skilled in the art and limited only by the following claims.
|
The present invention discloses a method for determining, in a computer environment, the equivalence, if any, of two blocks of assignment statements in a computer program for use in compiler optimization of source code, program verification, program proving, and like computing tasks. The method, inter alia, successfully eliminates, from a block of assignment statements, all intermediate variables and statements which are identities and also those which are irrelevant to the computation of the output variables and brings the block to a form suitable for comparing two or more blocks of assignment statements. A system for carrying out the above method and a computer program product incorporating the method are also disclosed.
| 6
|
This application is a Divisional of U.S. patent application Ser. No. 10/373,384, filed Feb. 24, 2003 now abandoned.
FIELD OF THE INVENTION
This invention relates to pneumatic tires having a carcass and a belt reinforcing structure, more particularly to high speed heavy load radial ply tires such as those used on aircraft.
BACKGROUND OF THE INVENTION
Pneumatic tires for high speed applications experience a high degree of flexure in the crown area of the tire as the tire enters and leaves the contact patch. This problem is particularly exacerbated on aircraft tires wherein the tires can reach speed of over 200 mph at takeoff and landing.
When a tire spins at very high speeds the crown area tends to grow in dimension due to the high angular accelerations and velocity tending to pull the tread area radially outwardly. Counteracting these forces is the load of the vehicle which is only supported in the small area of the tire known as the contact patch.
In U.S. Pat. No. 5,427,167, Jun Watanabe of Bridgestone Corporation suggested that the use of a large number of belt plies piled on top of one another was prone to cracks inside the belt layers which tended to grow outwardly causing a cut peel off and scattering of the belt and the tread during running. Therefore, such a belt ply is not used for airplanes. Watanabe found that zigzag belt layers could be piled onto the radially inner belt layers if the cord angles progressively increased from the inner belt layers toward the outer belt layers. In other words the radially inner belt plies contained cords extending substantially in a zigzag path at a cord angle A of 5 degrees to 15 degrees in the circumferential direction with respect to the equatorial plane while being bent at both sides or lateral edges of the ply. Each of the outer belt plies contains cords having a cord angle B larger than the cord angle A of the radially inner belt plies.
In one embodiment each of the side end portions between adjoining two inner belt plies is provided with a further extra laminated portion of the strip continuously extending in the circumferential direction and if the radially inner belt plies have four or more in number then these extra laminated portions are piled one upon another in the radial direction. The inventor Watanabe noted the circumferential rigidity in the vicinity of the side end of each ply or the tread end can be locally increased so that the radial growth in the vicinity of the tread end portion during running at high speed can be reduced.
SUMMARY OF THE INVENTION
A pneumatic tire having a carcass and a belt reinforcing structure wherein the belt reinforcing structure is a composite belt structure having at least one pair of radially outer zigzag layers and at least one spirally wound belt layer with cords inclined at an inclination of 5 degrees or less relative to the tire's centerplane and located radially inward of and adjacent to the at least two radially outer zigzag belt layers.
The at least two radially outer zigzag belt layers have cords inclined at 5 degrees to 30 degrees relative to the tire's centerplane and extending in alternation to turnaround points at each lateral edge of the belt layer. At each turnaround point the cords are folded or preferably bent to change direction across the crown of the carcass thus forming a zigzag cord path.
In a preferred embodiment at least two radially inner zigzag belt layers are positioned between the carcass and the at least one spirally wound belt layer. Each of the radially inner zigzag belt layers has cords wound at an inclination of 5 degrees to 30 degrees relative to the centerplane of the tire and extending in alternation to turnaround points at each lateral edge of the belt layers.
The cords of the at least two radially inner spirally wound belt layers are wound from a single cord or from a group of 2 to 20 cords which continuously extend to form spirally wound belt layer and the at least two radially outer belt layers.
Alternatively, the cords of the spirally wound belt layer in a single cord or a group of 2 to 20 cords may be continuously wound to form the at least two radially outer belt layers.
As described above the tire should have three belt layers, preferably five, as a minimum as measured at the tire's center.
The tire is well suited for high speeds and large loads such as found in aircraft tires.
DEFINITIONS
“Apex” means a non-reinforced elastomer positioned radially above a bead core.
“Aspect ratio” of the tire means the ratio of its section height (SH) to its section width (SW) multiplied by 100% for expression as a percentage.
“Axial” and “axially” mean lines or directions that are parallel to the axis of rotation of the tire.
“Bead” means that part of the tire comprising an annular tensile member wrapped by ply cords and shaped, with or without other reinforcement elements such as flippers, chippers, apexes, toe guards and chafers, to fit the design rim.
“Cut belt or cut breaker reinforcing structure” means at least two cut layers of plies of parallel cords, woven or unwoven, underlying the tread, unanchored to the bead, and having both left and right cord angles in the range from 10 degrees to 33 degrees with respect to the equatorial plane of the tire.
“Bias ply tire” means a tire having a carcass with reinforcing cords in the carcass ply extending diagonally across the tire from bead core to bead core at about a 25°-50° angle with respect to the equatorial plane of the tire. Cords run at opposite angles in alternate layers.
“Carcass” means the tire structure apart from the belt structure, tread, undertread, and sidewall rubber over the plies, but including the beads.
“Circumferential” means lines or directions extending along the perimeter of the surface of the annular tread perpendicular to the axial direction.
“Chafers” refer to narrow strips of material placed around the outside of the bead to protect cord plies from the rim, distribute flexing above the rim, and to seal the tire.
“Chippers” mean a reinforcement structure located in the bead portion of the tire.
“Cord” means one of the reinforcement strands of which the plies in the tire are comprised.
“Equatorial plane (EP)” means the plane perpendicular to the tire's axis of rotation and passing through the center of its tread.
“Flipper” means a reinforced fabric wrapped about the bead core and apex.
“Footprint” means the contact patch or area of contact of the tire tread with a flat surface at zero speed and under normal load and pressure.
“Innerliner” means the layer or layers of elastomer or other material that form the inside surface of a tubeless tire and that contain the inflating fluid within the tire.
“Net-to-gross ratio” means the ratio of the tire tread rubber that makes contact with the road surface while in the footprint, divided by the area of the tread in the footprint, including non-contacting portions such as grooves.
“Nominal rim diameter” means the average diameter of the rim flange at the location where the bead portion of the tire seats.
“Normal inflation pressure” refers to the specific design inflation pressure and load assigned by the appropriate standards organization for the service condition for the tire.
“Normal load” refers to the specific design inflation pressure and load assigned by the appropriate standards organization for the service condition for the tire.
“Ply” means a continuous layer of rubber-coated parallel cords.
“Radial” and “radially” mean directions radially toward or away from the axis of rotation of the tire.
“Radial-ply tire” means a belted or circumferentially-restricted pneumatic tire in which the ply cords which extend from bead to bead are laid at cord angles between 65° and 90° with respect to the equatorial plane of the tire.
“Section height” (SH) means the radial distance from the nominal rim diameter to the outer diameter of the tire at its equatorial plane.
“Zigzag belt reinforcing structure” means at least two layers of cords or a ribbon of parallel cords having 2 to 20 cords in each ribbon and laid up in an alternating pattern extending at an angle between 5° and 30° between lateral edges of the belt layers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 us a schematically section view of a first embodiment of the tire according to the invention;
FIG. 2 is a partially cutaway top view of the tire shown in FIG. 1 ;
FIG. 3 is a schematically perspective view of an inner or outer zigzag belt layer in the middle of the formation;
FIG. 4 is a schematically developed view of the inner or outer zigzag belt layers In the middle of the formation;
FIG. 5 is an enlargedly developed view of the inner or outer zigzag belt layers in the vicinity of the side end of the ply in the middle of the formation;
FIG. 6 is an enlargedly developed view of another embodiment of the inner belt layer in the vicinity of the side end of the ply in the middle of the formation;
FIG. 7 is a schematically enlarged section view of the composite belt layers in the vicinity of side end portions of these plies;
FIG. 8 is a schematically developed view of the inner layer located at an outmost side;
FIG. 9 is a schematically enlarged section view of another embodiment of plural inner belt plies in the vicinity of side end portions of these plies;
FIG. 10 is a lateral force graph for tire B according to the invention and for two comparative tires A and C.
DETAILED DESCRIPTION OF THE INVENTION
In FIGS. 1 and 2 , numeral 21 is a radial tire of the preferred embodiment of the invention, as shown, to be mounted onto an airplane, which comprises a pair of bead portions 23 each containing a bead core 22 embedded therein, a sidewall portion 24 extending substantially outward from each of the bead portions 23 in the radial direction of the tire, and a tread portion 25 of substantially cylindrical shape extending between radially outer ends of these sidewall portions 24 . Furthermore, the tire 21 is reinforced with a carcass 31 toroidially extending from one of the bead portions 23 to the other bead portion 23 . The carcass 31 is comprised of at least two carcass plies 32 , e.g. six carcass plies 32 in the illustrated embodiment. Among these carcass plies 32 , four inner plies are wound around the bead core 22 from inside of the tire toward outside thereof to form turnup portions, while two outer plies are extended downward to the bead core 22 along the outside of the turnup portion of the inner carcass ply 32 . Each of these carcass plies 32 contains many nylon cords 33 such as nylon-6,6 cords extending substantially perpendicular to an equatorial plane E of the tire (i.e. extending in the radial direction of the tire). A tread rubber 36 is arranged on the outside of the carcass 31 in the radial direction.
A belt 40 is arranged between the carcass 31 and the tread rubber 36 and is comprised of plural inner belt plies or layers 41 located near the carcass 31 , i.e. two radially inner belt layers 41 in the illustrated embodiment and plural radially outer belt layers 42 located near to the tread rubber 36 , i.e. two radially outer belt layers 42 in the illustrated embodiment. As shown in FIGS. 3 and 8 , each of the radially inner belt plies 41 is formed by providing a rubberized strip 43 of one or more cords 46 , winding the strip 43 generally in the circumferential direction while being inclined to extend between side ends or lateral edges 44 and 45 of the layer forming a zigzag path and conducting such a winding many times while the strip 43 is shifted at approximately a width of the strip in the circumferential direction so as not to form a gap between the adjoining strips 43 . As a result, the cords 46 extend substantially zigzag in the circumferential direction while changing the bending direction at a turnaround point at both ends 44 , 45 and are substantially uniformly embedded in the first inner belt layer 41 over a full region of the first inner belt layer 41 . Moreover, it is intended to form the radially inner belt layer 41 by the above method, the cords 46 lie one upon another, so that two first and second inner belt layers 41 are formed while crossing the cords 46 of these plies with each other. Similarly the radially outer belt layers 42 are made using the same method. Interposed between the inner layers 41 and outer layers 42 is at least one spirally wound layer 39 of cords 46 , the cords being wound at an angle of plus or minus 5 degrees or less relative to the circumferential direction.
In the pneumatic radial tire for airplanes, there are various sizes, the tire illustrated is a 42×17.0R18 with a 26 ply rating and the tire 21 has the belt composite reinforcing structure as shown in FIG. 9 . As shown the tire of FIG. 9 has two inner zigzag layers 41 and three spiral layers 39 and two outer zigzag layers 42 . In any such tire size, the cords 46 of the inner belt plies 41 cross with each other at a cord angle A of 5 degrees to 15 degrees with respect to the equatorial plane of the tire when the strip 43 is reciprocated at least once between both side ends 44 and 45 of the ply within every 360 degrees of the circumference as mentioned above.
In the illustrated embodiment, the widths of the inner belt layers 41 become narrower as the ply 41 is formed outward in the radial direction or approaches toward the tread rubber 36 . Further, when the inner belt layers 41 is formed by winding the rubberized strip 43 containing plural cords 46 arranged in parallel with each other as mentioned above, a period for forming the ply layer 41 can be shortened and also the cord 46 arrangement can be made accurate. However, the strip 43 is bent at the side ends 44 , 45 of the ply with a small radius of curvature R as shown in FIG. 5 , so that a large compressive strain is produced in a cord 46 located at innermost side of the curvature R in the strip 43 to remain as a residual strain. When the cord 46 is nylon cord, if the compressive strain exceeds 25%, there is a fear of promoting the cord fatigue. However, when a ratio of R/W (R is a radius of curvature (mm) of the strip 43 at the side ends 44 , 45 of the layer, and W is a width of the strip 43 ) is not less than 2.0 as shown in FIG. 6 , the compressive strain produced in the cord 46 can be controlled to not exceed 25%. Therefore, when the inner belt layer 41 is formed by using the rubberized strip 43 containing plural nylon cords 46 therein, it is preferable that the value of R/W is not less than 2.0. In addition to the case where the strip 43 is bent at both side ends 44 , 45 of the ply in form of an arc as shown in FIG. 5 , the strip 43 may have a straight portion extending along the side end 44 ( 45 ) and an arc portion located at each end of the straight portion as shown in FIG. 6 . Even in the latter case, it is favorable that the value of R/W in the arc portion is not less than 2.0. Furthermore, when the strip 43 is wound while being bent with a given radius of curvature R at both side ends 44 , 45 of the ply, a zone 47 of a bent triangle formed by overlapping three strips 43 with each other at a half width of the strip as shown in FIG. 7 is repeatedly created in these bent portions or in the vicinity of both side ends 44 , 45 of the ply in the circumferential direction as shown in FIG. 5 . These two strips 43 are usually overlapped with each other by each forming operation. The width changes in accordance with the position in the circumferential direction continuously in the circumferential direction. Moreover, these laminated bent portions 47 turn inward in the axial direction as they are formed outward in the radial direction as shown in FIG. 7 because the widths of the inner belt layers 41 become narrower toward the outside in the radial direction as previously mentioned. In the bent portion 47 , the outer end in widthwise direction of the middle strip 43 c sandwiched between upper and lower strips 43 a and 43 b overlaps with the zone 47 located inward from the middle strip 43 c in the radial direction as shown in FIG. 7 . When the belt 40 is constructed with these inner belt layers 41 , the total number of belt layers or plies can be decreased while maintaining total strength but reducing the weight and also the occurrence of standing wave during the running at high speed can be prevented.
The middle layers 39 of the composite belt structure 40 are spirally wound around the radially inner belt layers 41 . As shown in FIG. 7 the spirally wound layer 39 extends completely across the two radially inner belt layers 41 and ends at 39 a just inside the end 41 a . The cords 46 within each strip 39 extend at an angle of 5 degrees or less relative to the circumferential equatorial plane. As shown four cords are in each strip. In practice the strips 41 , 39 , and 42 could be wound using a single cord 46 or plural cords 46 in a strip or ribbon having plural cords in the range of 2 to 20 cords within each strip. In the exemplary tire 21 of the size 42×17.0R18 strips 43 having 8 cords per strip 42 were used. The strips 43 had a width W, W being 0.5 inches. It is believed preferable that the strip width W should be 1.0 inch or less to facilitate bending to form the zigzag paths of the inner and outer layers 41 , 42 .
In the most preferred embodiment the layers 41 , 39 , and 42 are all formed from a continuous strip 43 that simply forms the at least two radially zigzag layers 41 and then continues to form the at least one spirally wound layer 39 and then continues on to form the at least two radially outer layers 42 . Alternatively, the spirally wound layers 39 could be formed as a separate layer from a strip 43 . This alternative method of construction permits the cords 46 to be of different size or even of different materials from the zigzag layers 41 and 42 . What is believed to be the most important aspect of the invention is the circumferential layer 39 by being placed between the zigzag layers 41 and 42 greatly reduces the circumferential growth of the tire 21 in not only the belt edges 44 , 45 but in particular the crown area of the tread 36 . The spirally wound circumferential layer 39 , by resisting growth in the crown area of the tire, greatly reduces the cut propensity due to foreign object damage and also reduces tread cracking under the grooves. This means the tire's high speed durability is greatly enhanced and its load carrying capacity is even greater. Aircraft tires using multiple layers of only zigzag ribbons on radial plied carcasses showed excellent lateral cornering forces. This is a common problem of radial tires using spiral layers in combination with cut belt layers which show poor cornering or lateral force characteristics. Unfortunately, using all zigzag layered belt layers have poor load and durability issues that are inferior to the more conventional spiral belt layers in combination with cut belt layers.
The present invention has greatly improved the durability of the zigzag type belt construction while achieving very good lateral force characteristics as illustrated in FIG. 10 . The all zigzag belted tire A is slightly better than the tire B of the present invention which is shown better than the spiral belt with a combination of cut belt layers of tire C in terms of lateral forces. Nevertheless the all zigzag belted tire A cannot carry the required double overloads at inflation whereas the tire B of the present invention easily meets these load requirements.
The tire of the present invention may have a nylon overlay 50 directly below the tread. This overlay 50 is used to assist in retreading.
|
A pneumatic tire having a carcass and a belt reinforcing structure wherein the belt reinforcing structure is a composite belt structure having at least one pair of radially outer zigzag layers and at least one spirally wound belt layer with cords inclined at an inclination of 5 degrees or less relative to the tire's centerplane and located radially inward of and adjacent to the at least two radially outer belt layers. The at least two radially outer zigzag belt layers have cords inclined at 5 degrees to 30 degrees relative to the tire's centerplane and extending in alternation to turnaround points at each lateral edge of the belt layer. At each turnaround point the cords are folded or preferably bent to change direction across the crown of the carcass thus forming a zigzag cord path.
| 1
|
TECHNICAL FIELD
[0001] This disclosure relates to a three-dimension fabric suitable to be used for an object supporting surface such as a backrest and seating surface, having a three-dimension shape of an object supporting tool such as a chair.
BACKGROUND
[0002] There has been a body supporting tool such as an office chair and car seat, which supports a body with a cushioned body supporting surface such as a backrest and seating surface. Other than the body supporting tool, even an object supporting tool is sometimes required to have a cushioned object supporting surface to support a three-dimension object like a body. Such a cushioned object supporting surface often comprises a core member such as a metal frame, a foamed elastic member such as urethane foam, and an elastic body which covers them.
[0003] Recently, a well cushioned chair provided with a body supporting surface made of knitted or woven fabric mesh sheet instead of inner urethane foam is commercially available, and new product designs are appearing (See JP2007-117537-A and JP2006-132047-A). JP2007-117537-A discloses a chair having a backrest made of a sheet member having a saclike periphery through which a bone of a core member is inserted for a support JP2006-132047-A discloses a chair provided with a seating surface of a warp-knitted fabric manufactured by a double raschel warp knitting machine. The warp-knitted fabric is cushioned with the inserted weft made of elastic yarns. In both publications, only one kind of each fabric structure and each yarn is disclosed.
[0004] If a mesh sheet is used and the metal frame is made planar rectangle, the object supporting surface becomes planar, too. However, the object such as a body to be supported with the object supporting surface has a three-dimensional shape. The planar object supporting surface, even if well cushioned, tends to elastically deform greatly to support a prominent portion of an object such as a body so that a great reaction force is continuously generated to be applied to the body at the supporting portion. It is important for chairs to be comfortable that the elasticity, which means the initial tension, is adjusted properly at each portion by making the supporting surface fit to the shape of the contact surface of the object to be supported.
[0005] In the techniques disclosed in the above-described patent documents, hard work to assemble intricately-shaped frames and mesh fabrics under a high tension condition is required to optimize shape and elasticity of the supporting surface.
[0006] Accordingly, it could be helpful to provide a three-dimension fabric which can be used to make a desirable structure easily and of which object supporting surface can be easily shaped and elasticized at each portion, even if intricately-shaped frames are not used.
[0007] Besides, it is not a good solution that different materials and different fabrics are assembled by sewing or bonding at each portion on a supporting body. Namely, such a solution is not practical because of the high cost as well as the difficulty in sewing or bonding the mesh sheets.
SUMMARY
[0008] We thus provide a three-dimension fabric for forming a three-dimension fabric surface by being stretched while an edge part of the fabric is supported with a frame member, characterized in that the fabric that forms the fabric surface includes at least one heterogeneous portion of which yarn and/or fabric structure is different from an adjacent portion.
[0009] In the three-dimension fabric, it is possible that the heterogeneous portion and the adjacent portion are formed in three-dimensional shapes different from each other. For example, the heterogeneous portion and the adjacent portion are formed in three-dimensional shapes different from each other by a difference of a shrink and/or tension between the heterogeneous portion and the adjacent portion. Specifically, the heterogeneous portion and the adjacent portion are formed in three-dimensional shapes having curved surface different from each other.
[0010] When the three-dimension fabric surface is formed by stretching, it is possible that the edge part of the fabric having a shape along the frame member is supported with the frame member, or that the edge part of the fabric having a notch part corresponding to a shape of the frame member is supported with the frame member. The notch part may have a curved shape as shown in an example described later. In both configurations of the three-dimension fabric, it is possible that the heterogeneous portion and the adjacent portion are formed in three-dimensional shapes different to each other by a difference of a shrink and/or tension.
[0011] To form the fabric surface into a desirable three-dimensional shape, it is possible that the fabric stretched with frame member is heated to shrink and form a three-dimensional shape different from the one before heated. We provide a preferable method such as a heat shrinkage method. Namely, it is preferable that the fabric includes portions different from each other by at least 5% in a dry-heat shrinkage, which is defined by determining at least two unheated square cut pieces of fabric portions with a side as long as at least 5 times of a diameter of a main fiber having at least 50% proportion by weight among fibers included in the fabric to form each portion, at 160° C. in warp and weft directions.
[0012] It is possible that the fabric includes at least one heterogeneous portion of which yarn and/or fabric structure is different from an adjacent portion and that the heterogeneous portion and the adjacent portion are formed in three-dimensional shapes different from each other, as described above. Alternatively, either with or without forming the three-dimensional shapes different from each other, it is possible that the heterogeneous portion and the adjacent portion are formed to have a different characteristic from each other. Namely, it is possible that the fabric includes said at least one heterogeneous portion of which yarn and/or fabric structure is different from the adjacent portion, to form portions having at least one characteristic different from each other among elasticity, air permeability and texture.
[0013] Thus, in our three-dimension fabric, the fabric surface as forming the object supporting surface can be configured to change the yarn or fabric structure according to each portion and to utilize the difference of the shrinkage generated by applying the heat set at a temperature corresponding to materials while the fabric is set in the frame member. Thus, even if an intricately-shaped frame is not used, a three-dimensional shape such as a curved surface to fit a contact surface of an object to be supported and desirable characteristics such as elasticity can be easily achieved by simple methods.
[0014] It is possible that one portion is configured to have a shrinkage and tension in the warp direction much greater than that in the weft direction to form a flat surface connecting two portions adjacent in the warp direction. In reverse, it is possible that one portion is configured to have a shrinkage and tension in the weft direction much greater than that in the warp direction to form a flat surface connecting two portions adjacent in the weft direction. Though a misalignment in the normal direction may be generated by the positional relation of the two portions adjacent along the warp direction and the two portions adjacent along the weft direction, a curved surface connecting the four adjacent portions can be formed if the shrinkage and tension in the warp and weft directions are well balanced in the center. As a result, a desirable curved surface can be formed at a target portion differently from the periphery in the whole fabric surface and, therefore, a three-dimension fabric surface having desirable curved surface portions can be formed easily without sewing and bonding the fabric per se, as preventing the above-described difficult assembly.
[0015] Fibers included in the fabric are not specifically limited. If the three-dimension fabric surface is required to have a certain elasticity, etc., it is preferable that a main fiber having at least 50% proportion by weight among fibers included in the fabric to form each portion is made of an elastomer polyester. Natural fiber as well as synthetic fibers can be used and in particular, a polyester fiber or a polyamide fiber is suitably used.
[0016] The fabric can be either a woven fabric or a knitted fabric as a fabric structure to form a desirable three-dimension fabric surface. The above-described differences of shrinkage and tension in the warp and weft directions at each portion can be achieved by changing the yarn and fabric structure which are included in the fabric. Concretely, the differences can be achieved by designing to make each portion such as weft-knitted by shaping or jacquard.
[0017] The knitted fabric may even be a warp-knitted fabric though the weft-knitted fabric is preferable for the knitting. The weft-knitted structure may be a plain stitch (with the face stitch knitting), garter structure with the alternate face and purl stitch knitting along the warp direction), smooth structure (with the alternate knit and welt) or a rib structure (with the alternate face and purl stitch knitting along the weft direction).
[0018] The knitted structure can be combined with the welt and tuck knitting to decrease the number of stitches in the longitudinal direction, so as to increase the longitudinal tension. A lesser number of stitches comparison to the periphery makes the tension increase. Even if the number of stitches does not change, the garter structure can increase the longitudinal tension and the rib structure can increase the lateral tension.
[0019] In knitting each portion, the elasticity characteristics differ depending on flat knitting machines and its gauges, as well as materials and thicknesses of the yarn. The knitting method can be selected or designed based on desired characteristics at each portion.
[0020] The three-dimension fabric is applicable to everything required to form a desirable three-dimension fabric surface without sewing and bonding, and is suitable to a backrest and seating surface of chairs.
[0021] The three-dimension fabric makes it possible that the supporting surface is improved to have a target desirable three-dimensional shape by a simple assembly even without a frame of complicated shape. Therefore, an object supporting surface having desirable curved surfaces can easily be achieved. Further, the functional design becomes greatly flexible so that the object to be supported can be made to locally sink or supported by the surface without sinking. Furthermore, the elasticity, air permeability and texture at each portion can be changed to be given the optimum function at each portion. Also, because the color and drape can be changed, the design can be given an added value easily.
BRIEF EXPLANATION OF THE DRAWINGS
[0022] FIG. 1 shows a frame member of a three-dimension fabric according to an example, where (A) is an elevation view, (B) is a to view, and (C) is a side view.
[0023] FIG. 2 shows a three-dimension fabric according to Example 1, where (A) is an elevation view, (B) is a top view, and (C) is a side view.
[0024] FIG. 3 shows a three-dimension fabric according to Comparative Example 1, where (A) is an elevation view, (B) is a top view, and (C) is a side view.
[0025] FIG. 4 shows a three-dimension fabric according to Comparative Example 2, where (A) is an elevation view, (B) is a top view, and (C) is a side view.
[0026] FIG. 5 is an elevation view of a three-dimension fabric before being set in a frame according to Example 2.
[0027] FIG. 6 shows the three-dimension fabric according to Example 2 of the present invention, where (A) is an elevation view, (B) is a top view, and (C) is a side view.
[0028] FIG. 7 is an elevation view of a three-dimension fabric before being set in a frame according to Example 3.
[0029] FIG. 8 shows the three-dimension fabric according to Example 3 of the present invention, where (A) is an elevation view, (B) is a top view, and (C) is a side view.
EXPLANATION OF SYMBOLS
[0030] 1 : frame member
[0031] 2 , 3 , 4 , 6 , 8 : three-dimension fabric
[0032] 5 , 7 : fabric before being set in frame
[0033] 9 a , 9 b , 9 c : notch
[0034] i-iv: portion
DETAILED DESCRIPTION
[0035] Hereinafter, examples of our fabrics will be explained as referring to the figures.
[0036] FIG. 1 shows an example of a frame member, which is the one used in the Examples and Comparative Examples to be described, of a three-dimension fabric according to an example of our fabric. In this example, frame member 1 is made of metal and sufficiently rigid, and can alternatively be made of plastic. Frame member 1 has a rectangular shape as shown in FIG. 1 (A) as the elevation view, and its both sides comprise linear bodies 1 a which extend linearly. The top and bottom sides comprise linear bodies 1 b which bend with curvature radius R as shown in FIG. 1 (B) as the top view, and the distance between the top and bottom sides has been set to L as shown in FIG. 1 (C) as the side view. Besides, symbols of A, B. C and ( 1 ), ( 2 ), ( 3 ) respectively illustrate vertical and horizontal positions of frame member 1 , to help explaining shapes of three-dimension fabrics in the Examples and Comparative Examples to be described.
EXAMPLES
Example 1
[0037] FIG. 2 shows elevation view (A), top view (B) and side view (C) of three-dimension fabric 2 according to Example 1, where the fabric is stretched while the edge parts are supported by frame member 1 and heated to shrink at each portions to form a three-dimension fabric surface having desirable curved surface portions without sewing and bonding. In this Example, four kinds of fabric structures are included in one fabric surface such as an object supporting surface.
[0038] The three-dimension fabric in this Example is a knitted fabric made by a flat knitting machine having front and rear needle beds, such as “NSSG (registered trademark)” of Shima Seiki Mfg., Ltd. The three-dimension fabric may be made of thermal adhesive elastic yarn such as “Hytrel (Registered trademark)”.
[0039] Portion i constituting the object supporting surface is knitted by a face stitch, and heated after stretching to achieve elasticity characteristics being uniform in longitudinal and lateral directions.
[0040] Portion ii is knitted by a smooth structure with alternate knit and welt. Such a smooth structure can reduce the number of stitches in a longitudinal direction to half relative to peripheral portion i, so that even the number of stitches per unit area is reduced to half relative to portion i in a condition where the fabric is stretched while supported by the frame member and then the longitudinal tension is increased. Alternatively, the smooth structure can be replaced by a garter structure which shrinks in a longitudinal direction.
[0041] At portion iii, the peripheral shape is round and anelastic structure is formed inside. In this Example, such an anelastic structure is a combination of knit and tuck, and can be a combination of knit and welt alternatively. In these structures, the tuck and welt can suppress the stretching. Inside portion iii, a structure which is very elastic in longitudinal and lateral directions has been formed by combining the garter structure and rib structure.
[0042] Portion iv is formed to shrink greatly in a lateral direction by the rib structure. The rib structure is made with a face stitch knitting and a purl stitch knitting, which are repeatedly organized along the lateral direction with respect to each predetermined number. In this Example, they are organized with 2×2 rib structure. Characteristics of such a rib structure increase the tension in the lateral direction in spite of the same number of stitches as the peripheral portion i. To make the tension desirable, 1×1 rib structure or 3×3 rib structure may be selected.
[0043] Thus, the combination of portions ii, iii and iv having fabric structures different from portion i achieves a supporting surface (fabric surface) having a complex curved surface with different shapes at each portion as shown in FIGS. 2 (B) and (C). At portion iii, there is a local subduction different from the peripheral portion.
Comparative Example 1
[0044] FIG. 3 shows elevation view (A), top view (B) and side view (C) of three-dimension fabric 3 in Comparative Example 1 which is shown for comparison to Example 1, where the fabric surface constituting an object supporting surface is made mainly of a fabric which is organized with the warp uniformly positioned to shrink the fabric surface greatly in the warp direction. It remains semicylindrical along frame member 1 . Even coefficients of elasticity are not greatly different depending on portions. Therefore, it is difficult to form a complex curved surface with different shapes at each portion as well as a fabric surface with different characteristics at each portion.
Comparative Example 2
[0045] FIG. 4 shows elevation view (A), top view (B) and side view (C) of three-dimension fabric 4 in Comparative Example 2 which is shown for comparison to Example 1, where the fabric surface constituting an object supporting surface is made mainly of a fabric which is organized with the weft uniformly positioned to shrink the fabric surface greatly in the welt direction. The fabric surface is made symmetric in the warp and weft directions though more or less curved than the semicylindrical shape along frame member 1 . Therefore, it is difficult to form a complex curved surface with different shapes at each portion as well as a fabric surface with different characteristics at each portion.
Example 2
[0046] FIG. 5 and FIG. 6 show a three-dimension fabric according to Example 2. Fabric 5 before being set in the frame is shown in FIG. 5 as an elevation view. Three-dimension fabric 6 stretched by frame member 1 to have a complex curved surface is shown in FIG. 6 with elevation view (A), top view (B) and side view (C). Fabric 5 before being set in the frame is configured to make width a and longitudinal direction length b satisfy relations of a<Rπ and b<L. Fabric 5 is stretched while the edge parts are supported by frame member 1 , which is larger than the fabric before being set in the frame, by utilizing the stretch characteristics to form a surface of the three-dimension fabric having a mixture of desirable curved surface portions without sewing and bonding.
[0047] In this Example, the same kind of warp and weft yarns which is uniformly woven or knitted is stretched and then extended to generate a uniform stretch tension in the warp and weft directions at portion i (with uniform stretch in the warp and weft directions) of three-dimension fabric 6 . At portion ii (with smaller warp stretch and greater weft stretch), the stretch in the warp direction is much smaller than the one in the weft direction so that the tension is applied greatly in the warp direction. At portion iv (with greater warp stretch and smaller waft stretch), the stretch in the weft direction is much smaller than the one in the warp direction so that the tension is applied greatly in the weft direction. At portion iii (with peripheral stretch=0, inner stretch=local maximum), the periphery in which anelastic fibers are knitted by a high density is round and the inner fabric portion is made highly elastic. Thus, the combination of portions ii, iii and iv which are made of yarns different from portion i achieves a supporting surface (fabric surface) having a complex curved surface with different shapes at each portion as shown in FIG. 6 (B) and (C), like Example 1. At portion iii, there is a local subduction different from the peripheral portion. Specifically in this Example, the difference of yarn types makes the fabric structures different at each portion to make the warp and weft stretch stresses different from portion i.
Example 3
[0048] FIG. 7 and FIG. 8 show a three-dimension fabric according to Example 3. Fabric 7 before being set in the frame is shown in FIG. 7 as an elevation view. Three-dimension fabric 8 stretched by frame member 1 to have a complex curved surface is shown in FIG. 8 with elevation view (A), top view (B) and side view (C). Fabric 7 before being set in the frame is configured to make width a and longitudinal direction length b satisfy relations of a=Rπ and b=L. In this Example, fabric 7 before being set in the frame is provided with semicircular notches 9 a, 9 b and 9 c to a shape along frame member 1 . Fabric 7 is stretched while the edge parts are supported by frame member 1 as the notch parts generate the local stretch stress along a flat frame to form a surface of the three-dimension fabric having a mixture of desirable curved surface portions without sewing and bonding.
[0049] In this Example, the same kind of warp and weft yarns is uniformly woven or knitted, stretched and then heated to shrink uniformly in the warp and weft directions so that the tension is applied uniformly at portion i (with uniform stretch in the warp and weft directions). At portion ii (with peripheral stretch=0, inner stretch=local maximum), the periphery in which anelastic fibers are knitted by a high density is round and the inner fabric portion is made highly elastic. Thus, portion ii made of different yarns and fabric structures is combined with portion i while fabric 7 before being set in the frame is provided with notches 9 a, 9 b and 9 c to achieve a supporting surface (fabric surface) having a complex curved surface with different shapes at each portion as shown in FIG. 8 (B) and (C), like Examples 1 and 2. In position C, notches 9 b and 9 c contributed a local subduction different from the peripheral portion.
INDUSTRIAL APPLICATIONS
[0050] The three-dimension fabric is applicable to everything required to easily form a desirable three-dimension fabric surface, and is suitable for a supporting surface of a body supporting tool such as office chairs and car seats.
|
A three-dimension fabric by which a three-dimension fabric surface can be formed by supporting the fabric edges by a frame member and stretching the fabric, wherein the fabric per se, which constitutes the fabric surface, is provided with at least one heterogeneous portion that is different at least in yarn type and/or fabric structure type from the adjacent portion. Thus, the three-dimension fabric can be easily made into a construct of a desirable shape without using a frame having a complicated shape.
| 3
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to submersible pump installations for wells and to a safety system which maintains the well under control. The invention also relates to a novel system to direct control fluid to the safety valve used in the safety system.
2. Description of the Prior Art
In some hydrocarbon producing formations, sufficient reservoir pressure may be present to cause formation fluids to flow to the well surface. However, the hydrocarbon flow resulting from the natural reservoir pressure may be significantly lower than the desired flow. For these types of wells, electrically powered submersible pumps are sometimes installed to achieve the desired hydrocarbon flow rate. Submersible pumps can be used to raise various liquids to the well surface. Examples of prior art submersible pump and safety valve installations are shown in U.S. Pat. Nos. 3,853,430; 4,121,659; 4,128,127 and 4,134,454. Copending U.S. Pat. Application Ser. No. 186,980 filed Sept. 15, 1980 also discloses an improved safety system for use with submersible pumps. The preceding patents and patent application are incorporated by reference for all purposes within this application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view partially in longitudinal section and partially in elevation showing a typical well completion with a submersible pump and the safety system of the present invention.
FIG. 2 is an enlarged drawing in longitudinal section with portions broken away showing the engagement between the pump seating mandrel and the pump landing nipple of FIG. 1.
FIGS. 3A-K are drawings partially in section and partially in elevation showing the submersible pump and safety system of FIG. 1 disposed within a tubing string. The safety system is shown in its first or closed position blocking fluid flow through the tubing string.
FIGS. 4A-D are drawings in longitudinal section with portions broken away showing the safety system of FIG. 1 in its second or open position allowing fluid flow through the tubing string.
FIG. 5 is an enlarged drawing in longitudinal section with portions broken away showing a swivel connector means adapted for use with the submersible pump and safety system of FIG. 1.
FIG. 6 is a drawing in elevation with portions broken away taken along line 171 of FIG. 5.
FIG. 7 is a drawing in horizontal section with portions broken away taken along line 7--7 of FIG. 5.
FIG. 8 is a drawing in horizontal section taken along line 8--8 of FIG. 3H.
FIG. 9 is a drawing in horizontal section taken along line 9--9 of FIG. 3D.
FIG. 10 is a drawing in horizontal section taken along line 10--10 of FIG. 3E.
SUMMARY OF THE INVENTION
The present invention discloses a safety system for a submersible pump disposed within a well flow conductor comprising a submersible pump having an intake and a discharge, means for mounting or installing the pump within the flow conductor at a preselected downhole location and for forming a fluid seal with the interior of the flow conductor to direct fluid flow through the pump, means for mounting or installing a subsurface safety valve within the flow conductor at a preselected downhole location below the submersible pump and for forming a seal between the exterior of the safety valve and the interior of the flow conductor, the safety valve having hydraulically actuated means for opening and closing the safety valve, a landing nipple with a main longitudinal bore therethrough comprising a portion of the flow conductor at a preselected downhole location, the landing nipple comprising a portion of the means for mounting the submersible pump and the safety valve within the flow conductor, a plurality of longitudinal flow passageways extending partially through the landing nipple and communicating with the main longitudinal bore at preselected locations, and at least one of the longitudinal flow passageways comprising means for conducting fluid pressure from the pump discharge to the hydraulically actuated means to open the safety valve.
One object of the invention is to provide a submersible pump installation having a safety system including a subsurface safety valve which is controlled by hydraulic pressure from the pump discharge.
Another object of the invention is to provide a landing nipple in which a submersible pump and a safety valve can be mounted or installed at a downhole location. The landing nipple includes longitudinal flow passageways, which are protected from mechanical damage, to communicate fluid pressure from the pump discharge to the safety valve.
A further object of the invention is to provide a submersible pump installation including a universal landing nipple in which various submersible pumps and safety valves can be mounted or installed.
A still further object of the invention is to provide swivel connectors which transmit torque from the submersible pump to the landing nipple to prevent rotation of the pump relative to the landing nipple when mounted therein. The swivel connectors are used to attach the pump to one or more accumulators and provide the required flexibility for installation and removal of the pump from the downhole location.
A significant advantage of the invention is that applicant's landing nipple, swivel connector means, and accumulator means allow selecting various commercially available pumps, pump locking mechanisms, and subsurface safety valves to design a completion best suited for the existing well conditions.
Additional objects and advantages of the invention will be readily apparent to those skilled in the art from reading the following description in conjunction with the drawings and claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A submersible pump installation and safety system incorporating the present invention are schematically illustrated in FIG. 1. Well 20 is partially defined by casing 21 which extends from wellhead 25 to producing formation 24. Tubing or well flow conductor 22 is disposed within casing 21 and extends downwardly from wellhead 25. Well packer 23 forms a fluid barier between tubing 22 and the interior of casing 21 to direct production fluid flow from formation 24 to the well surface via tubing 22. Valve 26 controls production fluid flow from wellhead 25 into surface flowline 27.
To increase production fluid flow, submersible pump P is shown installed within well flow conductor 22. Pump P is driven by electrical motor 28 to discharge formation fluids from outlets 29 into tubing 22. Accumulator means 30 are attached to and extend downwardly from pump inlet 32. Pump support means or seating mandrel 33 is attached to the lower accumulator means 30. The weight of pump P, motor 28, and accumulator means 30 is supported by the contact between seating mandrel 33 and well flow conductor 22 and partially by cable C. Cable C also supplies electrical power from the well surface to motor 28. Wellhead 25 includes packing means 34 which forms a fluid barier around cable C and prevents undesired fluid flow therepast. Pump P, motor 28, and cable C are commercially available from various companies. One such company is REDA Pump Division of TRW in Bartlesville, Okla.
Bore 43 extends longitudinally through pump inlet 32, swivel connector means 40, accumulator means 30, and pump seating mandrel 33. Bore 43 provides a flow path for formation fluids to enter pump P. Bore 43 is given an alphabetic designation within each component attached to pump P to aid in describing the invention. As shown in FIGS. 3A-3E, appropriately sized o-rings are included within each connection between the various components attached to pump P to prevent undesired fluid communication between bore 43 and the exterior of the components.
Safety valve S is releasable installed within well flow conductor 22 below submersible pump P. Safety valve S can be opened and closed to control the flow of well fluids into tubing 22 from producing formation 24. Pump P and its associated components are not directly attached to safety valve S. Therefore, pump P can be removed from its downhole location for maintenance and/or repair while safety valve S blocks undesired formation fluid flow through tubing 22 to the well surface. When the complete system is in operation, formation fluids flow into casing 21 through perforations 35. Packer 23 directs formation fluid flow into the lower end of tubing 22. Safety valve S in its second or open position allows formation fluids to flow upwardly through accumulator means 30 and inlet 32 into pump P. Formation fluids are then pumped to the well surface from discharge ports 29 via tubing 22.
Pump P is attached to pump inlet 32 by bolted connection 38 as shown in FIG. 3A. One advantage of the present invention is that various submersible pumps can be attached to inlet 32 and satifactorily installed within tubing 22. Bolted connection 39 is used to attach electrical motor 28 (not shown in FIG. 3A) to pump P.
The total length of the submersible pump installation including motor 28, pump P, accumulator means 30, and seating mandrel 33 requires the use of swivel connector means 40 between various components of the installation. Swivel connector means 40 compensate for deviations of tubing 22 while raising and lowering pump P and attached components. Swivel connector means 40 could also be classified as a flexible joint or articulated joint. Each swivel connector means 40 comprises a ball member 41 with tubular leg 42 extending longitudinally therefrom. One end of swivel cap 44 has concaved sealing surface 45 which abuts ball member 41. Sealing surface 45 has a radius compatible with the radius of ball member 41. O-ring 46 is carried in a groove in the exterior of ball member 41 to form a fluid seal with surface 45 as ball member 41 moves relative to cap 44. Bore 43 extends longitudinally through both ball member 41 and cap 44. Housing means 47 is fitted around ball member 41 and engaged by threads 48 to swivel cap 44. Tubular leg 42 extends through housing means 47. A pair of lugs 49 are positioned within holes 50 on opposite sides of ball member 41. A portion of each lug 49 extends radially from ball member 41 to provide keys 51. A pair of keyways 52 are machined diametrically opposite from each other through housing means 47. Keys 51 are sized to slide longitudinally with keyways 52 but prevent rotation of ball member 41 relative to housing means 47. Heavy duty set screws 53 are used to prevent rotation forces from loosening threads 48. For ease of manufacture and assembly, circular opening 52a is formed at one end of each keyway 52. The diameter of each opening 52a is selected to allow insertion of lug 49 therethrough and into its respective hole 50. Swivel connector means 40 allows longitudinal flexing, as shown in FIG. 5, of tubular leg 42 relative to swivel cap 44 in only one plane determined by the orientation of keys 51 and keyways 52. Thus, installing several swivel connector means 40 between the various components attached to pump P allows limited flexing of the components relative to each other while installing and retrieving pump P. However, swivel connector means 40 prevent rotation of the components attached thereto relative to each other.
Pump inlet 32 is attached to swivel cap 44 of its associated swivel connector means 40 by bolts 56. Adapter subassembly 57 is used to attach tubular leg 42 to the adjacent accumulator means 30. As shown in FIGS. 3B and 3C, swivel connector means 40 will allow accumulator means 30 and pump inlet 32 to flex relative to each other in one plane as determined by keys 51 and keyways 52. In the same manner, a swivel connector means 40 is preferably installed between each accumulator means 30 and the last accumulator means 30 and seating mandrel 33 as shown in FIGS. 3D and 3E.
When pump P is turned off, safety valve S will close. Accumulator means 30 communicate with pump inlet 32 to supply a reservoir of fluid to allow discharge pressure from pump P to open safety valve S when pump P is turned on. Swivel connector means 40 allows the attachment of as many accumulator means 30 as required for each submersible pump installation. In FIG. 1, two accumulator means 30 are shown. In FIGS. 3C and D only one accumulator means 30 is shown to simplify the description of the invention.
Each accumulator means 30 includes an outer cylinder 60 and an inner cylinder 61. The cylinders are relatively long with cylinder 61 concentrically disposed within cylinder 60. Annulus 67 is formed between cylinder 60 and 61. Bore 43e is partially defined by the inside diameter of cylinder 61. The upper end of cylinder 60 is engaged by threads 62 to the exterior of upper end closure 63. Seal means 64 are carried on the exterior of end closure 63 to prevent fluid communication between the interior and the exterior of outer cylinders 60. Inner cylinder 61 abuts shoulder 65 on the inside diameter of end closure 63. Seal means 66 are carried on the inside diameter of end closure 63 to prevent fluid communication at the upper end of accumulator means 30 between annulus 67 and bore 43e.
The lower end of cylinder 60 is engaged by thread 68 to the exterior of lower end closure 69. Seal means 70 are carried on the exterior of lower end closure 69 to prevent fluid communication between the interior and the exterior of outer cylinder 60. Inner cylinder 61 is positioned within enlarged inside diameter portion 71 of lower end closure 69. A plurality of openings 72 extend radially through inner cylinder 61 near the lower end thereof. Openings 72 allow fluid commuication between the annulus 67 and bore 43e. End closures 63 and 69 hold cylinders 60 and 61 concentrically aligned with each other.
Prior to lowering accumulator means 30 into flow conductor 22, all liquids are removed from annulus 67 and bore 43e. Thus, annulus 67 will contain air or an inert gas such as nitrogen if desired. As each accumulator means 30 is lowered through tubing 22, well liquids will enter bore 43 and flow through openings 72 into annulus 67. Seal means 64 and 66 cooperate to prevent the gas within annulus 67 from escaping out of the upper end of accumulator means 30. Thus, as well fluid pressure increases, more liquid will flow through openings 72 to compress the gas in the upper end of annulus 67. This compressed gas is used to discharge the liquid stored in annulus 67 back into bore 43e when pump P is started. Bolts 56 are used to attach each end of accumulator means 30 to the adjacent swivel connector means 40.
Seating mandrel 33 is attached to the lower accumulator means 30 by a swivel connector means 40. Seating mandrel 33 is a relatively short hollow cylinder with bore 43h extending therethrough. Anti-rotation ring 74 abuts shoulder 75 on the exterior of seating mandrel 33. Ring 74 is preferably shrunk fit to the exterior of seating mandrel 33. Ring 74 has teeth 76 which face downwardly therefrom. A similar anti-rotation ring 77 is shrunk fit into the inside diameter of landing nipple 80 and abuts shoulder 78 therein. Anti-rotation ring 77 has teeth which face upward and are sized to receive teeth 76 on ring 74. Thus, when seating mandrel 33 is lowered into landing nipple 80, the engagement between the teeth on anti-rotation rings 74 and 77 prevents rotation of seating mandrel 33 relative to landing nipple 80. The weight of pump P and the components attached thereto is transferred from shoulder 75 via rings 74 and 77 to shoulder 78.
Packing means 79 are carried on the exterior of seating mandrel 33 below anti-rotation ring 74. Packing means 79 are sized to form a fluid barrier with inside diameter 81 of landing nipple 80. Packing means 79 blocks fluid discharged from ports 29 from flowing downwardly through main bore 82 of landing nipple 80.
Various mechanisms other than anti-rotation rings 74 and 77 could be used to secure seating mandrel 33 within landing nipple 80. U.S. patent application Ser. No. 199,034 filed on Oct. 20, 1980 and U.S. Pat. No. 4,121,659 disclose such mechanisms. Another alternative anti-rotation mechanism (not shown in the drawings) would be to attach one or more bosses to the inside diameter of landing nipple 80 with the bosses projecting into bore 82. Suitable longitudinal slots could be machined partially through seating mandrel 33 to receive the bosses and prevent rotation of seating mandrel 33 relative to landing nipple 80.
Landing nipple 80 is attached by threads 140 and 141 to flow conductor 22 and forms an integral part thereof. For ease of manufacture and assembly, landing nipple 80 has an upper nipple section 80a and a lower nipple section 80b engaged to each other by threads 83. Bore 82 extends longitudinally through landing nipple 80 and communicates with flow conductor 22. A possible alternative embodiment of the present invention is to modify landing nipple 80 to be a part of casing string 21 and eliminate the use of tubing string 22.
As previously noted, landing nipple 80 carries anti-rotation ring 77 which is part of the means for installing pump P within flow conductor 22. A set of locking grooves 84 is machined in the interior of bore 82 in nipple section 80b below shoulder 78 to provide part of the means for installing safety valve S within landing nipple 80. U.S. Pat. No. 3,208,531 to J. W. Tamplen discloses a locking mandrel and running tool which can be used to install safety valve S within landing nipple 80.
Locking mandrel 90 carries dogs 91 which coact with grooves 84 to anchor safety valve S within bore 82. Packing means 92 are carried on the exterior of locking mandrel 90 to form a fluid barrier with the inside diameter of nipple section 80b when dogs 91 are secured within grooves 84. Equalizing assembly 93 is attached to locking mandrel 90 by threads 94. Packing means 95 are carried on the exterior of equalizing assembly 93 to form a fluid barrier with the inside diameter of nipple section 80b. Packing means 92 and 95 are spaced longitudinally from each other. Valve housing means 96 is engaged by threads 97 to equalizing assembly 93. Packing means 98 are carried on the exterior of housing means 96 to form a fluid barrier with the interior of nipple section 80b when dogs 91 are engaged with profile 84.
Safety valve S includes locking mandrel 90, equalizing assembly 93, valve housing means 96 and the valve components disposed therein. Bore 100 extends longitudinally through safety valve S. Packing means 92 and 98 cooperate to direct formation fluid flow through bore 100 and block fluid flow between the exterior of valve S and the interior of nipple 80. When the submersible pump installation is operating normally, formation fluids flow from perforation 35 into pump P via bore 100 in safety valve S, bore 82 in nipple 80 and bore 43 in the components attached to pump P.
Valve housing means 96 consists of several concentric, hollow sleeves which are connected by threads to each other. Each housing means subassembly has an alphabetic designation. Hydraulically actuated means 101 comprising operating sleeve 102 and piston 103 are slidably disposed within bore 100. Increasing fluid pressure in variable volume chamber 104 will cause operating sleeve 102 to slide longitudinally relative to housing means 96. Inner cylinder 105, which has two subsections designated 105a and 105b, of poppet valve means 106 abuts the extreme end of operating sleeve 102 at 107. Elastomeric seal 108 is carried on the exterior of inner cylinder 105 intermediate the ends thereof. Metal seating surface 109 is provided on the interior of housing means 96 facing elastomeric seal 108. A plurality of openings 110 extends radially through inner cylinder section 105a. Another plurality of openings 111 extends radially through housing subassembly 96c. When safety valve S is in its first position as shown in FIG. 3I, elastomeric seal 108 contacts metal seating surface 109 blocking fluid communication through openings 110 and 111. When operating sleeve 102 slides longitudinally in one direction, it will contact inner cylinder 105 and displace elastomeric seal 108 away from metal seating surface 109. This displacement allows fluid communication through openings 110 and 111 as shown in FIG. 4B. Spring 112 disposed between shoulder 113 on the exterior of inner cylinder section 105b and shoulder 114 of housing means 96 urges elastomeric seal 108 to contact metal seating surface 109.
Poppet valve means 106 is included within safety valve S because openings 110 and 111 have a large flow area as compared to bore 100. Also, poppet valve means 106 is easily pressure balanced so that less control pressure is required to displace elastomeric seal 108 away from metal seating surface 109 as compared to opening a ball type valve.
Ball valve means 117 is disposed within safety valve S below poppet valve means 106. Operating sleeve 118 of ball valve means 117 is spaced longitudinally away from inner cylinder section 105b when poppet valve means 106 is closed. When piston means 103 shifts poppet valve means 106 to its open position, inner cylinder section 105b will contact operating sleeve 118 to rotate ball 119 to align bore 150 of ball 119 with bore 100 as shown in FIG. 4C. Ball valve means 117 is open when bore 150 is aligned with bore 100. Ball valve means 117 is shut when bore 150 is rotated normal to bore 100. Spring 120 urges ball 119 to rotate to block bore 100 when fluid pressure is released from piston means 103.
Ball valve means 117 is a normally closed safety valve which is opened by inner cylinder section 105b of poppet valve means 106 contacting operating sleeve 118. Both poppet valve means 106 and ball valve means 117 operate in substantially the same manner as other surface controlled subsurface safety valves. Control fluid pressure is applied to piston means 103 to shift safety valve S to its second or open position. When control fluid pressure is released from piston means 103, springs 112 and 120 cooperate to return safety valve S to its first or closed position blocking fluid flow through bore 100. As will be explained later, control fluid pressure to piston means 103 is supplied from the discharge of pump P.
Since inner cylinder section 105b is spaced longitudinally from operating sleeve 118 when safety valve S is in its first position, poppet valve means 106 will open first when pump P is started. Well fluids will initially flow into bore 100 through openings 110 and 111 to equalize any pressure difference across ball 119 and to supply well fluids to pump inlet 32. Thus, accumulator means 30 must contain at least enough fluid to open poppet valve means 106. Also, equalizing the pressure difference across ball 119 prior to rotating ball 119 significantly reduces the force required to open ball valve means 117 and minimizes the possibility of damage to safety valve S. If desired, a flapper valve could be substituted for ball valve means 117. Co-pending U.S. patent application Ser. No. 186,980 filed on Sept. 15, 1980 fully explains the operation of safety valve S.
Landing nipple 80 directs a portion of the fluid discharged from pump P to variable volume chamber 104 via longitudinal flow passageways 84 and 85. Longitudinal flow passageways 84 and 85 are formed by machining longitudinal grooves partially into the exterior of landing nipple 80. Radial ports 88 extend through nipple 80 near the upper end of passageways 84 and 85 to communicate fluids between bore 82 and passageways 84 and 85. Ports 88 are positioned above the point at which packing means 79 forms a fluid barrier with inside diameter 81 of landing nipple 80. Thus, a portion of the fluid discharged from pump P can flow from pump discharge 29 to longitudinal flow passageways 84 and 85 via bore 82 and ports 88. Rods 125 are partially inserted into each longitudinal groove and are welded to landing nipple 80 to provide a fluid barrier between longitudinal flow passageways 84 and 85 and the exterior of nipple 80. This method of constructing flow passageways 84 and 85 results in a relatively uniform outside diameter and minimizes the possibility of mechanical damage which could block control fluid flow to safety valve S.
Radial port 89 extends through nipple 80 near the lower end of each longitudinal flow passageway 84 and 85. Ports 89 are positioned to communicate fluid with bore 82 between packing means 95 and 98 on the exterior of safety valve S. A plurality of ports 126 extends from variable volume chamber 104 through valve housing means 96 adjacent to radial ports 89. The longitudinal flow passageways 84 and 85 comprise a portion of the means for conducting fluid pressure from pump discharge outlets 29 to hydraulically actuated means 101 to open safety valve S.
From studying the previous description and related drawings, it is readily apparent that the present invention allows a wide variety of subsurface safety valves to be used with the submersible pump installation. The minimum dimensional requirement for selecting an alternative safety valve is that when the valve is attached to threads 94 of locking mandrel 90, packing means must be positioned on opposite sides of radial ports 89 to direct control fluid flow to the safety valve's hydraulically actuated means. The minimum operational requirement for the alternative valve is that the relatively low discharge pressure from pump P can open the safety valve.
Equalizing assembly 93 is positioned within safety valve S between locking mandrel 90 and valve housing means 96. Equalizing assembly 93 provides means for selectively equalizing fluid pressure between bore 100 and the exterior of safety valve S while installing and removing safety valve S from bore 82 of landing nipple 80. A plurality of aperture 130 extend radially through equalizing assembly 93. Sliding sleeve 131 with a pair of o-ring seals 132 carried on its exterior is disposed within equalizing assembly 93. O-ring seals 132 are spaced from each other so that when sleeve 131 is in its first or upper position, o-ring seals 132 will straddle apertures 130 blocking fluid flow therethrough. Collet fingers 133 are carried by sleeve 131 to engage groove 134 and hold sleeve 131 in its first position. Various wireline tools are commercially available which can be lowered from the well surface through tubing 22, after pump P has been removed, to shift sleeve 131 to either open or block apertures 130.
Longitudinal flow passageways 86 and 87 are provided in the exterior of landing nipple 80 to communicate well fluids from below landing nipple 80 to equalizing assembly 93. Radial ports 135 extend from bore 82 through nipple 80 to the upper end of longitudinal flow passageways 86 and 87. Radial ports 135 are positioned adjacent to apertures 130 between packing means 92 and 95. Therefore, control fluid or pump discharge fluid is blocked by packing means 95 from communicating with longitudinal flow passageways 86 and 87. Rods 125 are used to seal longitudinal flow passageways 86 and 87 in the same manner as previously described for longitudinal flow passageways 84 and 85. The lower end of longitudinal flow passageways 86 and 87 communicates with bore 82 below packing means 98 through openings 145.
OPERATING SEQUENCE
Landing nipple 80 is installed within tubing 22 at the preselected downhole location using conventional well completion techniques. Safety valve S is lowered through tubing string 22 with equalizing assembly 93 open until locking mandrel 90 is engaged with locking grooves 84. Equalizing assembly 93 is then shut. Safety valve S would be in its first position blocking fluid flow from perforations 35 to the well surface via tubing 22. Spring 112 holds poppet valve means 106 shut, and spring 120 holds ball valve means 117 shut. Pump P and the components attached thereto can then be lowered through tubing 22 until seating mandrel 33 engages landing nipple 80 above safety valve S. When pump P is turned on, the liquid contained in accumulator means 30 is discharged from pump P to variable volume chamber 104 via longitudinal flow passageways 84 and 85 to open safety valve S. Poppet valve means 106 will open first to increase the supply of liquids to pump inlet 32. Continued operation of pump P will cause further movement of inner cylinder 105 of poppet valve means 106 until ball valve means 117 is opened. At this time, well fluids will flow from perforations 35 into bore 100 via ball 119 and openings 110 and 111. From bore 100 well fluids will flow through bores 82 and 43 into pump inlet 32 and be discharged from outlets 29 to the well surface. The discharge pressure of pump P is applied to variable volume chamber 104 to hold safety valve S open as long as pump P is operating. When pump P is turned off, springs 112 and 120 cooperate to return safety valve S to its first or closed position. Pump P and the components attached thereto may be safely removed from tubing 22 when safety valve S is in its first position.
The previous description illustrates only one embodiment of the present invention. Alternative embodiments will be readily apparent to those skilled in the art without departing from the scope of the invention which is defined by the claims.
|
A submersible pump and safety system for installation in wells having a submersible pump adapted to land within a well flow conductor for pumping well fluids to the surface plus a subsurface safety valve or valves for maintaining the well under control as the pump is run into and removed from the well. The subsurface safety valve is hydraulically actuated by the discharge pressure of the pump. The landing nipple in which the pump and safety valve are mounted has longitudinal flow passageways to communicate pump discharge pressure to the safety valve. The landing nipple and longitudinal flow passageways are designed for improved reliability and minimize the possibility of mechanical damage interrupting control fluid flow to the safety valve.
| 4
|
This invention relates to fluid treatment devices wherein fluid is passed through particulate material, within the device, for treatment thereby.
Fluid treatment devices are known which include a cylindrical housing containing particulate material. There are inlet means at or adjacent one end of the housing for the entry of fluid to be treated by the particulate material. There are outlet means at or adjacent the other end of the housing for the outlet of treated fluid. It is known that if such devices are installed in a horizontal disposition, that is, with the axis of the cylindrical form of the housing being horizontal, there is the problem that the particulate material may settle and create a void over the top of the particulate material and extending, perhaps, at worst, for the entire distance between the inlet and outlet means. If such a condition occurs, the fluid can travel between the inlet and outlet means along the void and not be in imposed and continuous contact with the particulate material during its temporary residence in, and passage through, the device. Such a condition obviously is very undesirable because the fluid does not get properly treated. Endeavors to overcome such problems have included making the space within which the particulate material is located, of variable volume so that the volume of the space can match the volume of the particulate material. Such endeavors have included making one of the ends of the space containing the particulate material, in the form of a piston spring-biased towards the other end of the space. Another proposal has been to make the cylindrical housing flexible and to cause it to be biassed towards its axis.
Such proposals for overcoming the problem are not always successful and/or desirable. It is an object of the present invention to overcome the above-described problem in known fluid treatment devices which contain particulate treatment material.
SUMMARY OF THE INVENTION
According to the present invention a substantially helical baffle is provided within the housing. The baffle extends at least part way between the inlet means and the outlet means and is in continuous contact with the internal surface of the housing along a line in the general form of a helix. With such a baffle, even if the above-described void should occur when the device is mounted horizontally, the fluid cannot travel all the way between the inlet means and the outlet means in the void. At some point, depending on the length of the baffle compared to the distance between the inlet and outlet means and on the pitch of the helix, the fluid is constrained by the baffle to flow downwards into the particulate material and along an approximately helical path submerged in the particulate material.
In a preferred embodiment, the baffle includes a spine extending generally along the axis of the cylindrical housing and fins extending along the spine and away from the spine into contact with the housing.
Advantageously, the baffle may include at least three fins with each fin being being resiliently deformable whereby its edge remote from the spine is in forced contact with the internal surface of the cylindrical housing.
In other advantageous embodiments, the spine is tubular. In such cases the fins may be straight in cross section. The tubular spine is formed of resiliently deformable material and is deformed by engagement of the fins with the housing whereby the fins are in forced contact with the housing.
The inlet and outlet means for flow of fluid into and out of the particulate material may each include a porous plug which is permeable to the fluid and impermeable to the particulate material. One of the plugs may be spring biassed towards the other of the plugs whereby the particulate material is subjected to a compressive force tending to avoid voids within the housing, free of particulate material. In such embodiments, the baffle should be shorter than the distance between the plugs to allow the spring biassed plug to approach the other.
The invention may be used in many different treatments of many different fluids. It has been found particularly beneficial in the treatment of water when the particulate material is activated carbon. However, amongst other uses may be mentioned drying of refrigerant fluid in refrigeration systems and in such embodiments the particulate material is beads of dessicant.
Embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of an activated carbon filter for water, embodying the present invention, mainly in axial section but with the baffle not in section, and with only some of the particulate carbon shown, for the purpose of ease of understanding;
FIG. 2 is the left end portion of FIG. 1, on an enlarged scale;
FIG. 3 is the right end portion of FIG. 2, on an enlarged scale;
FIG. 4 is a cross-section of an alternative baffle usable in the device illustrated in FIG. 1, in an undeformed state;
FIG. 5 is a cross-section of the baffle illustrated in FIG. 4, but in a deformed state and disposed within the housing of the device illustrated in FIG. 1;
FIG. 6 is similar to FIG. 4 but shows a second alternative form of baffle;
FIG. 7 is similar to FIG. 5 but shows the second alternative form of baffle in the deformed condition and within the housing;
FIG. 8 is similar to FIGS. 4 and 6 but shows a third alternative form of baffle; and
FIG. 9 is similar to FIGS. 5 and 7 but shows the third alternative form of baffle in the deformed condition within the housing.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 illustrates a carbon filter 10 for use as the third filtering stage, termed the post filter, in a combined pre-filter, reverse osmosis membrane filter and post filter, such as is described in our copending U.S. patent application Ser. No. 208,817, filed June 16, 1988, still pending which is suitable for use in a domestic water purification system such as that described in our copending U.S. Pat. No. 4,909,934.
The filter 10 includes a housing 12 which is a cylindrical tube formed of plastics material. As seen in FIG. 1, the left end 14 of the filter 10 is the inlet end and the right end 16 is the outlet end of the filter.
The inlet end 14 of the housing 12 is closed by inlet means 18 which are illustrated on an enlarged scale in FIG. 2, to which reference is now directed. The inlet means 18 includes a cap member 20 which is generally cup-shaped and includes a cylindrical flange 22 which is so formed as to be a push fit within the tubular housing 12. The cap member 20 also includes an annular flange 24 which serves to limit the extent to which the cap member can be inserted into the housing 12. The bottom 26 of the cup shape of the cap member 20 has a plurality of apertures 28 for inflow of water into the filter. The bottom 26 has a central bore 30 in which is retained the retaining hub 31 of an umbrella valve 32. The umbrella valve 32 includes a disc 34 of readily flexible resilient material which is impermeable to water and which seats and seals against the inside of the bottom 26 of the cup-shape form of the cap member 20. The umbrella valve 32 acts as a check valve preventing water which has entered the filter, flowing back out of the filter through the inlet. Fixedly and sealingly secured within the cylindrical flange 22 of the cap member 20 is a plug 35 comprising a collar 36 which serves as a retainer for a disc 38 of ceramic fibrous material which is permeable to water and impermeable to the particulate carbon which is yet to be described. The disc 38 is sealed to the collar 36 at its periphery. The cylindrical flange 22 is sealed to the housing 12. Thus, the only path for water between the exterior of the filter at the left end and the interior of the housing 12 is an inflow path, and it is through the apertures 28 and the water-permeable disc 38. Trapped between the collar 36 and a facing annular shoulder on the inside of the cap member 20, is a disc 39 of perforated stainless steel sheet which serves to prevent any untoward gross outward deformation of the fibrous disc 38.
Reference is now made to FIG. 3 of the accompanying drawings. The outlet end 16 of the housing 12 is closed by outlet means 40. The outlet means 40 include a cup-shaped member 42 having a cylindrical side wall 44 and a perforate bottom 46. The side wall 44 fits around the outside of the housing 12 and is secured thereto by adhesive, solvent welding or the like. Integral with the outside of the bottom 46 of the cup shape of the member 42 is a ring pull 48 which is a ring secured at at least one point to the bottom 46. The ring is deformable and may be engaged by a finger for pulling axially of the filter device 10 to remove it from an operative position.
Within the outlet end 16 of the housing 12 is an axially slidable plug 50 which is biassed leftwards, as seen in FIG. 3, i.e. towards the other end of the housing 12, by spring means, which, in the present embodiment, is in the form of a conical spiral spring 51 which reacts against a retaining device 52. The plug 50 includes an annular collar 54 which has a cylindrical outer surface which is a sliding fit within the housing 12. The radially inner surface of the collar 54 has an undercut in which is received the periphery of a disc 56 which is formed of ceramic fibrous material which is permeable to water and impermeable to the carbon particles which are yet to be described. The periphery of the disc 56 is sealed to the collar 54.
A disc 57 of perforated stainless steel is disposed between the collar 54 and the spring 51. It is stiff and serves not only to spread the force of the spring 51 but also to prevent any gross outward distortion of the fibrous disc 56. The spring 51 bears against both the disc 57 and the retaining device 52. The retaining device is dished, being convex towards the spring, and has tangs 58 which engage the housing 12 and prevent rightwards movement of the retaining device relative to the housing 12.
Referring again to FIG. 1, within the housing 12 between the inlet means 18 and the outlet means 40 there is a baffle 60 which is helical. In this embodiment of the present invention, the baffle 60 is an extrusion of plastics material, specifically, polyethylene. The baffle was made by extruding a tape having a width slightly greater than the diameter of the housing, and twisting the extrudant before it sets. In this way, the edges of the baffle follow perfect helices and the baffle as a whole has a screw like form. By making the width of the baffle slightly greater than the diameter of the housing the baffle has to be slightly flexed in order to insert it in the housing and this ensures that the edges of the baffle are a good sealing fit with the housing. Also, even if there are some departures from the true cylindrical form of the internal surface of the housing, the baffle can accommodate such imperfections and still seal to the housing. The baffle is slightly shorter than the distance between that end of the cylindrical flange 22 of the cap member 20 of the inlet means 18 which faces the outlet means 40, and that end of the collar 54 of the outlet means 40 which faces the inlet means 18, when the spring means 51 is in a relaxed condition.
Filling the housing between the disc 38 and the disc 56 there is particulate activated carbon 62 only some of which is represented in FIGS. 1, 2 and 3. The volume of the carbon and the positioning of the retaining device 52 are such that the spring means 51 is compressed and hence tends to prevent voids free of carbon. However, the baffle is the primary means of ensuring that water flowing through the filter from the inlet end 14 to the outlet end 16 is caused to flow in contact with carbon. Absent the baffle 60, and absent the spring means 51, and with a volume of carbon particles 62 less than the volume of the space within the housing between the discs 38 and 56, and with the filter 10 in a horizontal disposition, i.e. with the axis 64 of the cylindrical form of the housing 12 horizontal, a carbon particle free void could form above the carbon particles all the way between the inlet end 14 and the outlet end 16. If such a void developed, water could pass through the filter without any contact with, and treatment by, the carbon. Analysis has shown that if a situation should arise in which 95% of the cross-sectional area of the housing 12 were to be filled with particulate carbon, i.e. 5% of the cross-sectional area were to be void, throughout the length of the filter, then with a baffle in accordance with the present invention and having two full turns, as shown in FIG. 1, the path between the inlet means 18 and the outlet means 40 would be in the void for only 5% of the path length. It will be recognized by those skilled in the art that when a filter such as that specifically described above is used in a reverse osmosis domestic water purification system, the flow rate through the filter is so low that the flow could be accommodated by the void without any tendency for it to be through also the carbon particles. Thus, the entire flow could easily pass through the void without any imposed contact with the carbon and would leave the water untreated.
FIG. 4 is a cross-section of an alternative form of baffle 60a in an unstressed form, as extruded. The baffle 60a includes a spine 66 and four fins 68. The diameter of the baffle, that is, the distance between the free edges of opposed fins 68, is slightly greater than the inside diameter of the housing 12. The baffle 60a is compressed radially for insertion into the housing 12 and is slid axially into the housing. The material of the baffle is resilient so that it tends to resume its uncompressed state and, in so doing, bears against the inside surface of the housing 12.
FIG. 5 shows the baffle 60a with the spine still in a slightly deformed state and with the fins bearing against the inside surface of the housing 12.
FIG. 6 shows a second alternative form of baffle 60b in an unstressed state, as extruded. The baffle 60b includes a spine 70 and four fins 72. The diameter of the baffle, that is, the distance between the free edges of opposed fins 72, is slightly greater than the inside diameter of the housing 12. In this form of the baffle, the fins have a serpentine form, seen at 73, so that they may be readily compressed. The baffle 60b is compressed radially for insertion into the housing 12 and is slid axially into the housing. The material of the baffle is resilient so that it tends to resume its uncompressed state and, in so doing, bears against the inside surface of the housing 12.
FIG. 7 shows the baffle 60b with the fins still in a slightly deformed state and with the fins bearing against the inside surface of the housing 12.
FIG. 8 shows an alternative form of baffle 60c which is similar to the baffle 60b in that the force causing the fins to bear against the housing 12 is derived from the resilience of the fins and the fact that they are deformed upon assembly. The baffle 60c includes four fins 80 radiating from a spine 82. Each fin 80 is shaped somewhat like a dog leg in that it is angular as shown at 84. This bent form, and the fact that the baffle is formed of resiliently deformable plastics material, causes the fins to bear against the housing 12 after having been deformed for assembly in the housing as shown in FIG. 9.
The fact that the fins 68, 72 and 80 bear against the housing ensures that a good seal exists between the edges of the fins and the housing and also that any deformity of the internal surface of the housing 12 is accommodated without loss of the seal.
It is to be understood that FIGS. 4 to 9 show cross-sections and not cross-sectional views. Thus, the helical form of the baffles is not apparent. However, the fins and their edges are helical.
While four forms of baffle have been described, other forms may be adopted. It may be found desirable to have more than the two fins, which, in essence, the baffle described with reference to and illustrated in FIG. 1 has. If this is found to be the case, a baffle having three or more fins may be used.
The device 12 includes an O-ring seal 90 for sealing engagement with a housing in which the device is disposed in use. The seal serves to prevent water which is intended to flow through the device 12, but which has not, from mixing with water which has been treated in the device 12. In other words, the seal 90 prevents water bypassing the device.
The materials of some components have been mentioned. It is, of course, to be understood that if the filter device is to be used for drinking water purification, the materials should be selected to conform with all appropriate codes and standards.
While an embodiment of the invention has been described which is appropriate for treating water, it is to be understood that liquids other than water and fluids other than liquids, i.e. gases, may be treated in devices according to the present invention.
The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
|
A fluid treatment device is described which includes a cylindrical housing with fluid inlet and outlet means at or adjacent opposite ends. Particulate material for treating fluid flowed through the device, is disposed within the housing, between the inlet and outlet means. A helical baffle is disposed within the housing in the particulate material. The baffle extends axially along the housing and the free edges of its fins are in contact with the housing. The baffle serves to impose a helical path on fluid flowing through the device so that, when the device is mounted with its axis horizontal and with a volume of particulate material less than the volume of the space within the housing, fluid flows through the particulate material most of the time and not entirely along the void as would be the case if the baffle were not present.
| 2
|
This is a continuation of application Ser. No. 08/301,839, filed Sep. 7, 1994, now abandoned, which is in turn a continuation of application Ser. No. 08/028,467, filed Mar. 9, 1993, now abandoned.
FIELD OF THE INVENTION
The invention concerns a method for producing an alkali metal hydroxide by chlor-alkali electrolysis wherein an alkali metal chloride solution is electrolyzed to form an alkali metal hydroxide, chlorine and hydrogen.
BACKGROUND OF THE INVENTION
A problem of the chlor-alkali industries in many countries is the imbalance between the demands for the alkali metal hydroxide and chlorine which are the main products of the electrolysis. It is expected that the balance will get even worse in the future because of the environmental pressure caused by the use of chlorine and its finished products. The result of this is that alternative methods for producing alkali metal hydroxides have to be found, because they can't be produced in adequate quantities by the conventional chlor-alkali electrolysis.
Other known methods for producing alkali metal hydroxides include the following methods:
chemical decarbonation of soda with either lime milk or ammonia,
electrolytical breaking down of an alkali metal sulphate to an alkali metal hydroxide and sulphuric acid,
decarbonation of soda with an acid solution of an alkali metal sulphate and the electrolysis of so obtained sulphate solution to an alkali metal hydroxide,
catalytical breaking down of an alkali metal sulphide to an alkali metal hydroxide and sulphur dioxide and
electrolytical breaking down of an alkali metal chlorate to an alkali metal hydroxide and chlorine dioxide.
The chlorate is generally produced by electrical breaking down of alkali metal chlorides.
All of these known methods are unfavorable for the present producers of alkali metal hydroxide. The disadvantages of the most common alternative processes are the following: too much of sulphur compounds are produced as by-products in the process, having no use in a large scale; the raw material and energy costs of the process are too high compared to the market price of the product; big investments are required in the process and thus its capital costs are getting unfavorable in proportion to the market price of the product.
SUMMARY OF THE INVENTION
The intention of the invention is to provide a method for producing an alkali metal hydroxide, with which method the above disadvantages of the known methods are avoided and which can be carried out in chlor-alkali plants wherein additionally the ratio of the alkali metal hydroxide and the chlorine produced in the chlor-alkali electrolysis can be controlled to a desired level, and which method can additionally produce hydrogen and according to one embodiment also alkali metal chlorate, which products can be further utilized.
The principal characteristic features of the invention appear from the appended claims.
The invention resides in the realization that at least a part of the alkali metal chloride used in the chlor-alkali electrolysis can be produced by neutralizing or decarbonating an alkali metal carbonate either with chlorine or gaseous hydrogen chloride. By the decarbonation of an alkali metal carbonate with chlorine in an aqueous solution an alkali metal chlorate is at the same time formed.
By "alkali metal" it is in this connection primarily meant sodium and potassium, especially sodium.
When chlorine is used in the neutralization, the reaction products of the neutralization of an alkali metal carbonate in an aqueous solution are carbon dioxide, an alkali metal chloride and chlorate.
When hydrogen chloride is used in the neutralization, the reaction products of the neutralization of an alkali metal carbonate are carbon dioxide, an alkali metal chloride and water.
According to one preferred embodiment, the alkali metal carbonate and chloride are fed in the neutralization stage to the reactor which contains water or a solution of an alkali metal chloride or an alkali metal chlorate and an alkali metal chloride. When neutralizing an alkali metal carbonate with chlorine, an alkali metal chloride and chlorate are formed. The solution is becoming supersaturated in respect of the chloride, and hence, the alkali metal chloride can be separated from the solution as crystals. This alkali metal chloride is then used in a traditional way in the electrolysis in order to produce chlorine, alkali metal hydroxide and hydrogen. Preferably, at least a part of the chlorine is circulated back to the above mentioned reactor. In order to avoid the supersaturation of the reactor solution in respect of chlorate, a side stream is taken out from the reactor to the extended handling of chlorate.
The crystalline alkali metal chloride obtained from the reactor is preferably dissolved to the liquid circulation of the chlor-alkali plant, i.e., to the diluted alkali metal chloride solution which is leaving the chlor-alkali electrolysis, wherein the concentration of the obtained solution is preferably near that of a saturated solution. This solution is, after purification, returned to the chlor-alkali electrolysis.
According to a second preferred embodiment of the invention, an alkali metal carbonate and chlorine are mixed in the neutralization stage to the diluted alkali metal chloride solution leaving the chlor-alkali electrolysis. An alkali metal chloride and chlorite are formed in the neutralization of the alkali metal carbonate by chlorine. The alkali metal chlorate is removed from the solution obtained or changed to the desired product by a known method, and the concentrated alkali metal chloride solution thus obtained is, after purification, returned to the chlor-alkali electrolysis to produce alkali metal hydroxide, chlorine and hydrogen. Preferably, at least a part of the obtained chlorine is fed to the above mentioned neutralization stage.
According to a third preferable embodiment of the invention, the neutralization is carried out by adding the alkali metal carbonate to the alkali metal chloride solution which is leaving the electrolytic cells, to which alkali metal chloride solution gaseous hydrogen chloride has been absorbed, and the alkali metal chloride solution thus obtained is then fed, after purification, to the electrolytic cells.
According to a fourth preferable embodiment of the invention, the neutralization is carried out by adding the alkali metal carbonate to the alkali metal chloride solution which is leaving the electrolytic cells and by neutralizing the carbonate thereafter with hydrogen chloride gas, and the alkali metal chloride solution thus obtained is then, after purification, fed to the electrolytic cells.
According to a fifth preferable embodiment of the invention, the neutralization is carried out in a closed circulation containing initially either water or alkali metal chloride solution. To this circulation, there is then added alkali metal carbonate and either hydrogen chloride gas or hydrochloric acid. When the alkali metal carbonate is decarbonated, the solution is becoming supersaturated in respect to alkali metal chloride which can then be separated from the solution as crystals. These crystals are then led to the solution circulation of the chlor-alkali electrolysis in order to produce chlorine, an alkali metal hydroxide and hydrogen.
Consequently, in the neutralization zone, there is produced the alkali metal chloride solution of a conventional chlor-alkali plant, which alkali metal chloride solution is purified by known processes depending on the electrolytic cell method in question.
The alkali metal chloride solution to be fed to the chlor-alkali, electrolysis is preferably nearly saturated.
The pH value of the solution in the neutralization is preferably over 3 and especially between 3 and 11.
The neutralization can be carried out either continuously or batchwise at a broad temperature range which is preferably between 20° C. and 100° C. When chlorine is used in the neutralization, the alkali metal chlorate and chloride concentrations in the solution produced is influenced by the temperature. The neutralization can be carried out in one or several stages.
According to the method of the invention, the alkali metal chloride is electrolyzed in a known manner in the electrolytic cells in order to produce the alkali metal hydroxide. The electrolysis can be carried out in mercury cathode, diaphragm or membrane cells. The quality of the alkali metal hydroxide solution obtained after the electrolysis is equivalent to the quality obtained by the conventional chloride method.
The chlorine gas used in the neutralization of the alkali metal carbonate is preferably produced by the electrolysis. Chlorine is decarbonating a natural carbonate in the solution forming again alkali metal chloride, alkali metal chlorate and carbon dioxide. The carbon dioxide can be purified further and liquefied in a known manner for further use. The alkali metal chlorate can be fed to the preparation of alkali metal chlorate, or to a process where alkali metal chlorate is spent, or it can be changed to a chloride solution with hydrochloric acid, or it can be destroyed, or it can be refined further by some other desired way.
Hydrogen chloride which is used in the neutralization of alkali metal carbonate is preferably produced from the chlorine and hydrogen gases produced in the synthesis apparatus, to which also a known excess of hydrogen gas needed for the hydrogen chloride synthesis is led. After the synthesis, the obtained hydrogen-containing hydrogen chloride gas can be absorbed in a known manner either in water or a diluted hydrochloric acid solution. By heating a concentrated hydrochloric acid solution, a pure hydrogen chloride gas is provided which is absorbed to the diluted alkali chloride solution leaving the electrolysis cells. The obtained acidic chloride solution is decarbonating the natural carbonate, forming again alkali metal chloride and carbon dioxide. The carbon dioxide can be purified further and liquefied in a known manner for further use.
A remarkable advantage of the present invention is that already existing but underutilized chlor-alkali plants can be utilized in the process. By controlling the amount of the alkali metal carbonate, it is, according to the invention, possible to influence how much of the chlorine produced by the electrolysis remains as a saleable product of the process. One of the essential characteristics of the invention is particularly that the ratio of saleable chlorine the alkali metal hydroxide can be regulated steplessly from about 0% to nearly 100% by varying the amount of salt obtained from the alkali metal carbonate and to be fed to the process. The rest of the alkali metal chloride needed in the electrolysis is provided by feeding new alkali metal chloride to the solution circulation.
Another important advantage of the invention is that in the chlorination of the carbonate, chlorate is preferably formed which can be utilized easily and economically. By adjusting the temperature in the reactor, the chlorate and chloride contents of the obtained solution can be influenced to obtain a composition of the solution which is best suited for the intended use,
A third important advantage of the invention is that the hydrogen formed in the chlor-alkali electrolysis can advantageously be utilized either in other chemical processes or pro-environmentally as a fuel in the energy production.
The neutralization degree of the alkali metal carbonate can be adjusted by adjusting the amount of chlorine or hydrogen chloride and, hence, to provide suitable conditions in respect of the purification and electrolysis of the alkali metal chloride solution.
Among the most remarkable advantages in respect of the existing chlor-alkali plants the following can be mentioned: in the method according to the invention a cheap, even unrefined alkali metal carbonate can be used which is suitable for electrolytic use. Noxious sulfur compounds are not produced in the method as by-products. The existing capacity-of an electrolytic cell can be utilized to its full value. The investments which the method needs in existing plants are very small compared to alternative processes with the same production capacity of alkali metal hydroxide. The method is very flexible when the the production demand for chlorine and lye is changing. The production costs of the alkali metal hydroxide realized by means of the present invention are very low compared to the alternative processes. When chlorine is used to the neutralization the method is producing chlorate and hydrogen as by-products which can be utilized economically, and hence the method is economically more uniform.
BRIEF DESCRIPTION OF THE INVENTION
The invention is now illustrated in more detail in connection of the appended Figures wherein:
FIG. 1 is a block diagram showing the principles of the production of an alkali metal hydroxide according to the invention, as adapted for the production of lye;
FIG. 2 is a block diagram showing the principles of a second production of an alkali metal hydroxide according to the invention, as adapted for the production of lye;
FIG. 3 is a block diagram showing the principles of a third production of an alkali metal hydroxide according to the invention, as adapted for the production of lye;
FIG. 4 is a block diagram showing the principles of a fourth production of an alkali metal hydroxide according to the invention, as adapted for the production of lye.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 the electrolysis is marked with the reference numeral 1 to the electrolysis cell, there fed a sodium chloride solution through the purification zone 4. From the electrolysis cell 1, the desired sodium hydroxide solution and hydrogen are obtained which can be treated further in a method which is known per se. The chlorine gas produced by the electrolysis cell 1 is transported to the reactor 2, where the chlorine gas can also be taken through liquefication 6 and vaporization 7. In reactor 2, the sodium chloride crystal formed as the reaction product of chlorine and soda is separated from the reactor solution and is at saturating station 3 dissolved to the diluted salt solution returning from the electrolysis cell 2 and where also additional sodium chloride is added as needed. The saturated salt solution is led from the saturating station 3 to the purification zone 4, and from there further to the electrolysis cell 1. In reactor 2 there are also carbon dioxide CO 2 and sodium chlorate, which are led to the extended treatments 5 and 8. The extended treatment 5 can be a separating of sodium chlorate from the solution or its utilization as such in other processes.
In FIG. 2 a sodium chloride solution is fed to the electrolysis cell 1 through the purification 4. From the electrolys cell 1, the desired sodium hydroxide solution and hydrogen are obtained, which can be further treated by a method known per se. The sodium carbonate, and chlorine produced by the electrolysis cell 1, are fed directly to the solution circulation of the chlor-alkali electrolysis in reactor 2. The chlorine gas can also be led to the reactor 2 through liquefication 6 and vaporization 7. In reactor 2, the chlorate formed to the solution circulation is transformed by a known method to a desired compound at point 9, from where the concentrated salt solution is led to the purification zone 4 and from there, further to the electrolysis cell 1. When chlorine is desired as a sales product, additional sodium chloride is added to the solution circulation e.g. at point 2.
In FIG. 3, the electrolysis cell is indicated by the reference numeral 1. To the electrolysis cell a sodium chloride solution is fed which has been obtained from the sodium chloride purification zone 4. From the electrolysis cell 1, a desired sodium hydroxide solution is obtained which can be treated further by a known method. The chlorine and hydrogen gases produced by the electrolysis cell 1 are taken to the hydrochloric acid synthesis zone 10, from where the hydrochloric acid is led to the separation of hydrogen chloride gas 11. The pure hydrogen chloride gas obtained is absorbed in the absorption of hydrogen chloride 12 to the diluted sodium chloride solution which is leaving the electrolysis cell. The acidic sodium chloride solution obtained is led to the neutralization zone 2, where even soda is fed. In the neutralization zone 2 the acidic chloride solution is decarbonating the soda wherein sodium chloride is formed which is lea to the purification zone of the sodium chloride 4, and carbon dioxide, which is fed to the purification zone of carbon dioxide 8.
In FIG. 4, the electrolysis cell is indicated by the reference numeral 1. In it, a sodium chloride solution is fed from the saturation zone 3, to which, when producing chlorine to be sold, external sodium chloride is brought. From electrolysis cell 1, a desired sodium hydroxide is obtained which can be treated further by a method known per se. The chlorine and hydrogen gases produced by electrolysis cell 1 are taken to the hydrochloric acid synthesis 10. From here, the hydrochloric acid can be led as such or through the vaporization zone 11 to the reactor 12. In reactor 12, the hydrochloric acid is decarbonating soda forming sodium chloride, carbon dioxide and water. The solution will become supersaturated in respect to of chloride, and sodium chloride can be separated from the solution as crystals. These crystals are then led to the saturation 3. From the reactor 12, the salt solution is returned to the dissolution of soda 2, from where it is led further through the purification 4 to the reactor 12. The carbon dioxide formed is purified in point 8 and is led to further treatment.
The workability of the process has been tested with several laboratory scale tests. In these tests the goal has been to find out the influence of temperature, pH and different concentrations on the progress of the reaction. According to the results, chlorine is produced five or over five times as much as chlorate. The end-pH is, depending on the chlorination degree, over 3. According to the chlorate/chloride-solubility curve, the temperature and concentrations have a correlation which dictates the composition of the solution to be removed from the reactor.
In the following the invention is explained with examples.
EXAMPLE 1
An amount of 250 ml of a solution was taken, containing
NaCl 170 g/l
NaClO 3 400 g/l
Na 2 CO 3 50 g/l
Temperature <30° C.
Chlorine gas was fed through this solution until all sodium carbonate had reacted with chlorine. The residual chlorine was destroyed from the solution thus obtained by mixing. The chlorinated solution and the crystals formed were analyzed. As a result, a solution was obtained containing
NaCl 185.2 g/l
NaClO 3 406.2 g/l
9.3 g of a crystalline salt was obtained, containing 0.42 g NaClO 3 and 8.92 g NaCl. The final pH was 4.7
EXAMPLE 2
Into 1 liter of water, 100 g Na 2 CO 3 was dissolved. The pH of the obtained solution was 10.2. This solution was chlorinated until Na 2 CO 3 had been spent. As a result, a solution was obtained containing 83.9 g NaCl, 25.5 g NaClO 3 and 5.5 g active chlorine. The final pH was 6.2
EXAMPLE 3
One thousand milliliters of a sodium chloride solution was taken having a temperature of 65° C. and concentration 253 g NaCl/1. To the solution, 30 g hydrogen chloride gas was slowly absorbed which had been produced by heating a 33% hydrochloric acid. To the acidic salt solution, 45 g of technical sodium carbonate having a concentration of 99.3% Na 2 CO 3 was slowly added. After cessation of the carbon dioxide evolution, a salt concentration 298 g/l was analyzed. The final temperature of the solution was 55° C. and a final pH of 5. According to the analysis, 49 g sodium chloride had formed, well in accordance with the theoretical calculations. The solution obtained has such a quality that it can be used as the feed solution of electrolysis.
|
The invention concerns a method for producing an alkali metal hydroxide by a chlor-alkali electrolysis (1), wherein an alkali metal chloride solution is electrolyzed in order to form alkali metal hydroxide, chlorine and hydrogen, wherein at least a part of the alkali metal chloride used in the electrolysis is prepared by neutralizing (2) an alkali metal carbonate with chlorine or hydrogen chloride.
| 2
|
FIELD OF THE INVENTION
[0001] The invention refers to an arrangement for the anticipatory assessment of plants to be gathered with a harvesting machine.
BACKGROUND OF THE INVENTION
[0002] With harvesting machines, a measurement of crop throughput is sensible for the purpose of an automatic adjustment of crop conveyors and or crop processing devices. The crop throughput is also frequently measured for the purpose of the management of partial areas. Furthermore, with the aid of the measured crop throughput, the advance speed of the harvesting machine on a field can be adjusted by a corresponding control in such a we that a desired crop throughput is attained, which, for example, corresponds to an optimal utilization of the harvesting machine. It is normal to determine crop throughput with corresponding sensors in the harvesting machine. Since the measurement is carried out only after the crops were gathered by the harvesting machine, a sudden change of the crop throughput with such sensors can no longer be compensated for by a corresponding adaptation of the traveling speed, which can result in a reduced or excess loading of the crop processing devices or even in the processing devices becoming plugged.
[0003] DE 10 2008 043 716 A1 describes a harvesting machine equipped with a device to record the number of plants on a field, the device including a transmitter, which radiates electronic waves in the visible or near-infrared range from the machine at a forward and downward inclination onto plants that are in front of the machine, and a receiver, which works with a local or angular resolution and which receives waves reflected by the plants in the plant group and/or by the earth. An evaluation device determines the transit time of the waves of the transmitter to the recipient at various points along a measurement direction running transverse to the forward direction of travel and determines me number of plants with the aid of the variation of the recorded transit times. A recording of the plant density is based on the fact that with dense groups of plants, almost all waves are reflected by the foliage of the crops or plants, which means a rather low variation of the recorded transit times, whereas with thin plant densities, a greater fraction of the waves is reflected by the earth, which, at the pertinent sites, results in substantially longer transit times of the light and greater variations of the transit times along the measurement direction. The density of the plant group is determined with the aid of statistical parameters (that is, the variations in the transit times of the waves), using a calibration table established by experiments and permanently stored, determined and multiplied with the vertical area of the plants, so as to ascertain the number of plants to be expected during harvesting. Taking into consideration the cutting height and the type of plant, a calibration of the detected number of plants follows with the aid of the measurement values of a crop throughout sensor of the harvesting machine, wherein for the adjustment of the calibration data, one has recourse to an expert system or a neuronal network, and the calibration data can again be determined from time to time, so as to take into account changed ambient conditions. Here, the connection between the statistical parameters and the density of the plants is accordingly determined by experiments and permanently pre-specified, so that it does not lead to optimal results under all operational conditions.
SUMMARY OF THE INVENTION
[0004] 1. Object of the Invention
[0005] The object on which the invention is based is to be found in making available an improved device and a method for determining the number of plants on a field.
[0006] 2. Attaining the Object
[0007] This object is attained in accordance with the invention by the teaching of Patent claims 1 and 12 , wherein in the other patent claims, features are given, which further develop the way to attain the object in an advantageous manner.
[0008] An arrangement for the anticipatory assessment of plants to be gathered by a harvester comprises a sensor arrangement with a non-contact interaction with plants on a field, the sensor arrangement generating signals representing at least one characteristic of the plants. In addition to the sensor arrangement, there is provided a measurement device for the recording of one characteristic of the plants actually gathered by the harvesting machine, and an evaluation device for the production of calibration data, with the aid of signals of the measurement device and from statistical parameters derived from the signals of the sensor arrangement and for the calculation of the characteristic of plants to be gathered with the aid of statistical parameters, which were derived from the signals of the sensor arrangement, corresponding to the plants to be gathered, and with the aid of the calibration data. The evaluation device automatically determines connections between the statistical parameters cleaved from the signals of the sensor arrangement and the signals of the measurement device and takes into consideration these determined connections later during the calculation of the characteristic of the plants to be gathered.
[0009] Accordingly, the mode of operation of the arrangement in accordance with the invention is such that, at first, a learning process takes place. In this learning process, signals are conducted from a sensor device to the evaluation device; the sensor device records without contact one or more characteristics of (standing or lying, that is, cut) plants on a field. The evaluation device determines one or more statistical parameters of the plants with the aid of these signals. Furthermore, a measurement device likewise records one or more characteristics of the plants that have not been gathered by a harvesting machine, and in particular, precisely those plants that are investigated beforehand by the sensor device. The same characteristic that the sensor device already recorded can be recorded thereby or another characteristic. Thus, two different measurement devices with respect to the characteristics of the plants are available to the evaluation device, namely, the measurement values from the sensor device, which were recorded without contact and which are clouded with a certain degree of uncertainty because of the mode of operation of the sensor device that operates without contact, and the measurement values of the measurement device, which were recorded on board the harvesting machine, and which are quite sufficient. The evaluation device determines with these measurement values calibration data with which, after the end of the learning process, the measurement values of the sensor device (or the statistical parameters derived therefrom) can be converted in one application process into characteristics of the plants with the greatest accuracy possible. By means of the calibration produced in the learning process, the characteristic(s) of the plants is/are determined in the application process in an anticipatory manner and with sufficient accuracy, which facilitates an adaptation of parameters of the harvesting machine to the characteristic(s) of the plants.
[0010] In accordance with the invention, the proposal is made that during the learning process, statistical parameters of the plants be derived from the signals of the sensor device and connections between these statistical parameters and the signals of the measurement device be learned. Thus, differently from the state of the art (DE 10 2008 043 716 A1). not only the connection between a determined characteristic of the plants (for example, number of plants per area), which was determined with the aid of the signals of the sensor device and the statistical parameters derived therefrom, and the corresponding signals of the measurement device is determined, so as to set up calibration data, but rather the statistical parameters themselves, derived from the signals of the measurement device, are linked with the signals of the measurement device, so as to learn the connections between the statistical parameters and the signals of the measurement device and to take them up in the calibration data. In the application process, which can occasionally coincide with the learning process, then, the statistical parameters (perhaps together with other parameters of the signals of the measurement device) are converted into the sought characteristic(s) of the plants with the aid of the calibration data. In this way, the accuracy of the determined characteristic(s) of the plants is improved.
[0011] The characteristic of the plants to be determined can be the group density of all the plants (measured in volume or mass per area) and/or the grain and/or straw density of the plants (also measured in volume or straw per area) and/or the moisture of the plants.
[0012] The measurement device can interact directly with the plants gathered or processed by the harvesting machine, that is, can be constructed as a crop sensor and, for example, directly record the layer thickness or mass of the plants gathered by the harvesting machine. Alternatively, or additionally, the measurement device can record an operating value of a crop conveyor and/or a crop processing device, for example, the driving power of an inclined conveyor and/or a threshing device and/or losses of a separating device and/or losses of a cleaning device and/or a returns volume and/or the cleanness of refined grain. If the characteristic of the plants to be determined is moisture, the measurement device can be a suitable moisture sensor.
[0013] The sensor arrangement can be placed on the harvesting machine and look out onto the group of plants before the harvesting machine from a suitable point (for example, a cabin, a collecting conveyor or a harvesting attachment). It would be conceivable to place on a separate land vehicle or aircraft or on a satellite. The separate land vehicle can be an unmanned robot, which moves around or leaves a field to be harvested, or a fertilizing or spraying vehicle, which moves around on the field before the harvesting and simultaneously collects sensor data during the fertilizing or spraying work operation. The sensor arrangement can also be placed on a manned or unmanned vehicle or helicopter satellite.
[0014] The sensor arrangement can be a camera. The statistical parameters are then, for example, texture parameters and/or color histograms derived from the image (or partial images) of the camera. The camera can also be constructed as a stereo camera or 3D camera that is, a photon mixed camera).
[0015] The sensor arrangement can alternatively or additionally comprise a range finder, which scans the plants with electromagnetic waves, that is, a radar or laser range finder. The statistical parameters are then, for example, variables derived from the distance signals of the sensor arrangement, such as echo intensities and/or purse shapes and/or signal scattering (that is, widths of the chronological variations of the reflected signals) and/or the polarization of the electromagnetic waves and/or frequency shifts of the electromagnetic waves and/or changes in the course of time of those variables that were derived from the distance signals of the sensor arrangement.
[0016] One possibility is to adjust or regulate, using the characteristic of the plants to be gathered as determined with the evaluation device, at least one operational parameter of the harvesting machine, in particular, the advance speed and/or the size of the thresher basket and/or the rotating speed of a cleaning blower and/or the size of a sieve opening.
[0017] Preferably, during the application of the calibration data, the evaluation device takes into consideration the position of the harvesting machine in the field and/or known characteristics of the field. That means that previously determined calibration data were stored with information regarding the position where the data were gathered. If the harvesting machine then again approaches this position either in the same harvesting process or with a later (for example, next year's) harvesting process, then these calibration data are again used. Analogously, other characteristics of the field and the pertinent position of the field (for example, type of soil, elevation above sea level, magnitude and orientation of a slope inclination) with the calibration data can be stored, and the calibration data are again recalled with the aid of these characteristics. If several harvesting machines simultaneously work on one field and are each equipped with an arrangement in accordance with the invention, they can also exchange wirelessly among one another the calibration data and the aforementioned pertinent information regarding the position in the field and/or the characteristics of the field. In this regard, it should be mentioned that instead of using position and/or field characteristics-dependent calibration data, it is also possible to select the relevance of the calibration data (either in stages or continuously) depending on the position or field characteristic, that is, the calibration data to the extent they are dependent on the distance to the position where the data were obtained.
[0018] In the problem to be solved by the evaluation device—correlating the unknown characteristic(s) of the crop with the known statistical parameters (and perhaps other measurement values of the sensor device), states (characteristic(s) of the crop) are invisible, but data (statistical parameters) dependent on the states are visible. For the solution of such a problem, there is the possibility of using a hidden Markov model, although any other Bayes factor model can also be used.
[0019] The arrangement in accordance with the invention can be used, in particular, with self-propelled harvesting machines or with harvesters pulled by a vehicle or attached thereon, for example, combine harvesters, baling presses, or field choppers.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiment Example
[0020] An embodiment example of the invention described in more detail below is shown in the drawings, wherein:
[0021] FIG. 1 is a side view of a harvesting machine with an arrangement in accordance with the invention for the anticipatory assessment of plants gathered with a harvesting machine;
[0022] FIG. 2 is a schematic diagram for a first procedure in the operation of the arrangement; and
[0023] FIG. 3 is a schematic diagram for a second procedure in the operation of the arrangement.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] FIG. 1 shows a harvesting machine 10 in the form of a self-propelled combine harvester having a frame 12 , which is supported on the ground via driven front wheels 14 and back wheels 16 that can be steered, and which is moved by those wheels. The wheels 14 are made to rotate by means of a driving means (not shown), so as to move the harvesting machine 10 , for example, over a field to be harvested. Direction terms, such as “front” and “back” refer in the following to the forward direction of movement V of the harvesting machine 10 during harvesting operation.
[0025] A crop harvesting device 16 in the form of a cutting mechanism is connected in a detachable manner to the front end area of the harvesting machine 10 , so as to harvest threshable cereals or other threshable stalks from the field, and to conduct them upwards and backwards through an inclined conveyor 20 to a multi-drum threshing mechanism, which, arranged successively in the direction of crop flow through the machine 10 , comprises a threshing drum 22 , a stripping drum 24 , a conveying drum 26 , which works from above, a tangential separator 28 , and a turning drum 30 . Downstream from the turning drum 30 , there is a straw walker 32 . The threshing drum 22 is surrounded by a threshing basket 34 in its lower and back area. Below the conveying drum 26 , there is a cover 35 which is dosed or provided with openings, whereas above the conveying drum 26 , there is a fixed cover and below the tangential separator 28 , there is a separating basket 36 with adjustable finger elements. Below the turning drum 30 , there is a finger rake 38 .
[0026] The grain-containing and impurities-containing mixture, which goes through the threshing basket 34 , the separating basket 36 , and the straw walker 32 , arrives via the conveying trays 40 , 42 at a cleaning device 46 having a blower 96 and sieve 98 . Cereal cleaned by the cleaning device 46 is conducted by means of a grain auger 48 to an elevator (not shown), which conveys it into a grain tank 50 . A returns auger 52 returns non-threshed head parts through another elevator (not shown) to the threshing process. The chaff can be thrown on the back side of the upper sieve 98 by a rotating chaff spreader, or it is discharged by means of a straw chopper (not shown), located downstream from the straw walker 32 . The cleaned cereal from the grain tank 50 can be unloaded by an unloading system with cross augers 54 and an unloading conveyor 56 .
[0027] The aforementioned systems are driven by means of a combustion engine 58 and are controlled by an operator from a driver's cabin 60 . The different devices for threshing, conveying, cleaning, and separating are located within the frame 12 . Outside the frame 12 , there is an outer shell, which for the most part can be folded up. It remains to be noted that the multi-drum threshing mechanism depicted here is only one embodiment example. It could be replaced by a single transverse threshing drum and a subordinate separating device with a straw walker or one or more separating rotors or a threshing and separating device working in the axial flow.
[0028] A sensor arrangement 62 is located on the front side of the driver's cabin 60 in the vicinity of the roof; the sensor arrangement is connected to an evaluation device 76 . The sensor arrangement 62 could alternatively be placed on the crop harvesting device 18 . The evaluation device 76 is connected to a speed-specifying device 78 for example, an adjusting device for a swash plate of a hydraulic pump, which is connected with a hydraulic motor so as to conduct hydraulic fluid, which drives the wheels 14 ) which is set up to adjust the traveling speed of the harvesting machine 10 .
[0029] The sensor arrangement 62 comprises a first transmitter 64 , a first receiver 66 , a second transmitter 68 , and a second receiver 70 , which can be jointly rotated by a swivel drive 74 around a more or less vertical axis 72 , slightly inclined forwards. During operation, electromagnetic waves sent out by the transmitters 64 , 68 sweep in an arc over a measurement area in front of the combine harvester 10 , in that the transmitters 64 , 68 and receivers 66 , 70 (or only elements transmitting and/or receiving their waves) are swiveled around the axis 72 . In this way, the field 80 with the plants 82 standing thereon is swept along a measuring direction that extends in an arc with the shape of a circular segment in front of the combine harvester 10 .
[0030] The first transmitter 64 sends out first electromagnetic waves in the form of light in the near infrared or visible wave range, while the first receiver 66 is sensitive only to this light. As a result of the selected wavelength, the light is reflected by the plants 32 when it strikes them. On the other hand, if the light goes between the plants (for example, with thin or missing groups) and strikes the round 84 , it is reflected by the ground. The first transmitter 64 preferably comprises a laser for the generation of the light.
[0031] The second transmitter 68 sends out second electromagnetic waves in the micro or radar wave range, while the second receiver 70 is sensitive only to these waves. The wavelength is selected in such a way that the greatest portion of the second waves penetrates the plants and is reflected only by the ground 84 . A certain although smaller fraction of the second waves is also reflected by the plants 82 .
[0032] The electromagnetic waves sent out by the transmitters 64 , 68 reach the ground 84 at an interval of a few meters (for example, 10 m) in the direction of movement of the combine harvester 10 in front of the crop harvesting device 18 . The waves sent out by the transmitters 64 , 68 can be modulated by the amplitude or in another manner, so as to improve the signal to noise ratio. By means of a transit time measurement, the evaluation device 76 accomplishes a recording of the interval and/or another measurement variable between the sensor arrangement 62 and the point where the waves were reflected. The swivel drive 74 can be constructed as a servo or stepping motor, and the sensor arrangement 62 (or only elements sending out and/or receiving their waves) continuously or gradually swivels around an angular range of, for example, 30° around the axis back and forth. The evaluation device 76 is set up to record, for any swiveling angle of the sensor arrangement 62 , the individual angle around the axis 72 and the transit time of the wave, or the distance of the receiver 66 , 70 and the transmitter 64 , 68 from the reflection point. It would also be possible to derive from the signals of the receiver 66 , 70 , the echo intensities and/or pulse shapes and/or signal scatters and/or the polarization of the received electromagnetic waves and/or frequency shifts of the received electromagnetic waves and/or changes in the time course from the distance signals of the sensor arrangement 62 , and to take them into consideration in the later evaluation. Subsequently, the swivel drive 74 is, activated and the sensor arrangement 62 is brought to another position. Information regarding the individual angle of the sensor arrangement 62 is available to the evaluation device 76 since it controls the swivel drive 74 . A separate sensor for the recording of the swivel angle would also be conceivable, wherein the servo or stepping motor can be replaced by any motor. The angle of the sensor arrangement 62 around the axis 72 defines a measurement device, along which the transit times of the waves of the transmitter 64 , 68 to the corresponding receiver 66 , 70 are determined. It extends horizontally and in the shape of a circular arc, transverse to the forward direction of travel of the harvesting machine 10 .
[0033] The signals of the first receiver 66 contain information regarding the height of the upper ends of the plants 82 , since they are primarily reflected there. A few first waves, however, penetrate into thinner groups of plants further down, in part, down to the ground 84 , and are first reflected there and received by the first receiver 66 . In thinner groups, the intervals recorded by the first receiver 66 , accordingly, vary more than in thicker groups. These different variations, of the intervals, dependent on the density of the group of plants, are evaluated by the evaluation device 76 and are used for the determination of the density of the group of plants. Furthermore, the measurement values of the second receiver 70 are used for the determination of a ground profile, which is used in conjunction with the heights of the upper sides of the plants 82 recorded by the first receiver 66 for a more accurate determination of the plant heights, which are also used for the determination of the number of plants.
[0034] The sensor arrangement 62 also comprises a camera 86 , which looks out downward and forward from the roof of the cabin 60 at an incline onto the field 80 with the plants 82 standing thereon and in front of the crop harvesting device 18 . The signals of the camera 86 a also supplied to the evaluation device 76 . In other possible embodiments of the invention, the camera 86 or one or both range finders 64 , 86 and 88 , 70 can be omitted.
[0035] Furthermore, the harvesting machine 10 is equipped with several measurement devices 88 , 92 , 94 , 100 , and 102 , which directly or indirectly record characteristics of the harvested plants 82 and respectively transmit their signals to the evaluation device 76 . The evaluation device 76 records the angle position of a feeler 90 supported in such a way that it can rotate and that interacts with the crop mat in the inclined conveyor 20 . The measurement device 88 accordingly records the layer thickness of the plants 82 in the inclined conveyor 20 . The measurement device 92 records the drive torque or the drive performance of the threshing drum 22 , which depends in turn on the quantity (volume and mass) of the collected plants 82 . The measuring device 94 detects the driving torque or driving power of the blower 96 that depends on the load of the sieve 98 . The measurement device 100 comprises a camera and a near-infrared spectrometer, which interact with the cleaned drain conveyed by the grain auger 48 and on one hand, with the camera and an image processing determine the cleanliness of the grain and the broken grain, fraction in the cleaned train, and on the other hand, by means of the near-infrared spectrometer, determine the grain moisture. In this respect, reference is made to the disclosure, of DE 10 2007 007 040 A1.Finally, a measurement device 1 records lost grains on the discharge of the upper sieve 98 .
[0036] FIG. 2 illustrates the mode of operation of the arrangement in accordance with the invention for the anticipatory assessment of plants gathered with a harvesting nine in operation. In a learning process (left part of the figure), the signals from the sensor arrangement 62 are thereby evaluated with the camera 86 and the receivers 66 , 70 on the one hand, and the signals of the measurement devices 88 , 92 , 94 , 100 , and 102 on the other hand, so as to produce calibration data 106 , which are subsequently (or simultaneously) used in an application process (right part of the figure), so as to convert the signals from the sensor arrangement 62 , among others, into control signals for the speed specification device 78 . The calibration data 106 are produced geo-referenced on the basis of signals of a receiver 104 for signals of a satellite-based position determination system (for example, GPS, Glonass, or Galileo), and stored. The signals of the receiver 104 can also be supplemented or replaced by wheel sensors for the speed measurement and gyroscopes for the direction measurement.
[0037] In detail, statistical parameters 108 , 110 are calculated from the signals of the camera 86 by means of an image processor 107 , which can be integrated into the evaluation device 76 or into the housing of the camera 86 or can be constructed as an independent unit. The statistical parameter 108 is a histogram for the colors and/or the brightness of the plants 82 . The statistical parameter 110 comprises texture parameters of the plants, for example, the local dimensions (thickness and/or length) of the plants, the standard deviation of the local dimensions (thickness and/or length) of the plants and the local entropy (disorder or order, that is, the alignment) of the plants. This (these) statistical parameter(s) can be derived from the total image of the camera 86 or from parts of the image of the camera, in particular, those parts that contain a representative image of the crop. The other areas of the image of the camera 86 can be ignored or used for other purposes—for example, for steering.
[0038] Furthermore, in the operation of the swivel drive 74 , with the transmitters 64 , 68 and the receivers 66 , 70 , the evaluation device 76 brings about an incremental (or continuous) sweeping of a certain angular range in front of the harvesting machine 10 . The individual swivel angles and interval measurement values are thereby stored by the evaluation device 76 . A first range image 112 of the first receiver 66 and a second range image 114 of the second receiver 70 are formed. From the first range image 112 and the signals of the first receiver 66 , statistical parameters 116 , 118 are derived, wherein in one embodiment of the invention, one of the statistical parameters 116 comprises the standard deviation in the range image 112 , and the other statistical parameter 118 , a histogram for the intensity of the received light over time. Statistical parameters 120 , 122 are derived from the second range image 114 and the signals of the second receiver 70 , wherein one of the statistical parameters 120 comprises the standard deviation in the range image 114 , and the other statistical parameter 122 , a histogram for the intensity of the received waves over time.
[0039] It is possible without any problem to hereby recognize if the harvesting machine 10 moves over an area of the field that has already been harvested. Signals obtained there are ignored by the evaluation device 76 .
[0040] The position signals of the receiver 104 are converted by means of a stored card 124 into data 126 with regard to the actual site of the harvesting machine 10 , for example, with regard to the type of soil and/or the topography (for example, the magnitude and the direction of the ground inclination and the elevation above sea level), and furthermore made available as position signals 128 .
[0041] Finally, the measurement devices 88 , 92 , 94 , 100 , and 102 generate the signals described above with regard to the individually recorded characteristics of the harvested plants 82 . The statistical parameters 108 , 110 , 116 , 118 , 120 , 122 , the position signals 128 and data 126 , and the signals of the measurement devices 88 , 92 , 94 , 100 , and 102 are conducted to an evaluator 130 of the evaluation device 76 . In each case, signals that are at least approximately correlated with the same plants 82 , that is, the individual time and location differences in the recording of the signals and data are taken into consideration, are thereby linked. The evaluator 130 is able, with the use of a hidden Markov model or dynamic Bayes influence factor model, to independently determine the relationships between the statistical parameters 108 , 110 , 116 , 118 , 120 , 122 derived from the signals of the sensor arrangement 62 , and the signals of the measurement devices 88 , 92 , 94 , 100 , and 102 , and with the aid of these now determined relationships, to generate the calibration data 106 . With regard to the details of the hidden Markov model, reference is made to the technical literature (see http://en.wikipedia.org/wiki/ Hidden_Markov_model and the references mentioned there).
[0042] In the second embodiment according to FIG. 3 , an additional evaluator 132 is used in contrast to the embodiment in accordance with FIG. 2 , which from the signals of the measurement devices 88 , 92 , 94 , 100 and 102 and signals of one or more additional sensors (sensor 142 for separation losses of the shaker 32 or an axial separation direction; sensor 144 for the returns volume, sensor 148 for the cutting height, sensor 148 for the advance speed and data 150 for the working width of the crop harvesting device 18 ), first calculates the characteristics of the crop or the field, namely, the crop moisture 134 , the volume of the crop 136 , the grain yield 138 and the navigability 140 of the field, and perhaps also, other characteristics of the crop and/or the field The evaluator 132 is hereby used for the conversion of the measurement variables obtained on the harvesting machine 10 into the characteristics of the crop or of the field. The characteristics of the crop or of the field calculated by the evaluator 132 (instead of the signals of the measurement devices 88 , 92 , 94 , 100 , 102 in accordance with the first embodiment of FIG. 2 ) are then conducted to the evaluator 130 . The characteristics of the field (in particular, with regard to the navigability) can also be transmitted to other machines, in particular, transport vehicles for the transporting of the crop or vehicles for the subsequent processing of the soil.
[0043] For the adjustment of the forward speed of the harvesting machine 10 by means of the speed specification device 78 and/or other working parameters of the harvesting machine 10 , such as the threshing drum rpm, the threshing drum gap, the blower rpm, or the sieve opening, the calibration data 106 and the measurement values of the sensor device 62 are used in the form of signals of the camera 86 and the receivers 70 , 66 by the control unit 152 , which is part of the evaluation device 76 and can be integrated m its housing or constructed as a separate unit, so as to independently adjust the working parameters of the harvesting machine 10 . To this end, in particular, the statistical parameters 108 , 110 , 116 , 118 , 120 , 122 are supplied to the control unit 152 , although in addition, the range images 112 , 114 and the signals of the image processing 107 can also be supplied to the control unit 152 . The signals of the measurement devices 88 . 92 , 94 , 100 , 102 could also be supplied to the control unit 152 as feedback data. In the embodiment according to FIG. 3 , the characteristics of the crop and/or the field calculated by means of the evaluator 130 can also be supplied alternatively or additionally as feedback data to the control unit.
[0044] The control unit 152 is thus able, with the aid of the calibration data 106 and the measured statistical parameters 108 , 110 , 116 , 118 , 120 , 122 , and perhaps other data from the sensor device 62 , to determine the individual actual characteristics (like, in particular, the throughput) of the plants 82 that are soon to be gathered and on the basis of this, to adjust in an anticipatory manner the speed specification device 78 and/or the other aforementioned working parameters of the harvesting machine 10 . Since the calibration data 106 are geo-referenced and stored with information regarding the individual type of soil and/or topography of the field, calibration data 106 , which were obtained in the vicinity of the individual position and/or with a similar type of soil and/or topography, are taken into consideration to a greater extent for exclusively) by the control unit 152 than other data 106 obtained at a greater distance or with another type of soil and/or topography.
[0045] The calibration data 106 can be generated continuously, wherein older calibration data can either be deleted or taken in consideration to a lesser and lesser extent as time goes on or retained and combined with more recent calibration data, or they are generated only over as certain time period and stored for a longer period of time, possibly until the next harvest or even longer and used by the control unit 152 .
[0046] The invention under consideration is not only suitable for standing plants 82 as previously described, but rather also for plants lying in a swath or lying flat.
[0047] Having described the preferred embodiment, it will become apparent that various modifications can be made without departing from the scope of the invention as defined in the accompanying claims.
|
A arrangement is provided for the anticipatory assessment of plants to be gathered by a harvesting machine, disclosed as a combine harvester, and includes a non-contact sensor arrangement for the generation of signals representing at least one characteristic of plants located ahead of the machine, a measurement device for recording at least one characteristic of the plants actually gathered by the machine, and an evaluation device for producing calibration data with the aid of signals generated by the measurement device and from statistical parameters derived from the signals of the sensor arrangement and for the calculation of the characteristic of plants to be gathered with the aid of statistical parameters, which were derived from the signals of the sensor arrangement, corresponding to the plants to be gathered, and with the aid of the calibration data.
| 0
|
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from U.S. Provisional Patent Application No. 60/716,816, filed Sep. 14, 2005, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field Of The Invention
The present invention relates generally to the field of computer programming and more specifically to an interactive method for building and representing computer programs, and their control constructs, as visualizations or visual expressions in the form of shapes, such as lines, arrows, strokes, or directed paths, or a plurality of such visualizations that map to a plurality of multifarious, textual computer programming language control constructs.
2. Description Of Related Art
Software development is complex and buggy. As complexity continues to increase, our ability to comprehend the architecture and operation of large software systems as well as the ability to create large, complex software systems correspondingly decreases resulting in an ever-increasing gap, which has been referred to as the software crisis. The Wikipedia.org website defines the software crisis as a term used early in the days of software engineering, before it was a well-established subject, to describe the impact of the rapid increases in computer power and the complexity of the problems which could be tackled. It refers, in essence, to the difficulty of writing correct, understandable and verifiable computer programs.
Over the last century, the task of programming a computer has been marked with progressively discrete levels of abstraction away from underlying hardware. This progression will be described below up to the most recent modeling technologies that have been produced to grapple with voluminous amounts of code. State-of-the-art modeling paradigms show no signs of traction.
There is no silver bullet to date regarding the software crisis. Historically, the software industry has attempted to evolve programming with more and more incarnations of character-based languages to deal with the ever-increasing complexity and speed with which to program.
The use of computers and computer languages can be traced back to the nineteenth century. Charles Babbage's difference engine in 1822 was programmed to execute a task by changing gears, which made calculations.
Eventually, mechanical motion was replaced by electrical signals in a first generation digital computer in 1942. Execution then became a tedious task of resetting switches and rewiring the entire system—similar to the original telephone switchboards. The computer operator was a scientist that needed to intimately know the machine's instruction set. This instruction set consists of a seemingly endless stream of 1's and 0's, which are the machine language of digital computers.
After core memory was developed, programs could be easily loaded into memory and subsequently the CPU manually by flipping toggle switches. Address switches were set, then data switches, then a WRite switch. This process was repeated for all data and instructions, then the run switch was toggled.
Punch cards and paper tape were the proven input technology of the mid-nineteenth century and had been around since the early 1800's. Naturally, instructions ultimately were then stored on paper via hex keypads or terminals.
The first computer programming language for electronic computers was Short Code. It appeared in 1949 and operators manually changed shorthand statements such as JMP, BR or SUB, into 1's and 0's. In 1951 Grace Hopper wrote the first compiler, A-0, which translates a language's statements into 0's and 1's. Although easier to write and understand than machine language, operators still had to intimately understand how a computer functioned in order to create a working program.
The first high-level language, FORTRAN, appeared in 1957 and was used on second generation digital computers that used transistors instead of vacuum tubes. It's control constructs were limited to IF, DO and GOTO statements, which were a vast improvement over simple mnemonics such as JMP and BR used by assembly code. Data structures today can be traced back to FORTRAN 1. Other languages followed like COBOL for business applications, and Lisp for artificial intelligence. Programmers were insulated from the actual hardware by computer operators who were handed stacks of punch cards to feed into the machines.
Imperative languages (high-level languages centered around assignment statements) flourished during the third generation of digital computers, which shrank in size, due to the integrated circuit, but grew in capacity. Algol, BASIC, Pascal, Simula, Smailtalk, PL/1, and CPL are just a few, each with their own contribution. For example, CPL evolved into BCPL, that evolved into B, which subsequently paved the way for C. C is the first portable language that allowed a program written for one type of machine to be compiled and run on many other machines, again further removing the programmer from the underlying hardware. C has been one of the most popular programming languages for over 25 years.
C, with the help of Simula, spawned the object oriented computer language C++. The late 80's and early 90's saw object oriented languages dominate the scene. Smalltalk and C++ influenced the creation of Java, which influenced the creation of the now modern and state-of-the-art computer programming language C#.
FIG. 1 illustrates a block diagram depicting the different layers of abstraction programming languages have provided over the evolution of prior art in the field of programming, which insulate or distance the computer programmer from the underlying hardware. Block 1200 depicts the computer hardware that executes desired tasks since the first electronic computers were developed in the 20 th century. Block 1210 depicts the machine language of digital computers—ones and zeros. Block 1220 depicts low-level assembly languages which appeared in the mid 20 th century and are compiled down to machine language for the computer to understand. Block 1240 depicts high-level languages that flourished during the third generation of computers during the mid-to-late 20 th century and are also compiled or interpretted. Block 1230 depicts a middle-ware approach inserted between high-level and low-level languages that have become widely popular beginning in the late 20 th century to the present.
Looking at the history of programming languages, it is seen that most features are general and are available in many languages. It can be appreciated that many features of modern languages have been around for years. It can also be seen how the programmer's knowledge of the underlying hardware has been diminished over time.
There have been many attempts to address the way computers are programmed using visual programming languages over the past few decades. A visual language manipulates visual information or supports visual interaction, or allows programming with visual expressions. This is taken to be the definition of a visual programming language. Visual programming languages may be classified according to the type and extent of visual expression used: into icon-based languages, form-based languages, or diagram languages. Visual programming environments provide graphical or iconic elements which can be manipulated by the user in an interactive way according to some specific spatial grammar for program construction.
Current state-of-the-art visual programming is often referred to as iconic programming or executable graphics. Some visual languages are mere data flow models. A broader definition is systems that use graphics to aid in the programming, debugging and understanding of computer programs. This can include UML, Unified Modeling Language. A simple list of prior art follows.
One attempt to use flow diagrams is disclosed in U.S. Pat. No. 5,301,336, entitled “Graphical Method For Programming A Virtual Instrument”, issued to Kodosky et al. on 5 Apr. 1994. Here, a GUI, or Graphical User Interface, utilizes data flow diagrams to represent a given procedure. Data flow diagrams are assembled in response to user input, again using icons, which correspond to executable functions, scheduling functions and data types and are interconnected by arcs on the screen.
One attempt using icons is disclosed in U.S. Pat. No. 5,313,575, entitled “Processing Method For An Iconic Programming System”, issued to Beethe on 17 May 1994. This system is based on an iconic programming system which enables a programmer to create programs by connecting or linking various icons together to comprise a program.
Yet another attempt, this time with modeling, lies in U.S. Pat. No. 5,325,533, entitled “Engineering System For Modeling Computer Programs”, issued to McInerney et al. on 28 Jun. 1994. This system provides a human oriented object programming system where modeling is used to assist in the development of computer programs.
Visual Basic and the entire Microsoft Visual™ family are not, despite their names, visual programming languages. They are textual languages which use a graphical GUI builder to make programming interfaces easier on the programmer.
SUMMARY OF THE INVENTION
By abstracting the character-based syntax away, the present invention provides one common, standard programming interface for all textual languages enterprise-wide analogous to the Esperanto spoken language. The invention also has a reduced learning curve from an intuitive, visual front-end; more correct syntax by reducing the chance errors produced by typing statements one character at a time; and a real Rapid Application Development (RAD) programming environment where single strokes replace numerous, repetitive statements.
Program control constructs are common to nearly every language. Yet, each has evolved into their own dialect. As Latin is the root of all Western spoken languages, FORTRAN is the root of all high-level computer languages. Strokes can be thought of as one common representation to represent a control construct in many different textual programming languages. For example, in the present invention, a function or procedure is represented as a straight line or an arrow from top to bottom. This is analogous to the main thread of execution. Multithreaded applications could of course have two or more parallel lines. A loop is a branch off of the previous flow that loops back to a point of previous execution. A pre-condition loop would start at the top and loop back up. A post-condition loop would start at the bottom and loop back down. A conditional statement is a branch off of the previous flow that supports traditional if-then-else clauses.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a hierarchical relationship of different layers of abstraction in prior art programming;
FIG. 2 is a simplified flow diagram illustrating a method of capturing visual logic and synthesizing textual code in accordance with the present invention;
FIG. 3 is a block diagram of an exemplary computer system, such as a tablet PC, that may be utilized to implement the present invention;
FIG. 4 is a block diagram showing a hierarchical relationship of the present invention to the prior art programming languages of FIG. 1 ;
FIG. 5 is a diagrammatic illustration of a windowed screen display of an empty canvas displayable on the display device of the computer system of FIG. 3 ;
FIGS. 6-11 b show the progressive use of drawing symbols and data entry in a manner to produce a computer program in accordance with the present invention;
FIGS. 12 a - 12 b show a final diagram made from the drawing symbols and data entries made in FIGS. 6-11 b ; and
FIGS. 13( a )- 13 ( m ) show exemplary drawing symbols (or control constructs) and their text-based equivalents.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described with reference to the accompanying figures where like reference numbers correspond to like elements.
The capture of program logic using the present invention utilizes state-of-the-art technologies that provide natural input methods. The invention utilizes, but is not limited to, the use of the pen recognition engine of the Microsoft Tablet PC operating system; the voice recognition engine of the Tablet PC operating system; as well as the shape recognition engine of the Tablet PC operating system. The Microsoft speech synthesis engine may be used to provide audible feedback and audible queues. The software development kits for these technologies are readily available from Microsoft Corporation.
The main development environment of the present invention is Microsoft Visual C# using the .Net Common Runtime Language. A Windows Forms application is used to handle the main event loop for the main software application. A so-called “ink control” from the Tablet PC software development kit (SDK) is used as the main control to accept “ink” drawn with a pen. The main application is menu driven.
The present invention utilizes custom shape recognition algorithms for handling limitations found in the built-in shape recognition engine of the Tablet PC operating system. Mainly, the Tablet PC shape recognition engine is limited to single-stroke gestures. The custom shape recognition algorithms of the present invention handle complex shapes with multiple strokes.
Pattern recognition based on a spatial parser applies an order of precedence for parent shape and child shape relationships. The order of precedence is left-to-right, top-to-bottom. A left-to-right sequence of shapes is a parent-child relationship with the parent being the leftmost shape. This defines a block of shapes. The leftmost, topmost shape is the topmost parent object in the internal ordered tree data structure. Within a block, a top-down sequence defines an ordered sibling relationship. Any left-to-right relationships defines another block, or sub-block, with a parent-child relationship.
A Tablet PC ApplicationGesture event, or similar custom or third-party event, is subscribed to handle the basic shape recognition of gestures. The Tablet PC SrokesAdded event, or similar custom or third-party event, is subscribed to handle the complex shape recognition for compound shapes. Using these events as triggers, the specific, recognized shapes or gesture combinations determine which program control constructs are to be created. This comprises shape recognition.
A class library of data structures is created internally that map to universal control constructs of text-based languages using an abstract syntax tree. These internal data structure objects mostly derive from a Shape object and are as follows: Parent, Namespace, Function, Program, If, Loop, For, Foreach, While, Print, Comment, Declaration, Expression, Assignment, Class, Field and Method.
In response to an event trigger, such as the entry of a drawing figure or shape, a new data structure object is instantiated. This object then knows how to prompt the user for string-literal identifiers that define the recognized control construct. For example, the drawing or construction of a down arrow would trigger the shape event handler. The handler would instantiate a new Program object. This object would then prompt the user for a program name. The hand-writing recognition engine would capture the digital ink and convert it into ASCII text, or the user could enter the ASCII text through a keyboard. This object is then the top-level object of the immediate visual programming script and the parent object in an ordered tree data structure. In the internal data structures, each specific shape inherits from the Shape object. Therefore, each shape has an array of multiple children nodes which are themselves members of the ordered tree data structure.
With reference to FIG. 2 , a block diagram illustrating an overview of a method of capturing program logic using the visual programming language of the present invention is shown. In FIG. 2 , a visual representation of program logic is captured graphically as depicted in block 1010 . In one embodiment, block 1010 depicts the use of a visual programming language editor application to capture pen strokes comprising a visual programming language on a Tablet PC. Block 1020 depicts a textual representation of computer program logic as synthesized from the visual representation. The textual representation may conform to any number of standard computer programming languages. Block 1030 depicts the program logic stored or persisted on disk in a physical form for use as source code to be compiled into machine language. Block 1030 can also be translated into the visual programming language as depicted in block 1010 as a visualization of existing high-level code for viewing, manipulation and edits.
With reference to FIG. 3 , a block diagram illustrating an overview of a computer in which an embodiment of the invention may be implemented, such as a Tablet PC, is shown. This computer includes a communication bus block 1050 configured to convey information to other components of the system. Block 1060 depicts a main memory module used for storing computer instructions and program data structures for use in the system's central processing unit, CPU, as depicted in block 1080 . Static information used to bootstrap the system may be stored in read-only memory, or ROM, as depicted in block 1070 . Block 1090 depicts a persistent storage device, such as a magnetic or optical disk, for storing program instructions and information. Bus block 1050 may couple the system with a display device, such as a liquid crystal display device, or LCD, for display to the computer operator as depicted in block 1100 . Block 1110 depicts an input device, such as a pen, for communicating information to the computer system. Block 1110 may be tightly coupled or integrated with display block 1100 , which would comprise a device such as a Tablet PC. Block 1120 depicts a keyboard input device.
With reference to FIG. 4 , an abstraction of the present invention is manifested in an ultra-high-level visual programming language. Block 1310 depicts the invention above all other textual programming languages as depicted in block 1300 , also shown in FIG. 1 , in accordance to the progressive trend of abstraction away from the underlying hardware.
With reference to FIG. 5 , an embodiment of the invention that a user would see as a graphical visual programming language (VPL) editor, or environment, on display device 1100 in FIG. 3 , is shown. This editor can be referred to as VPL editor or just editor. The entire figure depicts a main window representing the main editing application in a windowing operating system, such as the Microsoft Windows Tablet PC Edition operating system. Element 20 depicts a title bar for the main window. Element 30 depicts a menu bar for the main window. The menu bar has a “File” and “Edit” menu like most windowed applications which includes common sub-menu commands representing frequently used functions or commands related to a file operation or an edit operation. Element 30 also includes a “Synthesize” menu command. Element 40 depicts a minimize, maximize and close control. Element 50 depicts a drawing and display canvas.
With further reference to element 30 , the “Synthesize” command performs two tasks. The first task is to translate the visual control constructs of the visual programming language of the present application to a text-based representation in any one of a number of existing high-level or intermediate-level computer programming languages. The second is to properly pass through the non-control-construct statements as ASCII text in the same order of execution as captured during the visual and logical representation of the invented language. Execution of this command may be referred to as code synthesis.
The inner workings of code synthesis in accordance with the present invention are as follows. The internal data structures representing program logic are traversed during the code synthesis operation where each node of the syntax tree is visited. A virtual function overridden from the top-level object is called, Synthesize(), which subsequently iterates over all possible target languages checking for enabled targets. Each enabled target object has a corresponding function that contains the correct syntax associated with the named shape. For example, a top-level target is a Program. The Program shape's Synthesize() function is invoked. Each enabled target's Program function is subsequently invoked. The target's Program function opens a file and outputs the correct syntax for a main program in the target language's grammar. This process is repeated for each enabled target. The target's Program function then iterates over each child node in the Program's shape data structure, recursively calling Synthesize on each child shape. This process is repeated until every node is visited in the ordered tree data structure using a depth-first traversal.
With reference to FIG. 6 an instantiation of an exemplary program demonstrating the present invention includes element 100 depicting a “program” shape, or “function” shape depending on the context, that may be captured or drawn with a pen input device. Element 100 is a line or arrow drawn from the top of the page down toward the bottom. The computer recognizes the down-arrow shape and responds with a prompt for the function or program definition name 110 . This is known as shape recognition in the Tablet PC operating system's application program interface, or API.
The user may enter the name using a pen into a pen-enabled input box or by other means of entering data, such as a keyboard or voice recognition. In the case of pen-enabled input, the computer recognizes hand-written text and converts the name to ASCII text. This is known as text recognition in the Tablet PC's API. The computer stores the shape representation and it's named text in variables adhering to the internal data structures that represent a structured syntax tree conforming to standard compiler theory.
In response to this shape recognition, the computer realizes that a function named “Main” does not exist and therefore implicitly designates this function as the main function named “Main”. Every executable binary program must contain a main entry point. In code compiled from the C# programming language, that entry is called “Main”. Therefore, the text captured in element 110 becomes the name of the text file, in this case, MyProgram.cs, that is created during the code synthesis operation including a “.cs” file extension. In compiler terminology, this file is known as a translation unit. This text-file based representation of program logic may be run through a compiler tool, such as the csc.exe Microsoft C# compiler, to produce a binary executable representation of the program logic.
This embodiment will synthesize the data structures representing the code needed to create a main function in the C# programming language as depicted in the following Listing 1 :
Listing 1
namespace MyProgram
{
class MyProgram
{
static void Main( )
{
}
}
}
In the presence of a main program definition, alternatively, the invention would explicitly recognize the arrow shape as a named function and store the named shape in the appropriate variables adhering to the internal data structures representing a structured syntax tree conforming to standard compiler theory.
Declaring a program as in FIG. 6 defines a main thread of execution. Compiled versions of computer programs like the one depicted in Listing 1 are loaded from disk into memory and then executed from top to bottom, one instruction at a time. Therefore, the actual shape of the “Program” or “Function” shape is an arrow from top to bottom that visualizes this flow of computer instruction execution or control flow.
The present invention utilizes traditional input from a keyboard, as well as natural input mechanisms of the Tablet PC operating system to recognize hand-written text. Therefore, it is defined that any text recognition performed by the VPL editor application that is initiated without a computer prompt is interpreted as a literal block of non-control construct statements in the targeted text-based programming language upon code synthesis. The definition of blocks of non-control constructs is analogous to typing in a word processor or other computer program editors. The text is captured by the input device and displayed on the computer's display device at the place where the insertion cursor is located. This process is known as an echo to the screen, one character at a time.
With reference to FIG. 7 and with continuing reference to FIG. 6 , a block of non-control-construct statements is created just as in any traditional text-based programming language. Elements 140 and 150 comprise a local variable declaration within the scope of the defined thread of execution, in this case the main program. Element 140 is the type declaration and element 150 is the named variable associated with the type declaration. This variable declaration is captured with the following sequence of events. After creating a named program, the user begins typing on the keyboard. The computer responds by storing the text as a block of statements to be translated literally in the text-based code synthesis. The block is stored as a node in the internal data structures at the appropriate location to preserve the sequence of program execution as defined by the visual programming language. This type of node may be referred to as a literal grammar block or a block of non-control construct statements.
Elements 160 and 170 define another local variable declaration with element 160 being a type declaration, e.g., integer, and element 170 being the named variable associated with the type declaration. Element 180 is a reference to a library function instruction to the computer to produce output constructed in the form of the string of characters presented in quotation marks.
This embodiment would synthesize the corresponding C# code as depicted in the following Listing 2 for the illustration in FIG. 7 :
Listing 2
namespace MyProgram
{
class MyProgram
{
static void Main( )
{
SomeClass theClass;
Int depth;
Console.WriteLine(“This is a library function”);
}
}
}
With reference to FIG. 8 and with continuing reference to FIGS. 6 and 7 , an instantiation of a conditional control-flow statement branching off of the main thread of execution is shown wherein element 204 depicts the entry point of the conditional statement branching from the previous control flow. Element 206 depicts another branch to form a parallel branch of control flow that is analogous to a parallel electrical circuit. Element 208 depicts a Boolean control statement that resolves to either true or false. Elements 208 and 210 are analogous to switches in an electrical circuit that are either on or off, allowing or preventing the flow of electrons respectively. Element 210 is another Boolean control statement. Elements 208 and 210 taken together depict an ‘or’ condition in text-based computer programming languages. Either condition can be true for the resulting block of code to be executed. Element 220 depicts the joining point of control flow that returns program control flow into element 230 . Element 230 depicts the local branch of control flow also known as the shapes body. Element 240 depicts a block of non-control construct statements that are executed if either conditions in elements 208 and 210 resolve to true. Element 250 is the return path of control-flow to the calling thread of execution.
In operation, the user constructs the visual shape by first drawing a line segment from a point 204 intersecting the main branch to the left and extending the line segment to the right as depicted by element 205 . The computer recognizes the shape as a conditional expression and responds with a prompt for a condition expression. The user types the conditional expression “depth==0”. The computer responds by completing the conditional expression shape depicted in elements 220 , 230 and 250 . This is analogous to completing an electrical circuit. The computer stores the shape representation and it's text in variables adhering to the internal data structures that represent a structured syntax tree conforming to standard compiler theory.
The user then draws with a pen and intersects element 205 with an “L” shape as depicted by element 207 . The computer recognizes this shape in the context of the conditional statement and prompts the user for another condition in parallel with element 208 . The computer responds with a prompt for another conditional statement. The user then types the conditional expression “theClass.Count==0”. The computer then joins the control flow from the preceding conditional statement in element 210 to the local branch of control flow depicted in element 230 . This join is depicted by element 225 . The computer updates the shape representation in internal data structures.
Element 240 depicts a block of non-control construct statements that are created when the user types text without a prompt from the computer. This is analogous to typing into a normal text editor at the current cursor location.
This embodiment would synthesize the corresponding C# code as depicted in the following Listing 3 for the illustration in FIG. 8 :
Listing 3
namespace MyProgram
{
class MyProgram
{
static void Main( )
{
SomeClass theClass;
int depth;
Console.WriteLine(“This is a library function”);
if(depth == 0 || theClass.Count == 0)
{
Console.WriteLine(“This is a block “);
Console.WriteLine(“of code in an “);
Console.WriteLine(“IF “);
Console.WriteLine(“control statement”);
}
}
}
}
FIG. 9 is an instantiation of a looping control construct branching off of the main thread of execution in sequence immediately following the conditional construct above it. This particular looping control construct is analogous to a ‘foreach’ loop in C#. Element 310 depicts the entry point of the looping statement branching from the previous control flow. Element 320 depicts a local variable type declaration to the looping body. Element 330 depicts a variable declaration associated with the type in element 320 that receives a member from the collection depicted in element 350 . Element 340 is the keyword ‘in’ that ties the local variable declaration from 320 and 330 to element 350 . Element 360 depicts the local branch of control flow that is executed for each element that exists in 350 . Element 360 is also known as the shapes body. Element 370 depicts a triple-headed arrow representing the point of return to the calling thread of execution. The shape of element 370 differentiates this loop from other forms of looping control constructs, such as ‘for’ and ‘while’ loops.
The user constructs the visual shape by drawing a curved arc intersecting the main branch at element 310 and initially extending the curve in the upward direction, then looping the curve downward and then back up to intersect the main branch again at element 370 . The user then draws three arrow heads at the head of the arrow depicted in element 370 . The computer recognizes this shape as a looping control construct and responds with a prompt for a local variable type and declaration for elements 320 and 330 , respectively. The user types the declaration. The computer responds by displaying element 340 and prompting for the name of the collection in element 350 . The user types the referenced collection name. The computer stores the shape representation and it's text in variables adhering to the internal data structures.
This embodiment would synthesize the corresponding C# code as depicted in the following Listing 4 for the illustration in FIG. 9 :
Listing 4
namespace MyProgram
{
class MyProgram
{
static void Main( )
{
SomeClass theClass;
int depth;
Console.WriteLine(“This is a library function”);
if(depth == 0 || theClass.Count == 0)
{
Console.WriteLine(“This is a block “);
Console.WriteLine(“of code in an “);
Console.WriteLine(“IF “);
Console.WriteLine(“control statement”);
}
foreach(Object oh in theClass)
{
}
}
}
}
FIG. 10 is an instantiation of a nested looping control construct branching off of the previous looping control flow. This particular looping control construct is analogous to a ‘for’ loop in C#. Element 410 depicts the entry point of the looping statement branching from the previous control flow. Element 420 depicts a local variable type declaration to the looping body. Element 430 depicts a conditional expression that resolves to true or false and is the terminating condition for the loop. Element 440 is an assignment statement associated with the control condition in element 430 . Element 450 depicts the local branch of control flow that is executed while the condition in element 430 resolves to true. Element 450 is also known as the shapes body. Element 460 depicts a double-headed arrow representing the point of return to the calling thread of execution. The shape of element 460 differentiates this loop from other forms of looping control constructs, such as ‘foreach’ and ‘while’ loops.
The user constructs the visual shape by drawing a curved arc intersecting the main branch at element 410 and initially extending the curve in the upward direction, then looping the curve downward and then back up to intersect the calling branch again at element 460 . The user then draws two arrow heads as depicted in element 460 . The computer recognizes this shape as a looping control construct and responds with a prompt for the expression in element 420 . The user types the expression. The computer responds by prompting the loop control expression depicted in element 430 . The user types the expression. The computer responds by prompting for the assignment expression depicted in element 440 . The computer stores the shape representation and it's text in variables adhering to the internal data structures.
Element 450 depicts a block of non-control-construct statements that are created when the user types text without a prompt from the computer. This is analogous to typing into a normal text editor at the current cursor location.
This embodiment would synthesize the corresponding C# code as depicted in the following Listing 5 for the illustration in FIG. 10 :
Listing 5
namespace MyProgram
{
class MyProgram
{
static void Main( )
{
SomeClass theClass;
int depth;
Console.WriteLine(“This is a library function”);
if(depth == 0 || theClass.Count == 0)
{
Console.WriteLine(“This is a block “);
Console.WriteLine(“of code in an “);
Console.WriteLine(“IF “);
Console.WriteLine(“control statement”);
}
foreach(Object oh in theClass)
{
for(int i; i < depth; i++)
{
Console.WriteLine(“This is a block “);
Console.WriteLine(“of code in an “);
Console.WriteLine(“FOR loop “);
Console.WriteLine(“control statement”);
}
}
}
}
}
FIGS. 11 a - 11 b show an instantiation of a nested conditional control-flow statement branching off of the previous thread of execution. Element 510 depicts the entry point of a conditional statement branching from the previous control flow. Element 520 depicts a Boolean control statement that resolves to either true or false. Element 530 depicts the point of control flow that returns program control flow into the shape's body. Element 540 depicts the local branch of control flow, or the shapes body. Element 550 depicts a block of non-control-construct statements that are executed if the condition in element 520 resolves to true. Element 560 is the return path of control-flow to the calling thread of execution.
The user constructs the visual shape by first drawing a line segment from a point intersecting the preceding branch to the left and extending the line segment to the right as depicted in element 510 . The computer recognizes the shape as a conditional expression and responds with a prompt for a conditional expression. The user types the conditional expression “oh==InkType”. The computer responds by completing the conditional expression shape depicted in elements 530 , 540 and 560 . This is analogous to completing an electrical circuit. The computer stores the shape representation and it's text in variables adhering to the internal data structures that represent a structured syntax tree conforming to standard compiler theory.
Element 550 depicts a block of non-control-construct statements that are created when the user types text without a prompt from the computer. This is analogous to typing into a normal text editor at the current cursor location.
This embodiment would synthesize the corresponding C# code as depicted in the following Listing 6 for the illustration in FIGS. 11 a - 11 b :
Listing 6
namespace MyProgram
{
class MyProgram
{
static void Main( )
{
SomeClass theClass;
int depth;
Console.WriteLine(“This is a library function”);
if(depth == 0 || theClass.Count == 0)
{
Console.WriteLine(“This is a block “);
Console.WriteLine(“of code in an “);
Console.WriteLine(“IF “);
Console.WriteLine(“control statement”);
}
foreach(Object oh in theClass)
{
for(int i; i < depth; i++)
{
Console.WriteLine(“This is a block “);
Console.WriteLine(“of code in an “);
Console.WriteLine(“FOR loop “);
Console.WriteLine(“control statement”);
}
if(oh == InkType)
{
Console.WriteLine(“This is “);
Console.WriteLine(“a block “);
Console.WriteLine(“of code “);
Console.WriteLine(“in an “);
Console.WriteLine(“IF “);
Console.WriteLine(“control “);
Console.WriteLine(“statement”);
}
}
}
}
}
Editing and moving shapes may be achieved by click-and-drag, and drag-and-drop techniques to change the imperative logic for the order of program execution. For example, moving a visual statement from one level of block hierarchy to another sub-block changes the order of program execution. Entire blocks, and their sub-blocks may be moved and manipulated, or even deleted.
Comparison logic is edited by similar click-and-drag, drag-and-drop techniques. Changing the sequence of expressions into different series or parallel order changes the logic of the comparison conditions. Likewise, applying or removing “not” conditions.
FIGS. 12 a - 12 b illustrate the completed program without detailed elements whose corresponding code is depicted in Listing 6 above.
FIGS. 13( a )- 13 ( m ) illustrate exemplary, non-limiting visual shape control constructs and their text-based equivalencies in accordance with the present invention that can be implemented.
As can be seen, the present invention enables a user to enter non-character based drawing symbols (drawing figures or drawing strokes) into a computer, which, in response thereto, prompts the user to enter data related to a programming function corresponding to each drawing symbol. In response to the entry of data for each drawing symbol, the computer converts the data into the corresponding correct syntax for the function associated with the drawing symbol. To each drawing symbol, one or more additional drawing symbols can be connected to define one or more functions and the corresponding syntax to be executed. Thus, by simply using drawing symbols and, for each drawing symbol, entering data related to functions corresponding to said symbol, a user can form a computer program or thread of execution that includes correctly syntaxed programming instructions.
The present invention has been described with reference to the preferred embodiment. Obvious modifications and alterations will occur to others upon reading and understanding the preceding detailed description. For example, the present invention was described in connection with the use of a pen for entering drawing symbols on a Tablet PC. However, this is not to be construed as limiting the invention since it is envisioned that other means for entering drawing symbols or figures into a suitably programmed computer can also or alternatively be utilized. For example, instead of utilizing a pen to input drawing symbols into a Tablet PC, a user can also or alternatively use his finger on a touchpad of a computer to enter such drawing symbols. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
|
The invention is a computer programming method that includes inputting a drawing shape or drawing figure into a computer via a user interface of the computer. In response to a prompt that is generated related to the input drawing shape or drawing figure, data is input into the computer via the user interface. Computer program code is then synthesized that is related to the input drawing shape or drawing figure and the input data. The foregoing steps can be repeated for at least one other drawing shape or drawing figure that has an entry point connected to a previously entered drawing shape or drawing figure.
| 6
|
BACKGROUND OF THE INVENTION
The present invention relates to the method, device and catalyst to clean exhaust gas discharged from an internal combustion engine including a car, and particularly to the method, device and catalyst to clean exhaust gas discharged from an internal combustion engine permitting lean burning of fuels and from a car equipped with said engine.
According to a heretofore known method, an exhaust gas cleaning catalyst is placed in the exhaust gas flow path of the internal combustion engine, and exhaust gas having an air-fuel ratio higher than theoretical air-fuel ratio (hereinafter referred to as “oxidation atmosphere”) and exhaust gas having an air-fuel ratio equal to or smaller than theoretical air-fuel ratio (hereinafter referred to as “reduction atmosphere”) are alternately made to contact said catalyst, thereby removing nitrogen oxides in exhaust gas. This method is disclosed, for example, in the Official Gazette of Japanese Patent Laid-Open NO. 212933/1998.
According to the Official Gazette of Japanese Patent Laid-Open NO. 327617/1997, a catalyst used in this type of exhaust gas cleaning method includes an alkaline earth metal and titanium. A catalyst containing titanium in the form of amorphous material is disclosed in said Gazette. The Official Gazette of Japanese Patent Laid-Open NO. 109032/1998 discloses a catalyst containing alkaline earth metal and titanium, wherein part of these materials take the form of composite oxides. The Official Gazettes of Japanese Patent Laid-Open NO. 327617/1997 and NO. 109032/1998 disclose that SOx contained in exhaust gas becomes difficult for alkaline earth metal to capture, and this makes it possible to suppress poisoning by SOx.
Inventions described in the Official Gazettes of Japanese Patent Laid-Open NO. 327617/1997 and NO. 109032/1998 are mainly intended to prevent alkaline earth metal as an NOx capturing agent from being poisoned by SOx. However, alkaline earth metal is not always immune to poisoning by SOx; it is subjected to poisoning by SOx if a long-term operation is performed in the oxidation atmosphere, and NOx removing performances are deteriorated.
SUMMARY OF THE INVENTION
The object of the present invention to provide an exhaust gas cleaning method ensuring excellent NOx removing performances, an exhaust gas cleaning catalyst, and an exhaust gas cleaning device, characterized by a high resistance to SOx poisoning.
The present invention ensures that the SOx deposited on catalyst in the oxidation atmosphere can be effectively removed by creating a reduction atmosphere.
The present invention relates to the exhaust gas cleaning method, exhaust gas cleaning catalyst and exhaust gas cleaning device featuring the following forms of embodiment:
1. An exhaust gas cleaning method for internal combustion engine wherein
(1) an exhaust gas cleaning catalyst is placed in the exhaust gas flow path of an internal combustion engine, and (2) exhaust gas having an air-fuel ratio higher than theoretical air-fuel ratio and exhaust gas having an air-fuel ratio equal to or smaller than theoretical air-fuel ratio are alternately made to contact said catalyst, thereby removing nitrogen oxides in exhaust gas; said exhaust gas cleaning method for internal combustion engine characterized in that said catalyst contains at least one element selected from alkaline metal and alkaline earth metal, Rh, Pt, and a CO absorbent component where the absolute value (ΔH) of Co adsorbent enthalpy on the metal single crystal (111) surface is 142 KJ/mol or more; said exhaust gas cleaning method further characterized in that the CO desorption temperature reaches the maximum level within the temperature range from 200 to 220° C. in the event of temperature rise in He gas flow at the rate of 5 to 10° C./min. after adsorption of CO to said catalyst by saturation at 100° C.
2. An exhaust gas cleaning method for internal combustion engine in said catalyst characterized in that said CO adsorbent compound comprises at least one type selected from Pd, Ir and Ru (claim 2 ).
3. An exhaust gas cleaning method for internal combustion engine characterized in that said catalyst contains at least one element selected from Ti, Si and Zr, and includes a composite oxide comprising said type(s) and at least one element selected from Na, Mg, K, Li, Cs, Sr and Ca.
4. An exhaust gas cleaning method for internal combustion engine wherein said catalyst further contains Ce.
5. An exhaust gas cleaning method for internal combustion engine wherein
said exhaust gas cleaning method for internal combustion engine being characterized in that said catalyst contains at least one element of alkaline metal or alkaline earth metal selected from Na, Mg, K, Li, Cs, Sr and Ca on the surface of a porous carrier, Rh, Pt, at least one element selected from Zr and Ti and Si, and at least one element selected from Pd, Ir and Ru; wherein the ratios of components relative to 100 parts by weight of said porous carrier are 5 to 30 pts. wt. for alkaline metal or alkaline earth metal in total, 8 to 35 100 pts. wt. for Ti, 3 to 25 pts. wt. for Si, 3 to 25 pts. wt. for Zr, 0.05 to 0.5 pts. wt. for Rh, 1.5 to 5 pts. wt. for Pt, and 0.25 to 3 pts. wt. for Pd, Ir and Ru in total.
6. An exhaust gas cleaning method for internal combustion engine wherein said catalyst further contains alkaline earth metal on said porous carrier, and the ratio of said alkaline earth metal relative to 100 parts by weight of said porous carrier is 5 to 50 pts. wt.
7. An exhaust gas cleaning catalyst for internal combustion engine which comprises at least one element selected from alkaline metal or alkaline earth metal, Rh, Pt and the CO adsorbent component where the absolute value (ΔH) of Co adsorbent enthalpy on the metal single crystal (111) surface is 142 KU/mol or more, and where the CO desorption temperature reaches the maximum level within the temperature range from 200 to 220° C. in the event of temperature rise in He gas flow at the rate of 5 to 10° C./min. after adsorption of CO to said catalyst by saturation at 100° C.
8. An exhaust gas cleaning catalyst for internal combustion engine wherein said CO adsorbent compound comprises at least one element selected from Na, Mg, K, Li, Cs, Sr and Ca, and contains a composite oxide comprising said element(s) and at least one element selected from Zr and Ti and Si.
9. An exhaust gas cleaning catalyst for internal combustion engine wherein said alkaline metal or alkaline earth metal comprises at least one type selected from Na, Mg, K, Li, Cs, Sr and Ca, and contains a composite oxide comprising said element(s) and at least one type selected from Zr and Ti and Si.
10. An exhaust gas cleaning catalyst for internal combustion engine which further contains Ce.
11. An exhaust gas cleaning catalyst for internal combustion engine which has on the surface of a porous carrier at least one element selected from alkaline metal and alkaline earth metal, Rh, Pt, at least one element selected from Ti, Si and Zr, and at least one element selected from Pd, Ir and Ru; wherein said alkaline metal or alkaline earth metal comprises at least one element selected from Na, Mg, K, Li, Cs, Sr and Ca;
the ratios of components relative to 100 parts by weight of said porous carrier are 5 to 30 pts. wt. for alkaline metal or alkaline earth metal in total, 8 to 35 pts. wt. for Ti, 3 to 25 pts. wt. for Si, 3 to 25 pts. wt. for Zr, 0.05 to 0.5 pts. wt. for Rh, 1.5 to 5 pts wt. for Pt, and 0.25 to 3 pts. wt. for at least one element selected from Pd, Ir and Ru in total.
12. An exhaust gas cleaning catalyst for internal combustion engine on the surface of said porous carrier, characterized in that said catalyst further contains rare earth metal, and the ratio of said rare earth metal relative to 100 parts by weight of said porous carrier is 5 to 50 pts. wt.
13. An exhaust gas cleaning device for internal combustion engine characterized in that an exhaust gas cleaning catalyst is arranged in the exhaust gas flow path of said internal combustion engine where there is a flow of exhaust gas having an air-fuel ratio higher than theoretical air-fuel ratio and exhaust gas having an air-fuel ratio equal to or smaller than theoretical air-fuel ratio;
said exhaust gas cleaning device further characterized in that said exhaust gas cleaning catalyst contains at least one element selected from alkaline metal and alkaline earth metal, Rh, Pt, and CO adsorbent component wherein the absolute value (ΔH) of CO adsorbent enthalpy on the metal single crystal (111) surface is 142 KJ/mol or more, and where the CO description temperature reaches the maximum level within the temperature range from 200 to 220° C. in the event of temperature rise in He gas flow at the rate of 5 to 10° C./ml after adsorption of Co to said catalyst by saturation at 100° C.
14. An exhaust gas cleaning device for internal combustion engine wherein said CO adsorbent component comprises at least one element selected from Pd, Ir and Ru.
15. An exhaust gas cleaning device for internal combustion engine wherein said alkaline metal or alkaline earth metal comprises at least one element selected from Na, Mg, K, Li, Cs, Sr and Ca, and contains a composite oxide comprising said element(s) and at least one element selected from Zr and Ti and Si.
16. An exhaust gas cleaning device for internal combustion engine wherein said catalyst further contains Ce.
17. An exhaust gas cleaning device for internal combustion engine characterized in that an exhaust gas cleaning catalyst is arranged in the exhaust gas flow path of said internal combustion engine where there is a flow of exhaust gas having an air-fuel ratio higher than theoretical air-fuel ratio and exhaust gas having an air-fuel ratio equal to or smaller than theoretical air-fuel ratio;
wherein said catalyst further contains on the surface of a porous carrier at least one element selected from alkaline metal and alkaline earth metal, Rh, Pt, at least one element selected from Ti, Si and Zr, and at least one element selected from Rh, Pt and Ru; said exhaust gads cleaning device further characterized in that the ratios of components relative to 100 parts by weight of said porous carrier are 5 to 30 pts. wt. for alkaline metal or alkaline earth metal in total, 8 to 35 pts. wt. for Ti, 3 to 25 pts. wt. for Si, 3 to 25 pts. wt. for Zr, 0.05 to 0.5 pts. wt. for Rh, 1.5 to 5 pts. wt. for Pt, and 0.25 to 3 pts. wt. for at least one element selected from Pd, Ir and Ru in total; wherein the CO desorption temperature reaches the maximum level within the temperature range from 200 to 220° C. in the event of temperature rise in He gas flow at the rate of 5 to 10° C./min. after adsorption of CO to said catalyst by saturation at 100° C.
18. An exhaust gas cleaning device for internal combustion engine on the surface of said porous carrier, characterized in that said exhaust gas cleaning catalyst further containing rare earth metal, and the ratio of said rare earth metal relative to 100 parts by weight of said porous carrier is 5 to 50 pts. wt.
According to the present invention, alkaline metal or alkaline earth metal causes NOx to be captured on the catalyst surface in the oxidation atmosphere. Then, a composite oxide comprising said alkaline metal, alkaline earth metal, and at least one element selected from Ti, Zr and Si makes it possible to capture NOx in the oxidation atmosphere firmly on the catalyst surface. Pt and Rh serve as an NOx reducing agent. They remove by reduction the NOx remaining captured onto the NOx capturing compound surface in the oxidation atmosphere by means of the reducing agent such ad HC, CO and H 2 coexisting in exhaust gas in the reduction atmosphere. The CO adsorbent compound acts to remove by reduction the SOx captured by the capturing compound, using the reducing agent such as CO, HC and H 2 contained in the exhaust gas of reduction atmosphere.
SOx poisoning in exhaust gas cleaning catalyst according to the present invention is caused approximately by equations (1) to (3). Firstly, as shown in equation (1), SO 3 is generated by oxidation of SO 2 . The generated SO 3 reacts with the compound capturing the NOx (M:NOX capturing agent) to generate sulfite compound as shown in equation (2), or sulfate compound as given in equation (3). Sulfite compound and sulfate compound are strongly acid; therefore, when these are generated, it becomes difficult to capture the NOx which will become acid molecule, as illustrated in equation 4.
SO 2 +1/2O 2 →SO 3 (1)
M+SO 3 →M−SO 3 (2)
M−SO 3 +1/2O 2 →M−SO 4 (3)
M+NOx→M−NOx (4)
The inventions disclosed in the Official Gazettes of Japanese Patent Laid-Open NO. 327617/1997 and NO. 1090327/1998 show that the progress of equations (2) and (3) is suppressed by Ti carried by alkaline earth metal serving as an NOx capturing agent.
By contrast, the present inventors consider that deposition of SOx onto the NOx capturing agent cannot be avoided in the oxidation atmosphere, and aimed at achieving an effective removal of the captured SOx in the atmosphere of reduction.
Reaction of removing the SOx captured on the catalyst surface is considered to progress approximately according to the equations (5) to (8). The HC, CO and H 2 coexisting in exhaust gas in the reduction atmosphere are captured on the HC, CO and H 2 adsorbent (represented in terms of PM). The HC, CO and H 2 (represented in terms of PM-HC, CO and H 2 ) adsorbed on PM react with sulfite compound as shown in expression (6), and the captured SOx is removed from the NOx capturing agent. SOx is also removed by the reaction of reducing sulfate compound to sulfite compound as expressed in equation (7) and by the reaction of reducing sulfate compound as given in equation (8).
PM+HC, CO, H 2 →PM−HC, CO, H 2 (5)
M−SO 3 +PM−HC, CO, H 2 −PM+M+H 2 S+SO 2 +CO 2 +H 2 O (6)
M−SO 4 +PM−HC, CO, H 2 −PM+M−SO 3 +CO 2 +H 2 O (7)
M−SO 4 +PM−HC, CO, H 2 −PM+M+H 2 S+SO 2 +CO 2 +H 2 O (8)
To develop the reaction in the equation (5), it is necessary to have HC, CO and H 2 adsorbent to adsorb HC, CO and H 2 . Study of the reaction of removing the captured SOx in the reduction atmosphere where NO and oxygen coexist has revealed that, of HC, CO and H 2 , CO makes the greatest contribution to the removal of captured SOx.
The captured SOx can be most effectively eliminated by the CO adsorbent which selectively adsorbs CO out of HC, CO and H 2 .
Reaction temperature is also involved in the reaction of removing the captured SOx. Higher the reaction temperature, the better for it. In automobiles, however, feed of exhaust gas in the reduction atmosphere of 600° C. or more leads to increase in fuel costs. From the view point of practical utility, therefore, reaction temperature is preferred to be about 500° C.
As can be seen from the above discussion, the present invention aims at achieving at effective removal of the captured SOx, using such reducing agents as HC, CO and H 2 in the reduction atmosphere of about 500° C.
The absolute value of CO adsorption enthalpy (ΔH) serves as an indication to judge the CO adsorption power of CO adsorbent. A material having a greater absolute value in CO adsorption enthalpy has a greater capacity to attract CO. The following shows the absolute values (ΔH) of CO adsorbent enthalpy on the metal single crystal (111) surface in the descending order (Source: Basic Course in Chemical Handbook by The Chemical Society of Japan):
Ru (ΔH: 160 KJ/mol)>Pd (142), Ir (142)>Pt (138)>Rh (132)>Co (128)>Ni (125)>Fe (105)>Cu (50)>Ag (27).
The above shows that Ru, Pd and Ir are preferred as CO adsorbent having a greater capacity to attract CO. Ru is subjected to evapotranspiration at high temperature, and Ir is of rare occurrence. When practical utility is taken into account, Pd and CO less subjected to evapotranspiration and characterized by stable occurrence are best preferred as CO adsorbent.
CO adsorption power varies according to the carried state, added volume and catalyst baking temperature in addition to the type of metal of the CO adsorbent. The degree of CO adsorption power of the CO adsorbent can be evaluated according to the thermal desorption method. Measurement procedures can be described as follows: Temperature is raised in He gas flow at the rate of 5 to 10° C./min. after adsorption of CO onto exhaust gas cleaning catalyst by saturation at 100° C. Then the volume of CO desorption with respect to temperature is measured at the catalyst outlet. For the catalyst with high CO adsorption power, the temperature where the volume of CO desorption is maximized shifts to the higher side.
For the exhaust gas cleaning catalyst capable of removing the captured SOx in the reduction atmosphere of about 500° C., the volume of CO desorption was maximized at the temperature ranging from 200 to 220° C. For the exhaust gas cleaning catalyst incapable of removing the captured SOx, the volume of CO desorption was maximized at about 175° C.
The above discussion suggests that Pd, Ru and Ir having the absolute values (ΔH) of CO adsorbent enthalpy of 140 kJ/mol or more on the metal single crystal (111) surface are preferred as CO adsorbent. From the view point of practical utility, Pd is the most preferable for said reasons. Furthermore, the catalyst including CO adsorbent is best preferred when the maximum value of the CO desorption temperature reaches 200 to 220° C. in thermal desorption.
The captured SOx in the reduction atmosphere can be more quickly removed when the volume of SOx captured by the NOx capturing agent is smaller. Furthermore, formation of SOx on the catalyst surface as sulfite compound is more likely to be reduced than formation of SOx as sulfate compound. The NOx capturing agent comprises at least one type selected from Na, Mg, K, Li, Cs, Sr and Ca, and includes a composite oxide comprising said type(s) and at least one type selected from Ti, Si and Zr. When NOx is made to be captured on the catalyst surface by chemical adsorption, a smaller volume of SOx is deposited on the NOx adsorbent. Even when SOx is deposited, generation of sulfite compound proceeds, thereby facilitating SO reduction.
Composite oxides between Sr and Ti include SrTiO 3 , Sr 2 TiO 4 , Sr 3 Ti 2 O 7 , Sr 4 Ti 3 O 10 , SrTi 12 O 19 , SrTi 21 O 38 .
Composite oxides between Sr and Si include SrSiO 3 , Sr 3 SiO 5 and Sr 2 SiO 4 .
Composite oxides between Sr and Zr include SrZrO 3 , Sr 2 ZrO 4 , Sr 3 Zr 2 O 7 and Sr 4 Zr 3 O 10 .
Composite oxides between Sr and Ti and Zr include Sr 2 (Ti 0.25 Zr 0.75 ).
Composite oxides between Sr, Ti and Si include SrTiSi 2 O 8 .
Furthermore, composite oxides formed with at least one type selected from Na, Ti, Si and Zr include the following, for example:
Composite oxides between Na and Ti include Na 2 TiO 3 , Na 2 Ti 3 O 7 , Na 2 T 14 O 9 , Na 2 Ti 6 O 13 , Na 4 Ti 5 O 12 , Na 0.23 TiO 2 , Na 2 TiO 19 , Na 4 Ti 3 O 8 , Na 4 Ti 3 O 8 , Na 4 TiO 4 , Na 8 Ti 5 O 14 , γ-Na 2 TiO 3 , β-Na 2 TiO 3 , NaTiO 2 and Na 0.46 TiO 2 . Of these, Na 2 TiO 3 and Na 2 Ti 3 O 7 are preferred.
Composite oxides between Na and Si include Na 4 SiO 4 , β-Na 2 Si 2 O 5 , Na 2 Si 2 O 5 , Na 2 Si 4 O 9 , γ-Na 2 Si 2 O 5 , Na 6 Si 2 O 7 , α-Na 2 Si 2 O 5 , δ-Na 2 Si 2 O 5 , Na 2 Si 3 O 7 , α-Na 2 Si 2 O 5 , Na 6 Si 8 O 19 , Na 2 Si 3 O 7 , α-Na 2 Si 2 O 5 , Na 2 SiO 3 , Na 4 SiO 4 , Na 2 SiO 3 , Na 4 SiO 4 , α-Na 2 Si 2 O 5 , Na 2 Si 2 O 5 and Na 2 Si 4 O 9 . Composite oxides between Na and Zr include NaZrO 3 , α-NaZrO 3 and Na 2 ZrO 3 . Composite oxides between Na, Zr and Si include Na 2 ZrSiO 5 , Na 2 Zr 2 Si 10 O 31 , Na 14 Zr 2 Si 4 O 11 , Na 2 ZrSi 4 O 11 and Na 14 Zr 2 Si 10 O 31 .
Composite oxides between Na, Ti and Si include Na 2 TiSi 2 O 7 , NaTiSi 2 O 6 and Na 2 TiSiO 5 .
The structure of the above composite oxides can be confirmed by powder X-ray diffractometry. To get said composite oxides, heat treatment at 600° C. or more is preferred. The preferred baking temperature is 700° C.
The catalyst according to the present invention has a three-way component catalyst function in the reduction atmosphere. To increase this function, it is preferred to add to the catalyst of this invention the component which has an oxygen storage function. The material having an oxygen storage function includes cerium (Ce).
To increase the heat resistance of exhaust gas cleaning catalyst, it is preferred to add such rare-earth metals as La and Y in addition to Ce.
The following shows the particularly preferred percentages of the catalyst of the present invention relative to 100 parts by weight of said porous carrier:
8 relative to 100 parts by weight of said porous carrier: 8 to 15 pts. wt. for alkaline metal or alkaline earth metal in total, 4 to 15 pts. wt. for Ti, 5 to 10 pts. wt. for Si, 5 to 10 pts. wt. for Zr, 0.10 to 0.20 pts. wt. for Rh, 1.0 to 3.0 pts. wt. for Pt, 0.25 to 0.8 pts. wt. for Pd, and 10 to 30 pts. wt. for rare-earth metal.
Catalyst of the present invention can be used in a great variety of forms. For example, it can be used in the form of honeycomb which is obtained by coating with powdered catalyst carrying various components the honeycomb structure comprising various materials such as cordierite and stainless. Furthermore, it can be used in the form of pellets, granules and powder. The form of honeycomb is preferred when it is placed in the exhaust gas flow path of a car.
Catalyst can be prepared by physical preparation methods including impregnation method, kneading method, coprecipitation method, sol-gel method, ion exchange method and vapor deposition method, as well as by methods based on chemical reaction.
If the CO adsorbent and NOx capturing agent are placed close to each other, the reaction of removing the captured SOx in equations (5) to (8) is likely to progress. In the case of catalyst preparation by impregnation method, therefore, it is preferred to use the mixed solution of CO adsorbent and NOx capturing agent and to provide simultaneous impregnation of CO adsorbent and NOx capturing agent on the carrier.
Nitrate compound, acetic acid compound, complex compound, hydroxide, carbonic acid compound, organic compound, dinotrodiamine complex and other various types of compounds, as well as metal and metal oxide can be used as starting materials for NOx removing catalyst.
When Pd is used as CO adsorbent, dinotrodiamine Pb solution is preferred. Use of dinotrodiamine Pb solution increases the proximity effect with NOx capturing agent. This leads to resultant removal of captured SOx from the NOx capturing agent by reduction.
In said methods, alumina, titanium, silica, silica-alumina, magnesia and such related metal oxides as well as composite oxides can be used as as a porous carrier. Since it is heat resistant, alumina is most preferred.
BRIEF DESCRIPTION OF DRAWING
FIG. 1 shows the relationship between the CO desorption capacity and temperature for catalyst 1 (embodiment) and catalyst 1 (comparative example).
FIG. 2 is a schematic diagram representing the engine system installed on the exhaust gas cleaning device according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 2 shows an example of the engine system equipped with exhaust gads cleaning device. The engine 99 of the present embodiment is designed as a cylinder internal jet type. Said engine is supplied with air fed through air cleaner 1 and fuel jetted from the injector 5 fed from the fuel tank 13 . Air flow path is provided with an air flow sensor 2 and throttle valve 3 , and the fuel flow path is equipped with a fuel pump 12 . An exhaust gas cleaning catalyst 18 corresponding to the exhaust gas cleaning device of the present invention is placed in the exhaust gas flow path. An air-fuel ratio sensor 19 and exhaust gas temperature sensor 21 are installed on the upstream side of the exhaust gas clean catalyst 18 . A temperature sensor 22 to measure the catalyst outlet temperature is mounted on the downstream side. Various pieces of information required for engine operations are fed to the engine control unit 25 . In the present embodiment, the signals from the air flow sensor 2 , throttle valve 3 , load sensor 8 to measure the ratio of depressing the acceleration pedal 7 , air-fuel ratio sensor 19 , temperature sensors 21 and 22 , water temperature sensor 28 to measure the engine water temperature and crank angle sensor 29 are sent to the engine control unit 25 . Numeral 9 in FIG. 2 denotes a piston, and 26 shows a knock sensor. The injector 5 and firing plug 6 are controlled by signals from the engine control unit 25 .
The engine control unit 25 has an operation state determining means and an air-fuel ratio (A/F) controller. Said operation state determining means has a captured NOx volume estimating means, a discharged NOx volume estimating means, a captured SOx volume estimating means, and a discharged SOx volume estimating means. Captured NOx volume at the air-fuel ratio higher than theoretical ratio is estimated by the captured NOx volume estimating means, and captured SOx volume is estimated by captured SOx volume estimating means. When said captured NOx volume estimating means or captured SOx volume estimating means has determined that the predetermined level of captured NOx volume or captured SOx volume has been exceeded, then the discharged NOx volume estimating means and discharged SOx volume estimating means send a command to the A/F controller. In response to this command, the engine control unit 25 causes the cylinder internal injection engine 99 to be operated at the air-fuel ratio equal to or below the theoretical air-fuel ratio.
When the discharged NOx volume estimating means has determined that the predetermined level of captured NOx volume is removed, and the discharged SOx volume estimating means has determined that the predetermined level of captured SOx volume is removed, then a command is sent to the A/F controller. In response to this command, the engine control unit 25 causes the cylinder internal injection engine 99 to be operated at the air-fuel ratio above the theoretical air-fuel ratio.
Said predetermined volume is an arbitrarily set volume, e.g. 50% of the maximum captured NOx volume is set as a predetermined captured NOx volume.
Captured NOx and SOx volumes are estimated according to the information sent from air-fuel ratio sensor (or oxygen sensor) 19 , temperature sensors 21 and air flow sensor 2 .
An equation to calculate the adsorbed Nox volume is stored in the captured NOx estimating means in advance, based on the Nox volume in exhaust gas, exhaust gas temperature and lean operation time.
The NOx volume in exhaust gas is calculated from the air-fuel ratio of the exhaust gas obtained from air-fuel ratio sensor (or oxygen sensor) 19 and exhaust gas flow rate gained from air flow sensor 2 .
Exhaust gas temperature is gained from the exhaust gas temperature sensor 21 .
The lean operation time is obtained by time measurement of the air-fuel ratio of the exhaust gas obtained from air-fuel ratio sensor (or oxygen sensor) 19 .
Similarly, an equation to calculate the captured SOx volume is stored in the captured SOx estimating means in advance, based on the SOx volume in exhaust gas, exhaust gas temperature and lean operation time.
It should be noted here that the S volume in the commercially available fuel has an allowable range. To be on the safe side, therefore, the maximum value within the allowable range is stored in the captured SOx estimating means as the S volume in the fuel in advance.
Consequently, SOx concentration in the exhaust gas can be calculated from the volume of fuel used in the cylinder internal injection engine 99 and exhaust gas flow rate. Fuel volume can be calculated from the air-fuel ratio obtained from the air-fuel ratio sensor (or oxygen sensor) 19 . The exhaust gas flow rate is gained air flow sensor 2 .
The discharged volumes of captured NOx and SOx can be estimated by storing an equation for calculation from the air-fuel ratio of exhaust gas, exhaust gas flow rate and exhaust gas temperature into the discharged NOx volume estimating means and discharged SOx volume estimating means in advance.
The following describes the preferred embodiments of the present invention; however, it should not be understood that the present invention is limited only to the following description.
(Embodiment 1)
Slurry consisting of precursors of powdered alumina and alumina and having been adjusted to have nitric acidity was coated on cordierite-made honeycomb (400 cells inc 2 ), and was dried and baked to get alumina coated honeycomb. In this case, said honeycomb was coated with 190 g of alumina per liter of apparent honeycomb capacity. After said alumina coated honeycomb was impregnated with aqueous solution of nitrate and cerium, it was dried at 200° C., then baked at 600° C.
Then it was impregnated with dinitro diamine Pt nitric acid solution, and mixture solution of Rh nitrate, dinitro diamine Pd, Sr nitrate, Mg nitrate and titania sol, and was dried at 200° C., then baked at 700° C.
Then the present inventors obtained catalyst 1 (Embodiment) containing 0.26 g of Pd, 11 g of Sr, 4 g or Ti, 0.9 g of Mg, 0.11 g of Rh, 1.4 g of Pt, and 14 g of Ce for 100 g of alumina in terms of metals. Pd was used as CO adsorbent in catalyst 1 (Embodiment). The present inventors got catalysts 2 to 5 (Embodiments) carrying Co, Ni, Ir and Ru instead of Pd, and catalyst 1 (Comparative Examples) without carrying Pd. It should be noted that the first and second components in Table indicate the order of carrying. The first component is carried earlier. The carried volume with respect to 100 g of alumina is described before the carrier components. For example, “14Ce” indicates that 14 g of Ce is carried with respect to 100 g of alumina in terms of metals.
TABLE 1
1st
Catalyst
component
2nd component
Catalyst 1 (Embodiment)
14Ce
0.26Pd, 11Sr, 4Ti, 0.9Mg,
0.11Rh, 1.4Pt
Catalyst 2 (Embodiment)
14Ce
0.52Co, 11Sr, 4Ti, 0.9Mg,
0.11Rh, 1.4Pt
Catalyst 3 (Embodiment)
14Ce
0.52Ni, 11Sr, 4Ti, 0.9Mg,
0.11Rh, 1.4Pt
Catalyst 4 (Embodiment)
14Ce
0.26Ir, 11Sr, 4Ti, 0.9Mg,
0.11Rh, 1.4Pt
Catalyst 5 (Embodiment)
14Ce
0.26Ru, 11Sr, 4Ti, 0.9Mg,
0.11Rh, 1.4Pt
Catalyst 6 (Embodiment)
14Ce
0.26Ag, 11Sr, 4Ti, 0.9Mg,
0.11Rh, 1.4Pt
Catalyst 1
14Ce
11Sr, 4Ti, 0.9Mg, 0.11Rh,
(Comparative Example)
1.4Pt
TEST EXAMPLE 1
To study resistance to SOx poisoning in catalysts 1 to 6 (Embodiments) and catalyst 1 (Comparative Example), the present inventors examined the NOx removing rate before and after SOx poisoning, and investigated recovery of catalyst performances by catalyst regeneration. Gases used for test was model gas for oxidation atmosphere simulating the lean-burn exhaust gas, model gas for reduction atmosphere simulating combustion at the theoretical air-fuel ratio and SOx poisoning model gas for SOx poisoning in oxidation atmosphere. It should be noted that SOx concentration in said SOx poisoning model gas was set to 150 ppm in order to accelerate catalyst SOx poisoning.
Model gas for oxidation atmosphere was composed of the following; 600 ppm of NOx, 500 ppm of C 3 H 6 , 0.1% of CO, 10% of CO 2 , 5% of O 2 , 10% of H 2 O, and the remaining percentage of N 2 .
Model gas for reduction atmosphere was composed of the following; 1000 ppm of NOx, 600 ppm of C 3 H 6 , 0.5% of CO, 5% of CO 2 , 0.5% of O 2 , 0.3% of H 2 , 10% of H 2 O, and the remaining percentage of N 2 .
Accelerated SOx poisoning model gas was composed of the following; 150 ppm of SO 2 , 600 ppm of NOx, 500 ppm of C 3 H 6 , 0.1% of CO, 10% of CO 2 , 5% of O 2 , 10% of H 2 O, and the remaining percentage of N 2 .
Test was according to the following procedures:
Firstly, model gas for reduction atmosphere and model gas for oxidation atmospheres were subjected to the test in that order where they were alternately fed to the catalyst layer at intervals of three minutes (hereinafter referred to as “repeated test”) for a total of 18 minutes, and the NOx removing rate was measured. In this case, catalyst capacity was 6 cc, and SV was 30,000/h.
Then said accelerated SOx poisoned model gas was passed through the catalyst layer; then model gas for reduction atmosphere and model gas for oxidation atmospheres were alternately fed to the catalyst layer at intervals of three minutes for a total of 18 minutes, and the NOx removing rate was measured after being poisoned by SOx. In this case, poisoning temperature was 300° C. and poisoning time was one hour, with SV of 30,000/h.
Lastly, said model gas for reduction atmosphere was passed through the catalyst layer under the 30,000/h SV conditions at 500° C. for ten minutes (hereinafter referred to as “regeneration”); then model gas for reduction atmosphere and model gas for oxidation atmospheres were alternately fed through the catalyst layer at intervals of three minutes for a total of 18 minutes, and the NOx removing rate was measured.
Unless otherwise specified hereinafter, repeated tests were conducted at the temperature of 400° C. with SV of 30,000/h. Furthermore, NOx removing rate was assumed as the rate of reduction in NOx concentration before and after gas was passed through the catalyst layer after the lapse of ten minutes halfway through the repeated test, namely one minute after switching over to model gas for oxidation atmosphere. NOx removing rate was obtained from Equation 1.
NOx removing rate = ( ( NOx concentration before passing through the catalyst layer ) -
( NOx concentration after passing through the catalyst layer ) ( ( NOx concentration before passing through the catalyst layer ) × 100 ( Equation 1 )
(Test Result)
Table 2 shows the results of measuring the NOx removing rates before and after SOx poisoning treatment and NOx removing rate after regeneration. Recover of the NOx removing rate by regeneration was observed in catalyst 1 (Embodiment) where Pd was carried, catalyst 4 (Embodiment) where Ir was carried and catalyst 5 (Embodiment) where Ru was carried. However, no recover of the NOx removing rate by regeneration was observed in catalyst 1 (comparative Example), catalyst 2 (Embodiment) and catalyst 3 (Embodiment). This clearly indicates that recovery of NOx removing performances by regeneration can be promoted when Pd, Ir and Ru are carried.
Table 3 shows the absolute values (ΔH) of CO adsorbent enthalpy on the metal single crystal (111) surface in the descending order (Source: Basic Course in Chemical Handbook by The Chemical Society of Japan, revised version, 1993) for each CO adsorbent and recovery or non-recovery of NOx removing rate by regeneration. For the metals (Ru, Ir and Pd) with ΔH of 140 kJ/mol or more, recovery of the NOx removing rate was observed.
TABLE 2
NOx removing
NOx removing
Initial NOx
rate (%)
rate (%)
removing rate
after SOx
after
Catalyst
(%)
poisoning
regeneration
Catalyst 1
80
47
49
(Embodiment)
Catalyst 2
70
44
44
(Embodiment)
Catalyst 3
76
42
42
(Embodiment)
Catalyst 4
78
43
45
(Embodiment)
Catalyst 5
76
45
48
(Embodiment)
Catalyst 6
70
40
40
(Embodiment)
Catalyst 1
78
46
46
(Comparative
Example)
TABLE 3
CO adsorbent
Recovery/non-
CO adsorbent
enthalpy
recovery of
Catalyst
(PM)
(kJ/mol-PM)
NOx
Catalyst 1
Pd
142
Recovered
(Embodiment)
Catalyst 2
Co
128
Not recovered
(Embodiment)
Catalyst 3
Ni
125
Not recovered
(Embodiment)
Catalyst 4
Ir
142
Recovered
(Embodiment)
Catalyst 5
Ru
160
Recovered
(Embodiment)
Catalyst 6
Ag
27
Not recovered
(Embodiment)
Catalyst 1
Rh, Pt
Rh: 138, Pt: 132
Not recovered
(Comparative
Example)
TEST EXAMPLE 2
A power X-ray diffractometry was used to measure the structure of Sr in catalyst 1 (Embodiments 1 to 6). SrTiO 3 as a composite oxide of Sr and Ti was formed in any one of Embodiments 1 to 6.
TEST EXAMPLE 3
Catalyst 1 (Embodiment) and catalyst 1 (Comparative Example) were used to measure how CO desorption temperature rose.
(Test Procedure)
A reaction tube was filled with 1 g of powdered catalyst, and temperature was raised to 400° C. in the flow of He gas. Temperature was held at 400° C., and the tube was passed through the 3% CO—He gas for 30 minutes. Then temperature was raised again to 450° C. in the flow of He gas. Temperature was held at 450° C. in the flow of He gas for 30 minutes, then it was reduced to 100° C. After it was confirmed by TCD (thermal conductivity detector) gas chromatography that absorbed CO volume reached the saturation point, temperature was raised to 450° C. at the rate of 5° C. per minute in the flow of He gas. To detect CO desorbed from the catalyst, a TCD gas chromatograph was connected to the reaction tube outlet.
(Test result)
FIG. 1 shows the test result. TCD gas chromatography uses the TCD to measure the thermal conductivity of gas. In the flow of He gas, the thermal conductivity of gas detected by the TCD increases in proportion to CO temperature in the gas. So desorption of CO from the catalyst due to temperature rise causes CO concentration in the gas to be increased. This results in an increase in the thermal conductivity of gas detected by the TCD. CO desorption intensity shown in Table 1 indicates a relative intensity of the thermal conductivity of gas detected by the TCD. For catalyst 1 (Embodiment), the adsorbed CO volume reaches the maximum level at 220° C. For catalyst 1 (Comparative Example), however, the adsorbed CO volume reaches the maximum level at 175° C. To recover the NOx removing performance by regeneration, therefore, it is necessary to use CO adsorbent which has a CO adsorption power to ensure that the adsorbed CO volume reaches the maximum level at about 200° C.
TEST EXAMPLE 4
Model gas for reduction atmosphere was made to pass through catalyst 1 (Embodiment) at the temperature ranging 250 to 500° C. to measure the NOx removing rate and hydrocarbon removing rate.
NOx removing rate was assumed as the rate of reduction in NOx concentration before and after gas was passed through the catalyst layer one minute after switching over to model gas for oxidation atmosphere.
Hydrocarbon removing rate was assumed as the rate of reduction in hydrocarbon concentration before and after gas was passed through the catalyst layer one minute after switching over to model gas for oxidation atmosphere.
The result of measurement indicates that NOx removing rate reached almost 100% level at the temperature ranging from 250 to 500° C. The hydrocarbon removing rate was 80% or more at 300° C. or more, arriving at almost 100% at 400° C. or more.
(Embodiment 2)
For catalyst 1 (Embodiment), the carried Pd volume was changed with respect to 100 g of carrier at the rate of 0.20 to 3.5 g to study the resistance to SOx poisoning according to the test example 1 of Embodiment 1. The rise of Co desorption temperature was also measures according to Test example 3.
Table 4 shows the result. The range of the carried Pd volume where NOx removing performances by regeneration was recovered was 0.25 to 3.0 g with respect to 100 g of carrier. Within said range, the temperature where the desorbed CO volume reaches the maximum level was 200 to 220° C. When the carried Pd volume is 0.85 g or more, there is no improvement in the recovery of NOx removing performances by regeneration even if the carried volume is increased. Consequently, to keep the volume of Pb used to the necessary minimum, the range of the carried Pd volume is preferred to be 0.25 to 0.8 g with respect to 100 g of carrier.
TABLE 4
Temperature
where
Added Pd
desorbed CO
volume with
Initial
NOx removing
NOx removing
volume
respect to
NOx
rate (%)
rate (%)
reaches the
100 g of
removing
after SOx
after
maximum
carrier (g)
rate (%)
poisoning
regeneration
level (° C.)
0.20
78
46
46
175
0.25
80
47
49
200
0.80
95
50
55
220
0.85
85
45
48
200
3.0
80
45
58
200
3.5
78
45
45
175
(Embodiment 3)
Catalysts 1 to 7 (Embodiments) carrying Si and Zr were prepared according to catalyst 1 (Embodiment). Table 5 shows catalyst compositions.
The inventors of the present invention examined resistance to SOx poisoning according to Test Example 1 of Embodiment 1.
(Test Result)
Table 6 shows the rest result. Any one of catalysts (Embodiments 7 to 17) exhibited recovery of NOx removing performance by regeneration. Especially catalysts (Embodiments 15 to 17) including Zr and Ti made a remarkable recovery of NOx removing performance by regeneration.
TABLE 5
Catalyst
1st component
2nd component
3rd component
Catalyst 7
14Ce, 6Zr,
0.26Pd, 11Sr, 4Ti,
Not included
(Embodiment)
6Ti, 6Si
0.9Mg, 0.11Rh, 1.4Pt
Catalyst 8
14Ce, 6Si
0.26Pd, 11Sr, 4Ti,
Not included
(Embodiment)
0.9Mg, 0.11Rh, 1.4Pt
Catalyst 9
14Ce, 6Zr
0.26Pd, 11Sr, 4Ti,
Not included
(Embodiment)
0.9Mg, 0.11Rh, 1.4Pt
Catalyst 10
14Ce, 6Ti
0.26Pd, 11Sr, 4Ti,
Not included
(Embodiment)
0.9Mg, 0.11Rh, 1.4Pt
Catalyst 11
14Ce, 6Zr,
0.26Pd, 11Sr, 4Ti,
Not included
(Embodiment)
6Ti
0.9Mg, 0.11Rh, 1.4Pt
Catalyst 12
14Ce
0.26Pd, 11Sr, 4Ti,
4Ti
(Embodiment)
0.9Mg, 0.11Rh, 1.4Pt
Catalyst 13
14Ce, 6Zr
0.26Pd, 11Sr, 4Ti,
4Ti
(Embodiment)
0.9Mg, 0.11Rh, 1.4Pt
Catalyst 14
14Ce, 6Ti
0.26Pd, 11Sr, 4Ti,
4Ti
(Embodiment)
0.9Mg, 0.11Rh, 1.4Pt
Catalyst 15
14Ce, 6Zr,
0.26Pd, 11Sr, 4Ti,
4Ti
(Embodiment)
6Ti
0.9Mg, 0.11Rh, 1.4Pt
Catalyst 16
14Ce, 6Zr,
0.75Pd, 11Sr, 4Ti,
4Ti
(Embodiment)
6Ti
0.9Mg, 0.11Rh, 1.4Pt
Catalyst 17
14Ce, 6Zr,
0.75Pd, 11Sr, 4Ti,
4Ti
(Embodiment)
6Ti, 6Si
0.9Mg, 0.11Rh, 1.4Pt
TABLE 6
NOx removing
Initial NOx
NOx
rate (%)
removing rate
removing rate (%)
after
Catalyst
(%)
after SOx poisoning
regeneration
Catalyst 7
71
45
49
(Embodiment)
Catalyst 8
72
42
44
(Embodiment)
Catalyst 9
80
43
47
(Embodiment)
Catalyst 10
78
44
46
(Embodiment)
Catalyst 11
80
41
45
(Embodiment)
Catalyst 12
80
54
56
(Embodiment)
Catalyst 13
76
52
56
(Embodiment)
Catalyst 14
69
40
42
(Embodiment)
Catalyst 15
63
41
50
(Embodiment)
Catalyst 16
61
40
48
(Embodiment)
Catalyst 17
65
41
49
(Embodiment)
(Embodiment 4)
The carried Ti volume in catalyst 1 (Embodiment) was changed with respect to 100 g of carrier at the rate of 2 to 40 g to study the resistance to SOx poisoning according to the test example 1 of Embodiment 1. Table 7 shows the result of this study. When the carried Ti volume is 2 g or less, there was no recover of the NOx removing rate by regeneration. Initial NOx removing rate was reduced by increase of the carried Ti volume. To maintain the initial NOx removing rate at 60% or more, carried Ti volume of 3 to 15 g gives good results. Furthermore, to keep the initial NOx removing rate at 50% or more, good results are provided by carried Ti volume of 3 to 35 g.
TABLE 7
Carried Si
volume with
NOx removing
respect to
Initial NOx
rate (%)
100 g of
removing rate
NOx removing rate (%)
after
carrier (g)
(%)
after SOx poisoning
regeneration
2
82
42
42
3
80
46
48
4
80
47
49
15
68
40
43
18
58
37
40
35
50
30
33
40
42
23
26
(Embodiment 5)
The carried Si volume in catalyst 8 (Embodiment) was changed with respect to 100 g of carrier at the rate of 2 to 30 g to study the resistance to SOx poisoning according to the test example 1 of Embodiment 1. Table 8 shows the result of this study. When the carried Si volume is 2 g or less, there was no recover of the NOx removing rate by regeneration. Initial NOx removing rate was reduced by increase of the carried Si volume. To maintain the initial NOx removing rate at 60% or more, carried Si volume of 3 to 10 g gives good results. Furthermore, to keep the initial NOx removing rate at 50% or more, good results are provided by carried Ti volume of 3 to 25 g.
TABLE 8
Carried Si
volume with
NOx removing
respect to
Initial NOx
rate (%)
100 g of
removing rate
NOx removing rate (%)
after
carrier (g)
(%)
after SOx poisoning
regeneration
2
82
42
42
3
80
46
48
6
72
42
44
10
63
38
41
15
56
34
36
25
50
31
33
30
38
25
26
(Embodiment 6)
The carried Zr volume in catalyst 15 (Embodiment) was changed with respect to 100 g of carrier at the rate of 2 to 30 g to study the resistance to SOx poisoning according to the test example 1 of Embodiment 1. Table 9 shows the result of this study. When the carried Zr volume is 2 g or less, where was no recover of the NOx removing rate by regeneration. Initial NOx removing rate was reduced by increase of the carried Zr volume. To maintain the initial NOx removing rate at 60% or more, carried Zr volume of 3 to 10 g gives good results. Furthermore, to keep the initial NOx removing rate at 50% or more, good results are provided by carried Zr volume of 3 to 25 g.
TABLE 9
Carried Zr
volume with
NOx removing
respect to
Initial NOx
rate (%)
100 g of
removing rate
NOx removing rate (%)
after
carrier (g)
(%)
after SOx poisoning
regeneration
2
82
42
42
3
72
45
48
6
63
41
50
10
60
38
43
15
57
34
38
25
50
31
35
30
36
25
28
(Embodiment 7)
Catalysts 18 and 19 (Embodiments) were prepared according to the Embodiment 1. Table 10 shows the compositions and their percentage of catalysts 18 and 19 (Embodiments). The inventors of the present invention also examined resistance of catalysts 18 and 19 (Embodiments) to SOx according to the test example 1. The result is given in Table 11. Catalysts 18 and 19 (Embodiments) exhibited recovery of NOx removing performance.
TABLE 10
Catalyst
1st component
2nd component
3rd component
Catalyst 18
14Ce
0.07Rb, 1.5Pt
10Na, 2Ti,
(Embodiment)
0.9Mg, 0.75Pd
Catalyst 19
27Ce
0.07Rh, 1.5Pt,
10Na, 2Ti, 0.9Mg
(Embodiment)
0.23Pd
TABLE 11
Initial NOx
NOx removing
NOx removing
removing rate
rate (%) after
rate (%) after
Catalyst
(%)
SOx poisoning
regeneration
Catalyst 18
90
68
70
(Embodiment)
Catalyst 19
90
50
52
(Embodiment)
As decribed above the exhaust gas cleaning method, exhaust gas cleaning catalyst and exhaust gas cleaning device according to the present invention have made it possible to improve NOx removing performances while maintaining resistance against SOx poisoning in the oxidation atmosphere.
The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.
|
In a method and apparatus for removing nitrogen oxides from the exhaust gas of a lean-burn automobile, a CO adsorbent component, which may, for example be made of Pd, Ru or Ir, is contained in an exhaust gas cleaning catalyst which captures NOx when the air-fuel ratio of exhaust gas is higher than theoretical air-fuel ratio, and reduces the captured NOx when the air-fuel ratio of exhaust gad is less than or equal to the theoretical air-fuel ratio. The catalyst, which includes Rh, Pt, and element selected from among the alkaline and alkaline earth metals (Na, Mg, K, Li, Cs, Sr and Ca), and a CO adsorbent material comprising Pd, Ir or Ru, has a CO desorption capacity that reaches at maximum level at a temperature within the range from 200 to 220° C. when its temperature is increased in a He gas flow at the rate of 5 to 10° C./min, after said catalyst is saturated at 100° C. Exhaust gas having an air-fuel ratio higher than theoretical air-fuel and exhaust gas having an air-fuel ratio less than or equal to the theoretical air-fuel ratio are alternately made to flow to the catalyst.
| 8
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 14/261,167 filed Apr. 24, 2014 which application is a continuation of U.S. patent application Ser. No. 13/727,241 filed Dec. 26, 2012, now abandoned, which application is a continuation of U.S. patent application Ser. No. 13/205,119 filed Aug. 8, 2011, now abandoned, which application is a continuation of U.S. patent application Ser. No. 12/982,408 filed Dec. 30, 2010, now abandoned, which application is a continuation of U.S. patent application Ser. No. 12/274,192 filed Nov. 19, 2008, now abandoned, which application claims priority of U.S. Provisional Application No. 61/003,657 filed Nov. 19, 2007. Each of the above identified applications is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to offshore facilities used in connection with the exploration and production of oil and gas, and in a particular though non-limiting embodiment, to a docking and drilling vessel system suitable for deploying self-standing risers and conducting oil and gas drilling, production and storage operations.
BACKGROUND OF THE INVENTION
Offshore drilling is quickly becoming the prevalent method of exploring and producing oil and gas, especially in Western countries where land operations are frequently inhibited by environmental concerns. There is, however, a serious shortfall of offshore drilling units called Mobile Offshore Drilling Units, or MODUs. The relative unavailability of MODUs has resulted in significant delays in many drilling projects. Consequently, the cost of obtaining either a new or existing MODU for an exploration and production operation has dramatically increased over the past decade.
As will be readily appreciated by those of skill in the art, MODUs are utilized during the early testing phase required to evaluate oil, gas, and other hydrocarbon discoveries. However, due to the lack of floating production facilities and the high cost of MODUs, early testing is seldom accomplished, which often results in unnecessary delays and inaccurate predictions of economic assessments, project development schedules, etc. Moreover, procurement of offshore production and storage facilities required to operate offshore projects in a timely manner can be quite difficult. In extreme circumstances or in especially remote regions, the lag time between hydrocarbon discovery and the production phase can reach 10 years or more.
Meanwhile, self-standing riser assemblies supported by buoy devices are becoming a more common method of performing oil and gas exploration and production related activities. Compared to the large scale riser assemblies typically serviced by MODUs, the self-standing riser provides for lighter and less expensive riser tubulars (e.g., drilling pipe, stack casing, etc.). Self-standing risers also admit to the use of lighter blowout preventers, such as those used by land drilling rigs.
Moreover, the top buoy of a self-standing riser system can be positioned near the surface of the water in which it is disposed (for example, less than around 100 ft. below surface level), allowing for efficient drilling in even shallow waters. Furthermore, where riser systems are tensioned and controlled with associated buoyancy chambers, buoy-based systems can be used successfully in much deeper waters.
However, as those of skill in the art have learned in the field, buoy-based systems utilizing general purpose vessels for riser and buoyancy chamber deployment are deficient in that large-scale operations (e.g., deployment in very deep or turbulent waters, or projects involving multiple combinations of riser strings and buoyancy chambers, etc.) are very difficult to control, and thus installation, operation and maintenance of the resulting system is significantly impaired.
There is, therefore, a need for a custom vessel that admits to efficient deployment of large-scale riser systems in a manner similar to the manner of a MODU even when a MODU is not available.
SUMMARY OF THE INVENTION
A sea vessel exploration and production system is provided, wherein the system includes a drilling station formed from at least one section of a first sea vessel hull; and a docking station, which is also formed from at least one section of a second sea vessel hull. A mooring system suitable for connecting the drilling station to the docking station is also provided. Means for anchoring the vessels to the seafloor, and for attaching them to turret buoys, are also considered. Various exploration and production packages, as well as equipment required to deploy and control a self-standing riser system in either deep or shallow waters, are also described. Also, described is a method for providing a sea vessel exploration and production system used with a sub-sea well.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is an overhead view of a docking and drilling station moored end-to-end, according to example embodiments.
FIG. 1B is a side view of a docking and drilling station moored end-to-end, according to example embodiments.
FIG. 2 is a schematic diagram of an anchored drilling station and docking station operating a self-standing riser assembly, according to example embodiments.
FIG. 3 illustrates a sequence of steps for mooring a docking station and a drilling station using an end-to-end method, according to example embodiments.
FIG. 4 illustrates a sequence of steps for mooring a docking station and a drilling station using a side-by-side method, according to example embodiments.
FIG. 5 illustrates a sequence of steps for mooring a docking station and a drilling station to a turret buoy anchoring assembly, according to example embodiments.
FIG. 6 is a schematic diagram of an alternative docking station with side-by-side docking to a docking station, according to example embodiments.
FIG. 7 is a schematic diagram of alternative docking station mooring schemes for varying current conditions, according to example embodiments.
FIG. 8 is a schematic diagram of a docking station or a drilling station attached to a turret buoy, according to example embodiments.
DETAILED DESCRIPTION
The description that follows includes exemplary systems, methods, and techniques that embody various aspects of the presently inventive subject matter. However, it will be readily understood by those of skill in the art that the disclosed embodiments may be practiced without one or more of these specific details. In other instances, well-known manufacturing equipment, protocols, structures and techniques have not been shown in detail in order to avoid obfuscation in the description.
Referring now to the example embodiment illustrated in FIG. 1A , an overhead view of a docking station 6 and a drilling station 8 are depicted as being moored together in an end-to-end manner. The embodiment of the drilling station 8 shown in FIG. 1B comprises crew quarters and an operations office 2 ; a drilling rig 4 ; a hull 5 ; a void space 13 designed for housing and deploying various buoyancy devices 14 ; a helipad 15 ; a moon pool 12 ; a plurality of anchor or mooring lines 20 used to anchor the system to an associated seabed S; and a mooring system defined by mooring or docking lines 19 configured to moor drilling station 8 and docking station 6 together. The example embodiment of the docking station 6 further comprises modular production, testing and injection facilities 10 ; a hull 11 ; a plurality of anchor lines 20 ; and mooring lines 19 configured to mate with the mooring assembly of the drilling station 8 . A self-standing riser SSR disposed in mechanical communication with one or more buoyancy devices 14 is also provided. A blast shield 21 is positioned on the docking station 6 between the helipad 15 and the facilities 10 .
In the embodiment depicted in FIG. 1A , the docking station 6 and drilling station 8 are moored together using mooring lines 19 in such a manner that both portions of the combined vessel are able to properly perform offshore drilling operations. In alternative embodiments, various other devices can be used to secure the mooring system, for example, clamps, rods, latches, locks and other mechanical devices; strong magnets and electrical control systems; vacuum systems, etc.
Typical embodiments of the docking and drilling stations further comprise a plurality of oil and gas related drilling, production and exploration equipment. For example, a modified land or platform drilling rig 4 installed on the drilling station 8 can be used to operate a self standing riser SSR while maintaining functional stability and efficient operational continuity. Similar equipment disposed within or upon the drilling station 8 enables storage, deployment, lifting, and retrieval operations, as well as storage of additional risers, such as stress joints 16 , and one more buoyancy devices 14 should they be required during drilling operations.
In further embodiments, hydrocarbons such as oil, gas, liquid natural gas, etc., encountered during the drilling process are separated, treated and stored either onboard or within docking station 6 . In still further embodiments, docking station 6 further comprises modular production facilities 10 and storage space that can be used for testing operations or as a facility to separate oil, gas, water, etc. Other embodiments of the docking station 6 comprise one or more of a flare boom 22 used to bleed off gas and fluid pressure; oil, water and gas separators; and storage facilities used to store crude and previously treated oil and gas. In further embodiments still, water and gas injection equipment used to re-inject wells and the mechanical equipment required to facilitate such operations are also included.
Since the drilling station 8 does not necessarily have to support deployment of conventional riser and buoyancy chamber systems, it can utilize a typical land or platform drilling rig 4 modified to endure extreme sea and weather conditions. The embodiment depicted in FIG. 2 , for example, illustrates an anchored drilling station 8 and docking station 6 operating in tandem to support and control a self-standing riser SSR system equipped with an associated buoyancy device 14 . The drilling station of FIG. 2 further comprises a void space 13 suitable for the storage and handling of buoyancy devices 14 , as well as a hoisting system 3 and retractable guide rails 26 that assist in guiding the buoyancy devices 14 below the hull 5 of drilling station 8 .
In various other embodiments, the drilling station 8 depicted in FIG. 2 allows the drilling rig 4 to hoist, lower and otherwise handle self standing riser SSR having a wellhead connector 27 and a riser pipe 28 , casing, drilling pipe, etc., passed through the moon pool 12 . One specific example embodiment permits self standing riser tubulars to be lowered into the water until a desired length is obtained and the required quantity of buoyancy devices 14 are in place. Although not depicted, those of skill in the art will appreciate that further embodiments of the drilling station 8 are equipped to deploy, store and handle most other types of routine or custom fit offshore drilling equipment, such as shear rams, ball valves, blowout preventers and hoists therefor.
Following installation of the self standing riser SSR, the drilling station 8 can commence drilling, completion, testing and workover operations, etc. As operations continue, some portions of the system can be removed so that the drilling station 8 can be utilized in other types of operations. In further embodiments, the drilling station 8 is utilized to drill a hole in a seabed S so as to permit installation of a wellhead 29 and associated casing. In still further embodiments, the drilling station 8 is used to remove and store the riser assemblies, such as stress joints 16 , as well as attendant buoyancy devices 14 and other offshore drilling equipment.
In some example embodiments, the described installation and removal process is applied to wellheads 29 created by others and abandoned. Such projects would typically utilize cranes, hoists, winches, etc., operating in mechanical communication with the drilling station in order to perform installation and removal of existing riser assemblies, wellheads 29 , production trees and blowout preventers.
In some embodiments, the void space 13 formed to store and handle buoyancy devices 14 further comprises a moveable floor 7 , tracks, a gantry 9 , etc., that transports buoyancy devices 14 to a desired location (e.g., near the moon pool 12 ) to be joined with a self standing riser assembly stack. Various embodiments of the moon pool 12 further comprise retractable guide rails 26 that assist in guiding and delivering the buoyancy devices 14 down below the hull 5 to a deployment station.
End-to-End and Side-to-Side Mooring of the Docking and Drilling Stations
FIGS. 3 and 4 depict an embodiment of the docking station 6 and the drilling station 8 moored together using end-to-end and side-to-side mooring methods, respectively. In the example embodiment illustrated in Step 1 of both FIGS. 3 and 4 , docking station 6 is towed by a towing vessel 30 toward anchor lines 20 preinstalled by workboats 31 , anchor handling vessels, etc. Towing of the docking and drilling stations can of course be facilitated by any vessel 30 capable of towing another vessel of appropriate size, such as a work boat, a tug, etc.
Step 2 of FIG. 3 depicts various transportation vessels (e.g., workboats 31 , towing vessels, etc.) transporting a plurality of anchor lines 20 to fastening members disposed in communication with the docking station 6 . Some embodiments of the fastening members assist in adding tension to the anchor lines 20 , and slowly moving the docking station 6 toward desired site coordinates.
In the end-to-end embodiment shown in FIG. 3 , the anchor lines 20 are affixed to fastening members positioned on all sides of the docking station 6 . Note, however, that the anchor lines 20 would typically be affixed to fastening members on a particular side of the docking station 6 in the side-to-side method depicted in Step 2 of FIG. 4 . Such embodiments of side-to-side mooring help maintain proper lateral spacing and controlled efficient movement as the drilling station 8 and docking station 6 are joined. In further embodiments, the drilling station 8 is transported to within a close proximity of the docking station 6 during Step 2 of FIG. 4 and Step 3 of FIG. 3 , and a plurality of anchor lines 20 are thereafter affixed to fastening members of the drilling station 8 in order to secure the system in a desired dynamic equilibrium.
Step 3 of FIG. 4 and Step 4 of FIG. 3 illustrate the drilling station 8 as disposed in stable operative communication with the docking station 6 . Various known attachment means, such as mooring lines, as well as any new or custom designed fasteners or the like can be used to facilitate stable and reliable operations. In the embodiment depicted in FIG. 3 , the drilling station 8 and the docking station 6 are mutually joined by mooring lines 19 and operated in a back-to-back or end-to-end manner, whereas in the embodiment illustrated in FIG. 4 , the drilling station 8 and the docking station 6 are joined by a yoking assembly YA in a side-to-side manner. Either manner will, if configured correctly, permit the drilling station 8 to drill, deploy casing, deploy self standing riser tubulars, etc. In some embodiments, the drilling station 8 is configured to position itself over an existing self standing riser system in order to perform workover operations, well completions, and other common drilling operations.
In the embodiment illustrated in Steps 5 and 4 of FIGS. 3 and 4 , respectively, the drilling station 8 is disconnected from the docking station 6 and towed away. In a typical example embodiment, anchoring lines 20 previously used to anchor the drilling station 8 in place are attached to the remaining docking station 6 , thereby resulting in a spread mooring configuration suitable for receiving a new vessel. In some embodiments, the docking station 6 is then used as a testing or production vessel to process and separate oil, gas and water, etc. In further embodiments, the docking station 6 provide facilities to inject water and gas back into well(s), power to operate electric submersible pumps, or lifting support to aid with other production methods.
Step 5 of FIG. 4 and Step 6 of FIG. 3 depict an embodiment of the mooring sequence in which an oil tanker 32 is joined in communication with the docking station 6 . As previously discussed, example embodiments may comprise a wide variety of attachment methods and means, such as mooring, docking, fastening, etc. In one example embodiment, the docking station 6 then utilizes pipes, tubulars, hoses, etc., to transfer oil, gas or other stored fluids to and from the tanker 32 .
End-to-End Mooring Using a Turret Buoy
FIG. 5 depicts an embodiment of a turret mooring buoy 18 that allows the drilling station 8 and the docking station 6 to cooperate in a synchronized manner even in very poor weather conditions, such as strong winds, rough currents, etc. In the embodiment illustrated in Step 1 of FIG. 5 , conventional mooring lines and anchor lines 20 are affixed to a turret mooring buoy 18 as known in the art. Embodiments of the drilling station 8 are subsequently towed to the turret mooring buoy 18 , as illustrated in Step 2 . In the embodiment depicted in Step 3 , a plurality of towing vessels 30 position the drilling station 8 in relatively close proximity to the turret mooring buoy 18 , where the drilling station 8 and the turret mooring buoy 18 are mutually joined. In Steps 4 and 5 , the docking station 6 is similarly joined to the system in accord with the principles previously discussed above. In one specific embodiment, the drilling station 8 is also capable of performing a multitude of other offshore drilling functions, including deployment and operation of drilling equipment; the drilling of holes on the seabed and installation of casing; deployment and operation of self-standing riser, etc.
In the embodiments illustrated in Step 5 and Step 6 , the docking station 6 is moved to a location and attached in communication with turret mooring buoy 18 after completion of operations by the drilling station 8 . In further embodiments, the drilling station 8 is then removed from turret mooring buoy 18 to allow for attachment of the docking station 6 so that testing and production can commence.
Side-by-Side Mooring Using a Spread Mooring System
Referring now to the example embodiment depicted in FIG. 6 , the docking station 6 and drilling station 8 are joined using a side-by-side mooring system. Various embodiments of the drilling station 8 are affixed to the docking station 6 using a system of attachment mechanisms 34 , such as mooring, docking, fastening devices, etc., which lend support and provide rigid separation in the lateral direction while still allowing mutual vertical movement. In one embodiment, conventional mooring with anchor lines 20 can secure the drilling station 8 and docking station 6 in proximity of a self-standing riser SSR.
Several embodiments of side-by-side mooring utilize hydraulically compensated cylinders to maintain constant lateral distance and compensate for wave and swell actions. For example, embodiments using a hydraulically compensated cylinder can maintain separation forces while dampening related transient forces caused by wave and swell movement.
End-to-End and Side-by-Side Mooring of the Drilling Station and Docking Station Using the Turret Moored Buoy
Referring now to the example embodiment in FIG. 7 , side-by-side and end-to-end mooring configurations of the drilling station 8 and docking station 6 attached in communication with a turret mooring buoy 18 is illustrated. In some embodiments, the turret buoy 18 is utilized for situations where a particular area of the water has significantly varying or conflicting currents. In further embodiments, turret mooring buoy 18 is designed to be attached to a self-standing riser SSR, while relative positioning of the drilling station 8 and docking station 6 is maintained. According to still further embodiments, the design of the turret mooring buoy 18 varies depending on the dimensions of the docking or drilling stations, or in conformity with the dimensions of the moon pool 12 .
In some embodiments, the drilling station 8 and the docking station 8 attach to the turret mooring buoy 18 using mechanical or hydraulic couplers or other fastening devices known in the art. In the embodiment illustrated in FIG. 8 , the turret mooring buoy 18 allows for a 360 degree rotation of the particular station with which it is disposed. For example, the docking station 6 can rotate 360 degrees once it is attached to the turret mooring buoy 18 .
In some example embodiments utilizing a turret mooring buoy 18 , the drilling station 8 is moored first, and used to perform one or more of drilling, deployment, workover, completion, testing, etc., operations. In other embodiments, the docking station 6 is moored to the drilling station 8 , and used to conduct one or more of the aforementioned operations, as depicted in FIG. 8 . Once the work of drilling station 8 is concluded, it is detached from the turret buoy 18 while the docking station 6 remains behind for continued operations.
The foregoing specification is provided for illustrative purposes only, and is not intended to describe all possible aspects of the present invention. Moreover, while the invention has been shown and described in detail with respect to several exemplary embodiments, those of ordinary skill in the art will appreciate that minor changes to the description, and various other modifications, omissions and additions may also be made without departing from the spirit or scope thereof.
|
A sea vessel exploration and production system is provided, wherein the system includes a drilling station formed from at least one section of a first sea vessel hull; and a docking station, which is also formed from at least one section of a second sea vessel hull. A mooring system suitable for connecting the drilling station to the docking station is also provided. Means for anchoring the vessels to the seafloor, and for attaching them to turret buoys, are also considered. Various exploration and production packages, as well as equipment required to deploy and control a self-standing riser system in either deep or shallow waters, are also described.
| 1
|
FIELD OF THE INVENTION
The present invention relates to a method for continuing measurements which have been interrupted or which have not started yet, when the measuring sonde is immobilized in a well into which it has been lowered at the end of a maneuvering and measure transmission cable.
BACKGROUND OF THE INVENTION
There are several well-known methods for trying to grapple a measuring sonde whose handling is no longer possible through the cable, but none allows measurements to be continued at the place where they have been stopped following the immobilization of the sonde or its sticking.
A first method is common to all operations for fishing tubular parts stuck or lost in a wellbore. The well is first cleared of the measuring cable so that it does not hinder later operations. To that effect, the cable is pulled until it breaks at the brittle point which is located on the fixing device on the upper part of the sonde. After taking up the cable by means of its winch, a fishing string mainly consisting of an "overshot", as it is commonly called in the profession, adapted to clutch the top of the sonde, is run down into the well. The other components are conventionally pipes and drill collars. In this method, the difficulty consists of covering the sonde with the overshot in the absence of guiding and while groping along from the surface. This operation may actually only succeed at a slight depth and in instances where the drill hole is well calibrated and where the axis of the tubular to be fished is almost parallel to the axis of the well. Concerning measuring sondes, most of them have a small diameter with respect to the hole and these conditions are scarcely present, except in small-diameter boreholes.
The most common method is called the "cut and thread" method. It consists of cutting the cable at the level of the derrick floor without dropping the part of the cable linked with the sonde into the well. Thus, the two ends of the cut cable are provided with two half-elements constituting a quick coupling. Assemblage of the overshot and of the first drill collars is started in the derrick. The end of the cable connected to the winch is passed through these first elements when they hang on the pipe hook. The two ends of the cable are connected through the quick coupling. The cable may then be maintained taut by its winch while the overshot and the first pipes are lowered around the latter into the well. After hanging them onto the rotary table, the cable is maintained before the quick coupling is opened so as to pass the end of the cable connected to the winch through new tubular elements assembled and hung on the pipe hook, as previously. The lowering maneuver is continued by repeating this operation until the overshot, guided by the coaxial cable, covers and clutches the top of the sonde. The fishing operation is ended, as in the previous method, after the cable has been broken.
This operation is long because passing the cable through each assembled length of tubular elements causes a waste of time which is relatively considerable in relation to the usual maneuver time. In case of sticking in a borehole, it is an accepted fact that speed is a preponderant factor for the success of the fishing operation.
None of the two methods described above allows measurements to be achieved or continued with the sonde in said well.
The method in accordance with the present invention reduces the maneuver time by limiting the number of operations for running the cable through the length of tubular elements, by using advantageously a side-entry sub.
With the "cut and thread method", the sonde is never connected electrically to the surface and it has never been attempted to keep the use of the sensors of the sonde once the latter is stuck. In fact, the use of a quick coupling including sealed connections for the conductors is of no interest here since the cable will be broken after the sonde has been clutched. Furthermore, the cable being coaxial to the string of tubular elements over its total length, it is not possible to move the sonde while keeping the entire cable continuity.
The method of the invention also has the advantage of allowing measurements to be continued when the sonde has been clutched, be it towards the bottom of the well or higher up towards the surface. The measuring operation, which has been interrupted or made impossible by the immobilization of the sonde, will not be totally missed since it is now possible, with the present method, to carry out the total or at least part of the measuring program.
Besides the main advantage cited above, the invention provides a means for knowing precisely the moment of contact of the grappling sub with the head of the sonde, then for checking the holding back of the sonde by said sub. In fact, the sonde is completely operational since it is connected mechanically and electrically to the surface installation, as at the beginning of the operation. By means of sensors and through the transmission of the signals towards the surface, the operator may control that the displacement of the string makes the sonde move identically. This advantage guarantees not only that further measurements will be possible, but also that grappling of the sonde will succeed, unlike prior methods which provide no reliable information on the quality of the grappling of the sonde, which accounts for the relatively high failure rate in the most difficult cases.
Another method called "side door" method may also illustrate the prior art. It consists of using a special overshot having a lateral opening allowing the measuring cable to be passed outside the fishing string. The cable needs not be cut. The string may then be lowered in a conventional way. The overshot is guided onto the head of the sonde as in the "cut and thread" method, then the operation is continued according to the same methodology. This "side door" method is not used for wells deeper than 1,000 meters because it involves high risks of damage of the cable upon lowering of the string towards the well bottom, and in case of cable breakage, the absence of guiding of the overshot most often compromises recovery of the sonde. In fact, when the overshot gets close to the head of the immobilized or stuck sonde, the well will, by that fact, give rise to considerable friction on the end of the string outside which the cable is located and is therefore very vulnerable. Moreover, the mechanical actions necessary to grapple the sonde are most often exceed the strength of conventional cables. In order to make the limited use of this method quite clear, the following recommendation, given to sonde fishing operators, may be cited: "the side door method should not be used to fish tools in open holes, but rather to fish tools stuck at the shoe of a casing string". But when measuring tools are at this level, measurements are generally finished.
SUMMARY OF THE INVENTION
The method of the present invention allows operations in deep, difficult, deflected wells, and also in open holes, because the cable is only present in the annulus defined by the tubular elements and the well at a depth chosen by the operator, where he knows that the cable does not risk any damage. The cable is thus protected against outer friction over a determined length with the method. The protection corresponds to the length of the string between the grappling sub and the side-entry sub.
According to its claims, the present invention thus provides a method allowing measurements to be continued by means of a measuring sonde immobilized in a well, said sonde being connected to the surface by a cable comprising at least one conductor connecting electrically said sonde to a surface control installation, and said cable may be operated by means of a winch.
The invention comprises the following stages :
cutting the cable substantially above the level of the rotary table,
fixing a half-connector on each of the two ends of the cut cable, said half-connectors being adapted to constitute a quick coupling for assembling the two ends of said cable,
lowering into the well a tubular string for grappling the immobilized sonde, said string comprising, in its inner channel, a the lower length of the cable substantially taut between said sonde and the derrick floor, said string comprising at least one grappling sub adapted to grapple said sonde and a determined, length of maneuvering tubulars elements,
fixing a side-entry sub onto the upper end of said determined length of tubular elements, said sub being adapted to pass said lower cable length from the inside to the outside of the tubular elements, connecting outside the string the two ends of the cable and connecting said conductors of said cable,
adding, above said sub, the corresponding length of tubular elements to reach the sonde immobilized in the well, while keeping said cable substantially taut,
guiding the string by means of the coaxial cable so as to grapple the sonde by way of said grappling sub,
carrying out measurements or servicings with said sonde grappled through said grappling sub to the lower part of said string and linked to the surface by said cable.
The method of the invention allows makes it possible to select the determined length of tubular elements contained between the grappling sub and said side-entry sub substantially equal to a length of mechanical protection of said cable, adapted both to reach the sonde with said grappling sub and to perform displacements during the continuation of the measurements without damaging the cable.
With the previous method, measurements may be carried out with said grappled sonde while going deeper than the depth of immobilization of said sonde, by adding tubulars elements to the upper part of the string. Measurements may also be achieved with said grappled sonde while going higher than the depth of immobilization, by disassembling at most the length of tubulars located above said side-entry sub, while keeping said cable substantially taut.
The method may allow circulation of the drilling fluid by pumping through the grappling string, the side-entry sub comprising seal means around the passage of the cable between the inside and the outside of said string.
The invention may provide a method for detecting the grappling of the sonde through said overshot by means of the surface control installation connected to the sonde by said conductors of said cable.
A mechanical quick coupling comprising means for connecting said electric conductors of said cable may also be used.
The method in accordance with the invention may allow the cable to be broken at the brittle point located at the top of the sonde and to be taken up by means of the winch. The sonde is taken up to the surface by the operation of pull-out of the string.
The previous method and all its variants may be used in oil wellbores, deflected or not with respect to the vertical, in which a measuring or a servicing sonde connected to the surface by a cable comprising at least one electric conductor is immobilized. Said sonde cannot reach the zones of said oil well in which measurements or servicings are performed by action on the cable.
One particular application may be characterized in that the sonde is immobilized by sticking in the well.
Another advantageous application may be characterized in that the sonde cannot reach measurement or servicing zones because of the too high inclination of the well with respect to the vertical, which does not allow descent of said sonde by gravity.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the present invention will be clear from reading the description hereafter given by way of non limitative examples, with reference to the accompanying drawings, in which :
FIGS. 1A, 1B, 1C, 1D and 1E illustrate various stages of the grappling of the sonde with the method of the invention;
FIGS. 2A and 2B show the measurement operations according to the method of the present invention; and
FIG. 3 shows an embodiment of a side-entry sub.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1A shows a well comprising a cased length 2 and an open hole length 3. A measuring or servicing sonde is immobilized in the open-hole section at a depth 25. The sonde has been lowered into the well by means of cable 4 operated through winch 5 located at the surface. The cable comprises conductors which connect electrically the sonde 1 to a control installation 6.
In the following description of the present invention, the term depth will refer to the length of the well measured from a fixed reference point located at the surface. It is generally the rotary table, but it may also notably be measured from the ground or from the seafloor. The change of the measurement reference point will have no effect on the description and the scope of the invention.
Also, without departing from the scope of this invention, the sonde may be immobilized at a depth where the well is cased, and similarly, the well may have no cased length yet.
In the invention, the sonde operated through cable 4 may be stuck mechanically in the well in such a way that it cannot be taken up to the surface or down towards the well bottom. Without departing from the scope of the invention, the sonde may be prevented from being displaced in only one direction, be it towards the surface or towards the bottom. This may be due to a partial mechanical sticking or to the fact that the well inclination is such that the action of gravity is no longer sufficient to allow descent of the sonde hanging on the end of cable 4. In this case, the sonde is immobilized when friction on the sonde becomes stronger than the force of gravity acting on the sonde. The immobilization depth may then be either the depth from which the sonde can no longer go down towards the well bottom, or a lower depth located above the latter, because the operator preferably chooses, in this case, to set the method of the invention into action with a sonde which is not laid on the walls of the well, but which hangs on the cable. To that effect, he pulls on the cable so as to take the sonde up to a determined depth.
In all the cases cited previously, the section of cable 4 connected to sonde 1 is supported by a conventional jaw device 9 set at the level of a rotary table 8 of the derrick floor. The cable is cut substantially above table 8 and two half-connectors 7 are fastened onto each end. The quick coupling constituted by the two half-connectors is of a conventional type comparable to those used for the "cut and thread" method. Without departing from the scope of this invention, a specific quick coupling comprising means for connecting cable conductors may be used. This specific coupling may be, for example, a quick plug-in socket capable of supporting the weight of the cable while connecting electrically the sonde to installation 6, or more simply a quick mechanical coupling which also allows the conductors to be connected to one another. But, advantageously, the electric connections are only achieved when indispensable, that is when the side-entry sub is set on the string.
After the stage illustrated by FIG. 1A, the operators assemble the first tubular elements of the grappling string above the rotary table. When the latter are still hanging on the lifting hook, the cable end 10 connected to the winch is then passed through these first elements, then the two ends of the cable are linked by connecting the two half-connectors 7. Quick coupling 14 is constituted thereby.
FIG. 1B shows the stage where the first string elements 12 hang on elevators 30 and comprise at their end the grappling sub 11 adapted to co-operate with the head of the immobilized measuring sonde. Quick coupling 14 being assembled, cable 4 is tightened through an action on winch 5. The means 9 for hanging the cable are removed. The driller lowers elements 12 into the well while keeping cable 4, located inside elements 12, substantially taut. The driller hangs them on the rotary table with the conventional means used in the profession. It should be noted that cable 4 and consequently quick coupling 14 are stationary with respect to the rotary table and that elements 12 are lowered concentrically to said cable.
In FIG. 1C, the hanging means 9 are placed on the cable and the quick coupling may then be disconnected.
The operators repeat the previous operations by passing the end of part 10 of the cable through another length 13 of tubular elements. After connection of the cable, the latter is tightened again, hanger 9 is removed and element 13 is screwed onto element 12. The assembly is lowered into the well and hung onto the table thereafter. These operations follow one another until the desired string length including the cable in its inner channel is constituted. This length 16 is shown in FIG. 1D.
A side-entry sub 28 is screwed onto the upper end of the determined length 16. This device is adapted notably for three main functions:
passing a cable from the inner channel of a tubular element towards the outside thereof,
forming a seal around the cable at the level of the window allowing the previous function,
letting the cable free to slide in the window, at least in the direction of sliding from the inside towards the outside, that is when the cable is pulled by means of the winch.
Such a side-entry sub is well-known and may be illustrated notably by documents FR-2,502,236 or U.S. Pat. No. 4,607,693.
The end of the part of cable 4 connected to the sonde is passed through the opening of the side-entry of said sub and connected mechanically and electrically to part 10 by means of a connector 27. This coupling restores the electric continuity of the conductors of the cable, it has to be drilling mud-tight and withstand a traction at least higher than the tensile strength of the cable. Without departing from the scope of this invention, a quick coupling 14 respecting the conditions stated for special coupling 27 may be used.
One operational difficulty then consists of screwing the side-entry sub when the cable is passed through the opening of the window. In fact, it is recommended to avoid applying torsions and frictions onto the cable. This is why it may be advantageous to use a side-entry sub device such as that illustrated in FIG. 3.
FIG.3 shows a sub referred to as a "three-part" sub. Element 31 is the side-entry sub proper, comprising a side entry 34 provided with a sealing system and with a device for possibly fastening the cable. This sub is screwed through a thread 39 onto another sub 32 comprising a screwing ring 35. This ring rotates freely around the cylindrical extension 42 of sub 32. A device 37 holds ring 35 in a fixed longitudinal position with respect to sub 32. This device may be constituted from a circular ring in two parts screwed radially in a groove 43 machined in extension 42. This device will be dimensioned so as to support the weight hanging on the ring by means of thread 38. A sealing system 41 completes the assemblage of the ring on the extension.
The lower third sub 33 co-operates with a lower string of tubular elements through its thread 40. An antirotation system 36 fastens sub 33 angularly with respect to sub 32.
Mounting of this three-part sub is achieved as follows:
screwing the lower sub 33 on the top of the tubular string of tubular elements hanging on the rotary table. The cable is kept coaxial,
elements 31 and 32 are previously screwed and locked by thread 39,
the cable being held on sub 33 by hanger 9, the free end is passed through opening 34 and connector 27 is assembled. The weight of the cable may then be controlled through winch 5, hanger 9 is removed,
placing assembly 31 and 32 onto sub 33 while making keying 36 coincide,
rotating ring 35 so as to screw the assembly 31 and 32 onto sub 33, without rotating the assembly with respect to sub 33. It should be noted that the antirotation system 36 must have a sufficient length and longitudinal play so as to be able to interlock at the beginning of the screwing operation and to allow the displacement corresponding to the screwing.
Determination of length 16 is important because it represents the wear bushing of the cable between the grappling sub and the side-entry sub.
In the example shown in FIG. D, the operators consider that the cable is in danger if it is in the annulus of the open hole, that is deeper than the shoe 26 of casing 2.
In order to reach the sonde immobilized at a distance 17 from the shoe and for the cable to be protected by the string in the total open-hole section, length 16 must be at least equal to the length 17 which corresponds to the length of the open-hole section between the shoe and the immobilization depth.
If measurements are to be carried out deeper than the immobilization point while keeping the cable protected in the total open-hole section, length 16 must be equal to the length of the open-hole section down to the furthest measurement depth. If the well bottom is to be reached, length 16 must be equal to the total length of the open-hole section.
In the same instance, it is obvious that it will be possible to carry out measurements between immobilization depth 25 and shoe 26 while keeping the cable protected in the total open-hole section, except if the length of casing 2 is shorter than length 17.
Without departing from the scope of this invention, the cable protection length may be different from the length of the open-hole section between the sonde and the shoe of the last casing. In fact, if part of the open hole, under the shoe, is properly calibrated and stable, it may be decided to lower the side-entry sub 28 down to this zone and thus have the cable in the uncased annulus.
It is actually advantageous to limit the length 16 of tubular elements passing around the cable because it is a long and tedious operation. But the risks incurred will have to be assessed.
Conversely, if a casing exhibits sharp bends resulting from deflections provided for example by a side tracking operation, it may then be decided not to lower sub 28 deeper than the side track depth where sticking of the cable through the tubulars can be foreseen. The side tracking operation consists of plugging a well with cement at a certain depth when the drilling operation can no longer be achieved as planned. A window is cut out in the casing, above the plug, and the well is deflected by forming an S-shaped trajectory. This S-shaped trajectory provides considerable friction.
FIG. 1E shows the grappling 18 achieved by the grappling sub 11 on the head of sonde 1. To reach this depth, the operators have assembled the length 20 of tubular tubular elements in a conventional and therefore faster way, without being hindered by a coaxial cable. Cable 4 exhibits a length 19 in the casing-string annulus. During the descent of length 20 of the grappling string, cable 4 is kept taut by means of winch 5. The sonde being still immobilized, the side-entry sub slides along the cable when the tubular string is lowered towards sonde 1.
When they get close to the head of the sonde, operators fasten a circulating head onto the upper part of the string so as to wash the grappling sub through circulation in the string. As it has been mentioned above, the side entry of sub 28 comprises a sealing system.
Gripping of the sonde is achieved through controlled tension on the cable and through the downward motion of the grappling sub. Operators find their way about notably by measurement of the lengths and by the reactions of the sensors of the sonde since the latter remains operational by means of the connections established by connector 27. Grappling may be visualized by control installation 6.
If the sonde is stuck mechanically, it is released according to the usual procedure while having the possibility of controlling the displacement of the sonde.
FIG. 2A shows the descent of the sonde deeper below immobilization depth 25 by a length shown here by bracket 21. The string length 22 represents in this case the sum of lengths 20 and 21. Measurements are carried out over this length 21 if need be. If the length 17 of the open-hole section between the immobilization point and shoe 26 is less than or equal to the depth of shoe 26, measurements may also be carried out over length 17.
In all other cases, the maximum upper measurement depth is determined when sub 28 is above ground.
If need be, it remains possible, at this stage of the method, to lower the measuring sonde into the well again so as to complete measurements or to carry out other servicings.
When operations are to be ended, the side-entry sub 28 being above ground, traction is applied onto cable 4 so as to break the brittle point 24 and the cable is entirely taken up through sub 28. When this operation is over, the sonde is taken up to the surface by disassembling the grappling string with the usual care.
Without departing from the scope of this invention, the well may be a complete open hole comprising no casing.
This invention is not limited to servicings in an uncased or a partly cased well. It is actually applicable and very advantageous when the measuring sonde run inside the casings is immobilized notably through the considerable friction provided by bends, deformations or deteriorations in a zone of these casings.
|
A method for continuing a measuring operation using a sonde immobilized in the well which method involves lowering, concentric to the cable, a length of tubular elements until the sonde is engaged by a special coupling fitted at the end of the length of tubular elements, the length of tubular elements serving to protect the cable. In addition, a coupling at an upper end of the length of tubular elements is equipped with a lateral window to minimize maneuvering time. After engagement, the sonde is used to carry out measurements by displacing the length of tubular elements.
| 4
|
[0001] This application is a continuation in part of U.S. patent application Ser. No. 12/853,296, filed Aug. 10, 2010 and incorporates that application by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention relate to rapidly deployable flexible enclosure systems for the collection, containment and presentation of hydrocarbon emissions from compromised shallow or deepwater oil and gas well systems, pipelines, and subsea fissures. In particular, the invention relates to such systems used in conjunction with enclosures connected to floating platforms for separating and routing liquid and gaseous hydrocarbon products captured by the enclosure systems.
[0004] 2. Discussion of Related Art
[0005] Oil leakage and or other environmentally sensitive hydrocarbon emissions originating from varied underwater compromised locations, including natural events, need to be addressed quickly and effectively to minimize damage. The longer the delay to respond and provide effective remediation for these situations, may cause unintended and exponential problems across economic, environmental and societal realms.
[0006] Current resources and technologies are limited to one incident at a time within the same response area. This is due to limited availability of an extensive required support infrastructure, the cost, and with few staged deployment locations. There were 1361 offshore projects active in 69 countries, operated by 198 companies as of Jul. 7, 2012.
[0007] The Deepwater Horizon oil spill (or BP oil spill) began gushing oil into the Gulf of Mexico on Apr. 20, 2010 after an explosion on the Deepwater Horizon oil rig killing 11 workers. It was not capped until Jul. 15, 2010, after 4.9 million barrels of crude oil were spilled into the Gulf. The economic and environmental devastation caused by this disaster are well known.
[0008] Government entities and regulators, as well as oil and gas companies, continue to search for improved methods to address future oil spills. There are a number of small to large scale Oil Spill Response Organizations (OSRO) all with inherent limitations in response times and capabilities.
[0009] In February of 2011, A group of oil companies led by Exxon formed a consortium called the Marine Well Containment Company MWCC and announced that they had developed a system that could stop an undersea oil spill in a matter of weeks, rather than the 85 days it took to cap the Deepwater Horizon oil spill. The system is designed to be assembled within two to three weeks after an oil spill begins.
[0010] Helix Energy Solutions, which assisted with the Deepwater Horizon oil spill, has developed a Fast Response System for future spills. Helix incorporates a number of deployed and operational resources that will stop work and redirect the vessels and required resources to the spill location.
[0011] BP recently constructed their own system weighing some 500 tonnes that requires 35 trailers, seven aircraft (Five Russian Antonov AN-124 and two Boeing 747-200s) to transport from storage to a major airport and then fly to the nearest airport that can handle such aircraft and equipment close to the spill location to start unloading for deployment. BP claims this system can be transported and deployed within ten days.
[0012] What is needed is a readily transportable, quickly deployable system to collect and contain hydrocarbon emissions from compromised shallow to ultra-deepwater oil and gas well systems, pipelines, and subsea fissures.
SUMMARY OF THE INVENTION
[0013] This summary is provided to introduce a selection of concepts in a simplified form that are further described in the detailed description of the invention and is not intended to limit the scope of the claimed subject matter.
[0014] One or more embodiments of the present invention are directed to a transportable, quickly deployable and operable system to collect and contain hydrocarbon emissions from compromised shallow to ultra-deepwater oil and gas well systems, pipelines, structures and subsea fissures.
[0015] The objective is to collect, contain and direct the compromised hydrocarbon emissions for proper presentation without requiring the use of dispersants or Hydrate inhibitors and associated support vessels, while significantly reducing the time to deploy and begin operations.
[0016] With a rapid deployment and versatile containment strategy provided by this invention commencing within a few days of a compromised emissions notification, other resources can focus on drilling a relief well or establishing other long term solutions including the initial spill remediation.
[0017] The system includes a self-supporting flexible containment enclosure (SSFCE) for capturing and containing leaking hydrocarbons and a floating platform, both providing for the separation and routing of liquid and gaseous hydrocarbon products. The separation of the gas, oil and water is performed within the uppermost portion of the SSFCE in conjunction with the floating platform in a controlled process using sensors and instrumentation to monitor and adjust the flow rates. The historical analogy is a “gun barrel separator”.
[0018] The system does not rely on sump or pumping of the product as a continuous method of removal. The gas is generally flared remotely under its own pressure and flow rate, and the liquid product is presented to the operators under its own pressure and flow rate.
[0019] The floating platform is attached to the SSFCE and together they separate liquid and gaseous products. The gaseous product may be burned at the platform or (more often) at a separate station, while the liquid product may be salvaged by a separate vessel via a pipeline. Burning the gaseous product at the floating platform requires a significantly large platform such as a vessel that could incorporate a flare system. Liquid product is generally salvaged by a separate vessel and/or temporarily stowed in floating assemblages awaiting offload or changeouts to a vessel/tanker.
[0020] Apparatus for collecting, separating, and delivering a combination of gaseous product and liquid product emitted into a liquid environment beneath the apparatus, includes a separator for separating the gaseous product and liquid product, the separator including a separator enclosure, a liquid product conduit for delivering liquid product to a liquid product destination, a gaseous product conduit for delivering gaseous product to a gaseous product destination, and a diverter within the separator enclosure for diverting gaseous product away from the liquid conduit.
[0021] The apparatus also includes a self-supporting flexible containment enclosure (SSFCE) forming a tube having a first end disposed at the source of the gaseous product and liquid product and having a second end disposed at the separator enclosure, such that the gaseous product and liquid product enter the SSFCE first end, rise within the SSFCE, and approach the SSFCE second end adjacent to and beneath the diverter. Note that the separator enclosure may include the top end of the SSFCE, and the diverter may be located partially or fully within the top end of the SSFCE or above it.
[0022] The liquid product conduit includes a first end above and adjacent to the diverter to collect the liquid product and above a second end spaced apart from the separator enclosure to deliver the liquid product. The gaseous product conduit includes a first end spaced apart from and above the diverter and the liquid product conduit first end to collect the gaseous product and a second end spaced apart from the separator enclosure to deliver the gaseous product.
[0023] As a feature, the apparatus may further include a control mechanism for determining volume of the liquid product and/or the gaseous product within the separator enclosure. The control system changes pressure within the separator enclosure based on the determined volume. For example, pressure within the separator enclosure could be controlled by affecting the flow rates of one or both of the products.
[0024] The SSFCE may comprise segments formed as elongated tubes, a loop material flap formed at one end of each segment, and a hook material flap formed at the other end of each segment, wherein the hook material flap on a segment engages with the loop material flap on an adjacent segment, forming a continuous tube, and subsea buoys attached to the segments for creating neutral buoyancy.
[0025] The hook flap may formed in an I shape and the loop flap formed in a V shape which is configured to engage both sides of the I shape, or vice versa.
[0026] Straps attached along the long sides of segments include connection points configured to allow a strap end to connect to the end of an adjacent strap. This provides structural support for the SSFCE.
[0027] A relief port having an opening configured to allow removal of a portion of SSFCE content (e.g. sea water, the combination of gaseous product and liquid product, solid particulates, or some combination of these).
[0028] As a feature SSFCE segments may form a Y shape such that one end of the Y allows for a single gaseous product and liquid product flow and the other end of the Y allows for two gaseous product and liquid product flows. In other words, one flow may be divided into two (or more) flows, or two flows may be combined into one flow, as needed.
[0029] The SSFCE preferably further included a terminator interface assembly configured to engage a targeted area of emissions. One sort of terminator interface assembly comprises a flaring canopy having a clamping mechanism for clamping the canopy to an underwater surface. This terminator is especially useful for covering extended areas of leakage, for example on the sea floor. Another sort of terminator interface assembly comprises a conduit and apparatus for engaging the conduit to an opening, such as a pipe end or a hole is a pipe or other surface.
[0030] As a feature, the gaseous product destination might be a flare platform configured to burn off gaseous product. In addition, the apparatus may further include a floating platform attached to the separator enclosure, the floating platform further including apparatus configured to selectively change platform buoyancy to change draft of the floating platform, partially or fully submerging it when advisable because of turbulence or the like.
[0031] The invention for the most part is a passively operated system except for the required flow controls, sensors, buoyancy operation functions and process control systems. Pumps used to manage the compromised emissions products would typically be located aboard Floating Production Storage Offloading (FPSO or FSO) vessels or shuttle tankers for receiving the products.
[0032] A method according to the present invention of collecting, separating, and delivering a combination flow of gaseous product and liquid product emitted into a liquid environment, includes the steps of providing a tubular self supporting flexible containment enclosure (SSFCE) having a bottom end disposed at a source of the emitted product flow and a top end above the source of the emitted product flow; allowing the emitted product flow to rise within the SSFCE, separating the gaseous product from the liquid product within a separator attached at the top end of the SSFCE, the separator comprising a diverter within a separator enclosure, presenting the separated gaseous product to a gaseous product destination; and presenting the separated liquid product to a liquid product destination.
[0033] The step of separating comprises the steps of introducing a closed concave diverter into the rising product flow, the closed side of the diverter disposed downward toward the emitted flow, diverting the flow around the diverter, allowing the liquid product to sink into the diverter upper open side, and allowing the gaseous product to rise above the diverter.
[0034] The method collects the liquid product within the diverter upper open side and passes it through a liquid conduit to the liquid product destination. The method also collects the gaseous product above the diverter and passes it through a gaseous conduit to the gaseous product destination.
[0035] The method also determines volume of at least one of either liquid product or gaseous product within the separator enclosure and changes pressure within the separator enclosure based on the determined volume.
[0036] The step of providing the SSFCE comprises the steps of forming segments formed as elongated tubes, forming a loop material flap at one end of each segment, forming a hook material flap at the other end of each segment, engaging the hook material flap on a segment with the loop material flap on an adjacent segment, forming a continuous tubular SSFCE, attaching the bottom end of the SSFCE adjacent to the source of the emitted product flow, partially filling the SSFCE with liquid from the liquid environment, and attaching the top end of the SSFCE to the separator.
[0037] The step of attaching the bottom end of the SSFCE adjacent to the source of the emitted product flow might comprise the step of providing a flaring canopy and clamping the canopy to an underwater surface or the step of attaching the bottom end of the SSFCE adjacent to the source of the emitted product flow further comprises the step of providing conduit and engaging the conduit to an opening.
[0038] The method may also burn off gaseous product at the gaseous product destination.
[0039] Those skilled in the art will appreciate that configurations similar to embodiments shown and described herein may be used.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] FIG. 1A shows a top view of a floating platform according to the present invention, FIG. 1B shows a side view of the floating platform of FIG. 1A , and FIG. 1C shows an isometric bottom view of the floating platform of FIGS. 1A and 1B .
[0041] FIGS. 2A , 2 B, 2 C, and 2 D show detailed views of portions of the floating platform of FIG. 1 .
[0042] FIG. 2A is an isometric side view of a solar panel elevated assembly according to the present invention.
[0043] FIG. 2B is an isometric side view of a manhole access port.
[0044] FIG. 2C is an isometric side view of an ingress bulkhead port and door formed in a side wall of the rigid enclosure for the ingress of water from an external pump.
[0045] FIG. 2D is an isometric side view of an outrigger pump assembly connected to the ingress bulkhead port shown in FIG. 2C . The hinged door assembly of FIG. 2C is removed for clarity.
[0046] FIGS. 3A through 3L show various views of SSFCE segments.
[0047] FIG. 3A is a side view of a first embodiment of an SSFCE segment including support straps and strap termination points for connecting segments.
[0048] FIG. 3B is a detailed view of one of connected strap termination points of FIG. 3A .
[0049] FIG. 3C is a detailed view of connected strap termination points as in FIG. 3A , further including a protruding attachment point for connecting a buoy and/or other lines.
[0050] FIG. 3D is a oblique detailed isometric wireframe view of a SSFCE Segment with hidden edges.
[0051] FIG. 3E is an oblique detailed hidden isometric view of a second embodiment of an SSFCE segment as in FIG. 3A , further including drag coefficient reduction panels and tail panels.
[0052] FIG. 3F is a top view of the segment of FIG. 3E .
[0053] FIG. 3G is a top view and variation on the segment of FIG. 3E without the tail panels where the drag coefficient reduction panels are connected using both opposing edges of the SSFCE segment or in some cases opposing edges of two or more SSFCE segments.
[0054] FIG. 3H is a side view of the segment of FIG. 3E .
[0055] FIGS. 3I-L show isometric views of another embodiment of a SSFCE segment including a relief port.
[0056] FIGS. 4A-4F show detailed side views of various hook-and-loop connections between segments.
[0057] FIG. 4A is a side view of a hook portion of a first embodiment of the connection, while
[0058] FIG. 4B is a side view of the loop portion.
[0059] FIGS. 4C and 4D (both side views) show a second embodiment of a hook-and-loop connection and FIGS. 4E and 4F (both side views) show a third embodiment of a hook-and-loop connection.
[0060] FIGS. 5A and 5B illustrate an example of a deployment configuration of the SSFCE. FIG. 5A shows a side view of the deployment. FIG. 5B shows the connection between a Positive Offset Neutral Buoyancy Attachment Device (PONBAD) and a strap termination point.
[0061] FIGS. 6A , 6 B, 6 C, and 6 D illustrate connections between the SSFCE and leak sources.
[0062] FIG. 6A is a side view of a first embodiment of a subsea terminator interface.
[0063] FIG. 6B is a side view of a terminator lower conduit assembly.
[0064] FIG. 6C is a top view of compression and strap plates for connection of frustum panel enclosure section to terminator conduit to complete the assembly as shown in side view FIG. 6A .
[0065] FIG. 6D is a side view of a second embodiment of a subsea terminator interface, configured to connect to dual SSFCE segments 300 .
[0066] FIGS. 7A and 7B illustrate an SSFCE tee assembly 300 B. FIG. 7A is a side view of the assembly, and FIG. 7B is bottom isometric view of the assembly.
[0067] FIG. 7C illustrates an outer side view of a canopy terminator assembly. FIG. 7D illustrates a side view of a skirt assembly.
[0068] FIGS. 8A-8E illustrate a floating flare assembly according to the present invention. FIG. 8A an isometric view of the floating flare assembly, FIG. 8B is a side view of the floating flare assembly, FIG. 8C is a stern side isometric view of the floating flare assembly, FIG. 8D is a bottom isometric view of the floating flare assembly and FIG. 8E is a detailed hidden isometric view of a thermal block used in the floating flare assembly.
[0069] FIG. 9 illustrates buoyancy control logic for the floating platform flotation vessels.
[0070] FIG. 10 is a flow chart illustrating product flow from origination to potential destinations,
[0071] FIG. 11 is a block diagram illustrating a majority of the Process Control System 950 operations performed on the Floating Platform 100
[0072] FIG. 12 is a block diagram illustrating a majority of the Process Control System 850 operations performed on the Floating Flare 800 .
[0073] FIG. 13 illustrates an example of the fluid flow control portion of the control system.
[0074] FIG. 14 illustrates a 4 phase solid, liquid and gas model of the Floating Platform Rigid Enclosure, Self-Supporting Flexible Containment Enclosure (SSFCE) and Bubble Diverting Assembly.
[0075] FIG. 15 illustrates communication pathway options.
DETAILED DESCRIPTION OF THE INVENTION
[0076] The following table lists elements of the illustrated embodiments of the invention and their associated reference numbers for convenience.
[0000]
Ref. No.
Element
100
Floating platform
100A
Aft position (Stern)
100B
Bow position (Fore)
100P
Port position (Left side)
100S
Starboard position (Right side)
101
Mooring point
102
Flotation vessel
103
Cleat
104
Flotation platform upper deck
105
Support block
106
Drilled and Tapped Mounting Block
107
Drilled and Tapped Solid Vertical and Horizontal Bars
108
Exterior structural beam assembly
110
Locator buoy support enclosure
112
Locator buoy
120
Valve assembly (121 and 122)
121
Valve (¼ turn Butterfly Valve)
122
Electrically controlled valve actuator
123
Pipe assembly
124
Liquid product port
125
Pipe segments
126
Gaseous product port
127
Flange
128
Elbow
129
Tee
130
Compressed air tank cascade array enclosure
131
Compressed air tanks
132
Regulator
140
Watertight equipment enclosures
150
Outrigger pump assembly
151
Outrigger pump assembly frame
152
Outrigger pump
154
Outrigger pump discharge pipe assembly
155
Outrigger pump discharge port flange
156
Hydraulic Pump
157
Hydraulic Motor
158
Hydraulic Lines (supply, return and drain lines)
159
Diesel Power Unit
200
Rigid enclosure
201
Rigid enclosure wall
202
Manhole entry w/bolted hatch cover
203
Flow pump bulkhead connection w/bolted hatch cover
204
Rigid enclosure upper deck
205
Interior instrument sensor watertight enclosure
206
Gaseous product port connection
208
Interior structural beam assembly
210
Lower perimeter mating assembly
220
Liquid product port bulkhead connection
225
Lateral conduit
230
Internal tee
235
Downward submerged conduit
240
Bubble diverting assembly
245
Stays
250
Elevated solar panel structure
252
Watertight solar panels with adjustable angle assembly
255
Navigation lighting aids
260
Antennas and support structure
265
Lightning arrester
276
Outrigger pump discharge external bulkhead port & hinged
door
278
Outrigger pump discharge port internal bulkhead flange
280
Rigid enclosure bubble diverter
282
Bubble diverter interior wall
283
Bubble diverter exterior wall
284
Bubble diverter upper opening
286
Bubble diverter closed bottom
288
Bubble diverter fin standoffs
290
Bubble diverter fin (paired dashed lines represent front
and rear fins/slats)
300
Self-supporting flexible containment enclosure (SSFCE)
segment
300A
Segment with drag coefficient reduction elements (302A,
302B, 308)
300B
SSFCE tee assembly
300C
Canopy Terminator
300D
Segment with relief port
302
Panel
302A
Leading edge panel
302B
Tail panel
302C
Frustum panel segment
303
Loop flap (Female Connector or Connection)
303A
Loop Flap Connection Double Flap
303B
Loop Flap Connection Quad Flap
304
Loop material
305
Hook flap (Male Connector or Connection)
305A
Hook Flap Single-Hook
305B
Hook Flap Tri-Hook
306
Hook material
308
Support strap
310
Eyelets
312
Strap termination connection point
314
Protruding attachment point
330
Interior membrane
332
Exterior membrane
344
Lateral sleeve
345
Skirt assembly
352
Switchable Magnet or other clamping device
354
Weighted anchoring object
370
One-way Relief port
371
One-way Relief port assembly upper terminus
372
One-way Relief port assembly lower terminus
373
One-way Relief port panel assembly
374
One-way Relief port panel assembly flanges
375
One-way Relief port membrane valve assembly
380
External membrane gasket panel
381
Internal membrane gasket panel
376
Slotted semi-flexible plate
377
Membrane flaps
382
Flexible membrane material
383
Flexible membrane material battens
378
One-way Relief port lower opening
384
One-way Relief port lower opening exterior seal perimeter
connection
379
One-way Relief port lower opening exterior flap seal
385
Exterior flap seal perimeter connection
500
Self-supporting flexible containment enclosure (SSFCE)
502
Waterline
503
Seawater
504
Seafloor
510
Mooring lines
516
Anchorage points
518
Tethered cable connection lanyard.
520
Subsea buoy
522
Eye hook
550
Targeted area of hydrocarbon emissions (leak source)
564
Liquid Hydrocarbon Emissions (Liquid Product or Crude
Oil)
566
Gaseous Hydrocarbon Emissions (Gas Product or Methane
Gas)
567
Methane Hydrates (Methane clathrate or Clathrate hydrate)
568
Reservoir Water
570
Elevated temperature ascending material
572
Lower temperature ascending material
574
Cooler Seawater Descending
576
Equal interior and exterior pressure. @ 100 feet = 44.5
psi gauge
577
Equal interior and exterior pressure. @ 2000 feet = 890
psi gauge
578
Equal interior and exterior pressure. @ 5000 feet = 2225
psi gauge
600
Subsea terminator interface assembly
600A
Dual subsea terminator interface assembly
604
Termination Points
605
Frustum panel enclosure section (302, 308, 310)
606
Panel terminator plate
607
Lower conduit section
608
Handles
609
Eye Bolts
610
Tapered pointed set bolts
611
Bolt strip
612
Mounting positions
613
Fasteners for compression straps
614
Split plates
615
Compression straps
616
Connector plate
620
Guy lines
622
Guy lines
625
Terminator section
650
Combined terminator tee assembly
652
Horizontal manifold tee section
654
Valves
656
Manifold port
658
Flanged port
700
Towable Bladder Bag
701
Flexible Marine Hose
702
Shuttle Tanker Vessel or other vessel to present the product to
750
Ancillary Sensors (Sensors including as an example 751-779)
751
Pulsed radar liquid level sensor
752
Laser liquid level sensor
753
Ultrasonic liquid level sensor
754
Ultrasonic gas flow sensor
765
Ultasonic liquid flow sensor
766
Mechanical vane liquid flow sensor
767
Multi-point liquid level sensor switch
768
Pressure sensor
769
Pressure sensor switch
770
Load Cell sensor (strain gauge)
771
Tri-axial accelerometer, rate gyro and magnetometer
772
Thermocouple sensor
773
Voltage and current sensor
774
Photoelectric cell sensor
775
Moisture detection sensor
780
Ancillary Equipment (For example 781-799)
781
Batteries
782
Charge Controller and Regulators
783
Solid State IGBT Relays
784
Snubber and Polarity Protection Diodes
785
Water to Air Heat Exchanger
786
Water Pump
787
Solenoid Operated Valve
788
Video Camera (internal or external)
789
LED Lighting
790
Polycarbonate Lexan ™ MR-10
791
Digital controlled rotary or linear actuator
794
Subsea qualified cables, connectors, etc
796
Water and Gas (high and low pressure) hoses, bulkhead
fittings, etc.
799
Electronic Modules
800
Floating flare platform
800A
Aft position (Stern)
800B
Bow position (Fore)
800P
Port position (Left side)
800S
Starboard position (Right side)
801
Lower horizontal structural beam assembly
802
Floating flare upper deck
804
Condensate collection enclosure
805
Chemical pump (Condensate collection enclosure)
806
Flashback enclosure - seal enclosure
807
Water pump (Flashback enclosure)
810
Vertical corner support assembly
812
Upper horizontal structural beam assembly
814
Exterior horizontal single support assembly
816
Exterior horizontal corner support assembly
820
Radiant panels
821
Radiant panel flare flange access plates
822
Thermal block
824
Thermal block base material
825
Countersunk fastener hole for base material
826
High temperature and high strength bonding material
828
Thermal block insulator material
829
Countersunk fastener hole for insulator material
830
Flare assembly (832, 834, 836}
832
Barrel
834
Arms
836
Orifice
840
Suspended counterweight
842
Cables
850
Process Control System
852
Flare Ignition Controller System
854
Flare igniter
856
Flare ignition fuel
858
Flare ignition purge gas
902
Top interior surface of flotation vessel
904
Bottom interior surface of flotation vessel
906
Air port via bulkhead
908
Water port via bulkhead
910
Air vent outlet
912
Ballast blow out port and inline check valve
914
Gross/Fine Filter Water Inlet
918
Water Pump
920
Electronic liquid level sensor
921
Surfacing logic
922
Compressed air inlet solenoid valve
924
Water outlet solenoid valve
925
Submerging logic
926
Air outlet solenoid valve
928
Water inlet solenoid valve
935
Buoyancy control system
950
Process Control System
951
Electronic Modules
954
Floating platform product flow system
958
External Operators
970
Fluid Flow In
971
Desired Liquid Level Reference Set Point SP
972
Liquid Level Sensors Process Variable PV
973
Offset (+ or −)
974
PID Controllers
975
Manipulated Variable MV
976
Gas Pressure Inputs Process Variable PV
977
Fluid Flow Out
980
Ground Radio Data Link (Digital Link Transceiver and
antenna)
982
External Operator (Local Site Deployment Group)
984
External Operator (Remote Spill Management and
Engineering
986
Internet Network
988
Satellite Data Link (Satellite transceiver and antenna)
990
Satellite Network
[0077] For convenience, in the following description the term “FIG. 1 ” is used to refer collectively to FIGS. 1A-C . There is no separate FIG. 1 apart from FIGS. 1A-C . Similarly, “FIG. 2 ” is used to refer collectively to FIGS. 2A-2D , “FIG. 3 ” is used to refer collectively to FIGS. 3A-3L , “FIG. 4 ” is used to refer collectively to FIGS. 4A-4F , “FIG. 5 ” is used to refer collectively to FIGS. 5A-5B , “FIG. 6 ” is used to refer collectively to FIGS. 6A-6D , “FIG. 7 ” is used to refer collectively to FIGS. 7A-7C , and “FIG. 8 ” is used to refer collectively to FIGS. 8A-8E .
[0078] The subsea hydrocarbon collection and containment system of the present invention comprises a self-supporting flexible containment enclosure (SSFCE) 500 for capturing the leaking hydrocarbons, and a floating platform 100 having a rigid enclosure 200 in which gaseous and liquid products from the captured hydrocarbons are separated. Floating platform 100 routes the liquid and gaseous products for further handling. FIGS. 1 and 2 illustrate floating platform 100 . FIGS. 3-5 illustrate SSFCE 500 . FIGS. 6 and 7 show examples of connections between SSFCE 500 and leak sources 550 (such as sea floor fissures or broken wellheads). FIG. 8 shows a floating flare platform 800 capable of burning off gaseous product provided by floating platform 100 . FIG. 9 is a block diagram illustrating buoyancy control logic for floating platform 100 flotation vessels 102 . FIG. 10 provides a flowchart of product flow from origination to potential destinations. FIG. 11 is a flow diagram showing an example of a Process Control System 950 form monitoring and controlling operations. FIG. 12 is a flow diagram showing an example of a Process Control System 850 for monitoring and controlling operations. FIG. 13 is a flow diagram and illustrates an example of the fluid flow control portion of the control system. FIG. 14 illustrates a 4 phase solid, liquid and gas model of the Floating Platform 100 Rigid Enclosure 200 , Self-Supporting Flexible Containment Enclosure (SSFCE) 500 and Bubble Diverting Assembly 240 . FIG. 15 illustrates communication pathway options.
[0079] FIG. 1 comprises FIG. 1A , showing a top view of floating platform 100 , FIG. 1B , showing a side view of floating platform 100 , FIG. 1C , showing an isometric bottom view of floating platform 100 , and FIG. 1D , showing a side view of a Rigid Enclosure Bubble Diverter 280 an extension of the Rigid enclosure 200 and containing within a Bubble Diverter 280 . Floating platform 100 includes flotation vessels 102 , rigid enclosure 200 (in which liquid and gaseous products from the captured hydrocarbons are separated), and various piping and valves for handling liquid and gaseous products from self-supporting flexible containment enclosure (SSFCE) 502 shown in FIGS. 3-5 after they are separated within rigid enclosure 200 .
[0080] FIG. 1A shows floating platform 100 from the top (including some perspective), showing floating platform upper deck 104 , upper deck 204 of rigid enclosure 200 , flotation vessels 102 , and various ports, enclosures and hardware. Flotation vessels 102 support the structure, and allow it to float or submerge as desired. FIG. 9 shows buoyancy control logic controlling floating platform 100 draft via flotation vessels 102 . FIG. 11 shows Process Control System 950 which monitors and controls draft, flow control, buoyancy and other operations.
[0081] This submergence capability provides an increased level of reliability for floating platform 100 , avoiding heaving seas prior to and during hurricanes as well as other surface disturbances or threats such as above surface flammable situations. Floating platform 100 may be partly or fully submerged to a depth at which there is minimal turbulence, protecting it from excessive mechanical loading and or stresses. Floating platform 100 can continue its functions of separating liquid and gaseous products from captured hydrocarbons in conjunction with attached SSFCE 500 while partly or fully submerged.
[0082] 100 A is the “Aft” or rear end of platform 100 looking forward, 100 B is the “Bow” or front end, 100 P is the “Port” or left side, and 100 S is the “Starboard” or right side.
[0083] The system is able to direct the output products concurrently to multiple ports with, for example the gaseous product output ported between the 100 A aft port and 100 B Bow port and the liquid product output directed among two 100 B Bow ports and one 100 A Aft port.
[0084] Locator buoys 112 are attached to Locator buoy support enclosures 110 , which are attached to Flotation vessel 102
[0085] Liquid products are removed from Rigid enclosure 200 bulkhead flange Gaseous product port connection 206 via Valve assembly 120 . The liquid products then pass through Pipe assembly 123 to liquid product port 124 . Pipe assembly 123 comprise “Stubs with Flanges”—pipe extenders used for both gas and liquid products and consisting of a pipe assemblage with pipe flanges and welded flanges for bolting onto welded plates. Five of these are common and are shown in FIG. 1A (for liquid ports 124 and gas ports 126 ). A double ended pipe with flanges and with two sets of support base mounting flanges form this Pipe assembly 123 . For example Pipe Assembly 123 might be a custom fabricated dual square base flanged mounting for a pipe segment with pipe flanges on each end.
[0086] Gaseous product is removed from rigid enclosure 200 via port connections 206 on Rigid enclosure upper deck 204 and passes via pipe segments 125 , through Valve assemblies 120 . The gaseous product then passes through Pipe assembly 123 to Gaseous product ports 126 .
[0087] Valve assemblies 120 are operated by the Process Control System shown in FIG. 11 . Compressed air tanks 131 are configured in a cascade array 130 which allows for buoyancy control (as shown in FIG. 9 ). Cleats 103 provide securing points for lines and the like. Watertight enclosures 140 house various equipment.
[0088] FIG. 1B is a side view (including some perspective) of floating vessel 100 . In addition to the elements shown in FIG. 1A , FIG. 1B shows mooring points 101 , butterfly valves 121 and electrically controlled valve actuators (for example digitally controlled rotary actuators) 122 of valve assemblies 120 , walls 201 of rigid enclosure 200 and several elements extending below flotation vessels 102 .
[0089] Flotation vessel support blocks 105 , lower perimeter mating assembly 210 of rigid enclosure 200 , liquid product Bubble diverting assembly 240 , liquid product submerged conduit 235 , and liquid product bubble diverting assembly stays 245 are also visible.
[0090] FIG. 1C is an isometric bottom view of floating platform 100 . This view best illustrates the interior of rigid enclosure 200 , as well as some structural aspects of flotation platform 100 (such as structural beam assemblies 108 and 208 ).
[0091] Floating Platform 100 and Rigid Enclosure 200 might alternatively be assembled with weldments replacing the majority of assemblages that are connected using conventional fasteners engaged into drilled and or tapped members. In this preferred embodiment the structure is illustrated with the majority of assemblages being assembled with fasteners, aiding in the ability to transport individual components taking into consideration logistics and available transportation modes.
[0092] Vertical Walls 201 are secured by Drilled and Tapped Mounting Block 106 welded to flotation Vessel 102 and also secured to Drilled and Tapped Solid Vertical and Horizontal Bars 107 along with Upper Deck 204 that comprise and form the structure of the Rigid Enclosure 200 located within the floating platform 100 . Vertical walls 201 are additionally secured using Exterior Structural beam assembly 108 connected to Drilled and Tapped Mounting Block 106 . Drilled and Tapped Mounting Blocks 106 are welded into place at various locations on the flotation Vessel 102 .
[0093] In a preferred embodiment, all mating vertical wall 201 and upper deck 204 surfaces connected to vertical and horizontal bars 107 have an appropriate gasket material like Buna-N, Viton, etc. to provide for a watertight seal including hinged door assembly 276 and manhole port 202 and other appropriate locations.
[0094] In a preferred embodiment, Watertight sensor enclosures 205 may be incorporated within Rigid Enclosure 200 and may contain various equipment (not shown) such as pulsed radar liquid level sensors, laser liquid level sensors, pressure sensors providing redundant sensing, a wide angle low light internally mounted video camera looking downward, and a downward projecting LED lighting source. Each Watertight sensor enclosure 205 is preferably provided with a clear Polycarbonate Lexan™ MR-10 bottom cover (not shown) for viewing, inspection and access. The aforementioned liquid level and pressure sensors might be mounted through the clear Polycarbonate Lexan™ MR-10 bottom cover.
[0095] Liquid product Bubble diverting assembly 240 prevents gaseous product from entering the recessed ingress flange (not shown) located in the lower section of the Bubble diverting assembly 240 . The gaseous product will rise vertically adjacent to Bubble diverting assembly 240 and continue its upward ascension above Bubble diverting assembly 240 into the interior of Rigid Enclosure 200 and into Gaseous product connection 206 . Bubble diverting assembly 240 enables liquid product within the Bubble diverting assembly 240 enclosure to travel upward via downward submerged conduit 235 via liquid product Internal tee 230 to liquid product Lateral conduit 225 . The liquid product then passes through Liquid product port bulkhead connections 220 , with the flow controlled by Valve assemblies 120 , and then passes through Pipe assembly 123 and on to Liquid product ports 124 . Bubble diverting assembly Stays 245 might be connected between the interior Rigid enclosure vertical walls 201 or other members within the Rigid Enclosure 200 and the Bubble diverting assembly 240 for the purpose of providing mechanical stability. The interior of Rigid Enclosure 200 might contain one or more Bubble diverting assemblies 240 and further might incorporate directional louvers for directing or channeling gaseous product 566 away from the ingress of the Bubble diverting assembly 240 .
[0096] FIG. 1D illustrates an alternative to Bubble Diverting assembly 240 shown in FIG. 1C . Rigid Enclosure Bubble Diverter 280 is a lower extension of Rigid enclosure 200 and containing within Bubble Diverter 280 attached to enclosure walls 201 and Drilled and tapped solid vertical and horizontal bars 107 provide a walled structure with an open bottom and top that may further comprise a lower horizontal framework using for example the Drilled and tapped solid vertical and horizontal bars 107 .
[0097] Bubble diverter 280 may have a frustum, trapezoidal or conical shaped vertical surface with a closed bottom with an open area at the top supported by members from the bottom or sides extending outward and connected to the surrounding structure and providing an opening around the lower perimeter as to allow the ascending liquid and gaseous product to rise adjacent to the exterior of Bubble diverting assembly 280 while conversely disallowing the gaseous product from descending within the interior of the bubble diverting assembly 280 where an open ended conduit is in proximity to the lower inside portion of the bubble diverting assembly 280 . Furthermore, Bubble diverting assembly 280 may have fins or slats 290 connected to standoffs 288 or may be further secured to an exterior wall 283 attached to the standoffs with exterior wall 283 comprising for example a plurality of elongated lateral open slots between the attached fins 290 . In the aforementioned assembly fins 290 are secured to an exterior wall 283 and attached to interior wall 282 of bubble diverting assembly 280 by standoffs 288 . This establishes a collective region between interior wall 282 and exterior wall 283 for liquid product flow and provides a minimal introduction of gas bubbles within said region. It further allows the liquid product to flow along the exterior of the interior wall and over upper opening 284 perimeter edge of bubble diverting assembly 280 . FIG. 1D shows a Bubble diverter fin 290 with a pair of dashed lines that represent a front or rear aspect of a fin as opposed to an edge or side view.
[0098] The Bubble diverting assembly 280 upper opening 284 is located substantially below the anticipated lower boundary of the variable gas liquid interface level within the rigid enclosure 200 and the uppermost portion of the SSFCE 500 . Furthermore, a port (not shown) that can be opened or closed remotely or manually might be introduced at the lower portion of the Bubble diverting assembly 280 interior wall 282 to initially allow a liquid to fill the volume or drain such volume within said assembly.
[0099] FIG. 2 comprises FIGS. 2A , 2 B, 2 C, and 2 D, and shows detailed views of portions of floating platform 100 of FIG. 1 . FIG. 2A is an isometric side view of a solar panel elevated assembly comprising an elevated structure 250 supporting watertight solar panels 252 including adjustable angle assemblies attached to the 200 Rigid enclosure Rigid enclosure upper deck 204 . The Floating platform 100 may obtain its power for operation from the plurality of Watertight solar panels 252 that charge batteries (not shown) enclosed within one of the Watertight enclosures 140 . Structure 250 also supports navigation lighting aids 255 , antennas and support structure 260 and lightning arresters 265 .
[0100] FIG. 2B is an isometric side view of a hinged manhole port 202 allowing entry into rigid enclosure 200 via wall 201 . A watertight equipment enclosure 140 (side view) is seen to the right of manhole cover 202 and compressed air tank enclosure 130 (showing one of a plurality of air tanks 131 ) is seen to the left.
[0101] FIG. 2C is an isometric side view of the Outrigger pump discharge external bulkhead port 276 with hinged door bolted to the Outrigger pump discharge port interior bulkhead flange 278 formed in a side wall 201 of rigid enclosure 200 . The Outrigger pump discharge port internal bulkhead flange 278 can be seen in FIG. 1C . Outrigger pump assembly 150 is connected as shown in FIG. 2D .
[0102] One embodiment for the introduction of water into SSFCE 500 is by way of a temporarily installed outrigger pump assembly containing a hydraulically operated axial flow pump as shown in FIG. 2D .
[0103] Outrigger pump assembly 150 is temporarily secured to the Floating platform 100 providing a connection with Flange 155 to Rigid enclosure 200 sidewall 201 formed port Outrigger pump discharge port internal bulkhead flange 278 shown in FIG. 1C . Outrigger pump 152 pumps seawater into rigid enclosure 200 , to fill SSFCE 500 to partial capacity.
[0104] FIG. 2D is an isometric side view of Outrigger pump assembly 150 , used to pump seawater into rigid enclosure 200 , to fill the SSFCE to partial capacity. Locator buoy support enclosure 110 , Locator buoy 112 and external bulkhead port attached hinged door 276 have been removed for clarity. Outrigger pump 152 connects to Outrigger pump discharge pipe assembly 154 , supported by Outrigger pump assembly frame 151 . Outrigger pump discharge pipe assembly 154 terminates at Outrigger Pump discharge port flange 155 and makes a bulkhead connection to Outrigger Pump discharge port internal bulkhead flange 278 via the Rigid enclosure 200 sidewall 201 .
[0105] Outrigger pump 152 in this embodiment is an Axial flow pump and may be operated by hydraulics using, for example, an external diesel power unit 159 (not shown) having a hydraulic pump 156 (not shown), and hydraulic lines 158 (not shown) connected to a hydraulic motor 157 (not shown) operating an impeller (not shown) within the outrigger pump 152 housing. An ultrasonic liquid flow sensor 753 (not shown) might be attached to Outrigger pump discharge pipe segment 154 for the measurement of flow and volume of the liquid introduced into the SSFCE 500 .
[0106] SSFCE 500 is generally assembled in segments 300 , attaching components such as Subsea buoys 520 and Tethered cable connection lanyards 518 and Mooring lines 510 as required.
[0107] SSFCE containment enclosure 500 creates an “Ocean within an ocean” system, capturing and containing all of the leaking hydrocarbons as well as containing a great deal of seawater. SSFCE 500 might be deployed horizontally and empty on the surface of the water 502 . The Subsea terminator interface assembly 600 end of SSFCE 500 is then drawn down or pulled toward the targeted area of hydrocarbon emissions 502 by a remote operated vehicle (ROV, not shown) or other means. During the descent, SSFCE 500 is partially filled with seawater via Outrigger pump assembly 150 being temporarily secured to Floating platform 100 . The water pumped into SSFCE 500 creates a transport medium for the oil and gas hydrocarbon emissions.
[0108] The SSFCE 500 contained water volume is based on the total volumetric capacity of SSFCE 500 minus the anticipated worst case mean flow rate and/or volume during transit of the liquid and gaseous hydrocarbons minus a percentage of the SSFCE 500 total volume to allow for dynamic changes and to provide a buffer for, e.g. compressive forces upon SSFCE 500 , changes in flow rates, additionally introduced reservoir water, etc. These factors and others not mentioned might provide guidance for the volume of water required as a liquid transport media.
[0109] Outrigger pump assembly 150 is removed and the Outrigger pump discharge external bulkhead port with hinged door 276 is secured to Outrigger pump discharge port internal bulkhead flange 278 after operations to partially fill the SSFCE 500 are completed.
[0110] In a preferred embodiment, SSFCE 500 comprises adjoined segments 300 , each comprising panels 302 formed of, for example, a non-elastic geomembrane fabric. Segments 300 are connected at their edges to form tubes. Buoys 520 comprise Positive Offset Neutral Buoyancy attachment Devices (PONBADs) and are used to fine tune the buoyancy requirements of segments 300 based upon their location and function by adjusting the buoyancy value required by the addition or subtraction internally or externally specific amounts of weight
[0111] The segments include structure along their edges which allows the segments to be attached to form SSFCE 500 .
[0112] FIG. 3 comprises FIGS. 3A through 3L , and shows various views of SSFCE 500 segments 300 . An SSFCE segment 300 is a tube formed of panels 302 affixed together and supported by straps 308 . The segments are then connected, for example via hook-and-loop connections, to achieve the desired SSFCE 500 length.
[0113] Straps 308 connect together at their ends provide the main vertical mechanical support loading between segments 300 and the hook and loop connections 303 and 305 are primarily used as the interconnects providing a continuation of the SSFCE segment 300 function in the transport of material emanating from the hydrocarbon leak.
[0114] FIG. 3A is side isometric view of a first embodiment of an SSFCE segment 300 including panels 302 , support straps 308 and strap termination points 312 for connecting adjacent segments 300 . As an example, panels 302 might comprise 500 foot by 100 inch pieces of high-performance reinforced geomembrane such as Seaman XR5 8130 EIA (Ethylene Interpolymer Alloy) Polyester.
[0115] Furthermore the panel material used in the SSFCE segments might also include additional layers or laminations of the same or different material to the interior or the exterior for purposes such as strength and or thermal considerations.
[0116] Those skilled in the art will appreciate that this is just one example, and many variations are possible. For example, the length or diameter of segments 300 may be different. Segment 300 lengths of approximately 500 feet work very well due to fabrication, weight, counter-buoyancy requirements, logistics handling, etc. Longer or larger diameter segments 300 would require an increase in the number and/or the size of subsea buoyancy modules 520 to reduce the total topside loading.
[0117] Segments 300 can be made of other materials and may have frustums or other geometrical characteristics that may be symmetrical or asymmetrical in geometry. Segments 300 are not limited to four panels in construction, as they might comprise one or more panels with or without a plurality of straps.
[0118] Four panels 302 are welded together, creating seams along their long edges to form a 500-foot tube. There are many methods of welding panels together, e.g. Hot Air Wedge, Contact Hot Wedge, Radio-Frequency weldments, extrusion fillet weldments, chemical bonding adhesives.
[0119] Support straps 308 might comprise 4-inch-wide polyester strap material folded in half to cover the 2 inch wide hot wedge weldment and dual double stitched to the weldment using for example a Gore Industries Tenara thread. Additional stitching of the Support straps 308 may be of benefit including variations of stitch patterns, thread of other means of attachment.
[0120] Widths and lengths of the material for the seams, stitching, straps and panels may all be variable in size and material.
[0121] Eyelets or grommets 310 are inserted in support straps 308 to allow attachment of mooring lines, tethered loop handles, rings or carabiners and to further allow operators to easily handle, tow and manipulate segments.
[0122] At the top of segment 300 , along the short edges of panels 302 , is disposed, for example, a loop material 304 in Y-shaped flaps 303 (as shown in FIG. 4B ) or some other configuration. In this case, hook material 306 formed on I-shaped flap 305 is disposed at the bottom of segment 300 along the short edges of panels 302 in a configuration selected to engage with loop material 304 at the top of the next segment 300 . This hook-and-loop connection is the main connection between segments, and provides a nearly waterproof seal. There is less chance of intrusion of the oil and gas into the connection, as those fluids are moving vertically upward and along the surface and the system typically is not under pressure. If the orientation was the other way, one could potentially have seepage of the compromised fluids into the inside portion of the connection. Straps 308 provide further the main structural support and connection between segments.
[0123] FIG. 3B is a detailed view of connected strap termination points 312 , to provide the primary vertical load bearing connection between one segment 300 and another. For example, termination points 312 might be formed of 316 Stainless Steel and comprise a terminator strap connector with a bolt hole for connecting two strap segments 308 (the bolt and nut connection—or other fastener—is not shown). Termination point 312 might also consist of one or more bolt holes to connect with another termination point 312 and matching number of bolt holes for connecting the protruding attachment point 314 .
[0124] FIG. 3C is a detailed view of connected strap termination points as in FIG. 3A , further including a protruding attachment point 314 for connecting a buoy 520 (see FIG. 5 ) and or engaging mooring or other lines, cables, etc.
[0125] FIG. 3D is a detailed oblique wireframe view of SSFCE Segment 300 .
[0126] FIG. 3E is an isometric view of a second embodiment of an SSFCE 300 A segment section comprising SSFCE 300 as in FIG. 3D , further including drag coefficient reduction panels 302 A and tail flap panels 302 B. Construction of SSFCE 300 A segments might include the attachment and welding of 302 A panels to 302 panels during the construction of SSFCE segment 300 A with the subsequent attachment of straps 308 and eyelets 310 and or grommets 310 , etc. Panels 302 A are the main constituents of the drag coefficient reduction system and panels 302 B assist in reducing drag and turbidity, vortex turbulence, etc.
[0127] FIG. 3F is a top view of the segment 300 A of FIG. 3E . FIG. 3G is a variation on the segment 300 A of FIG. 3E where the drag coefficient reduction panels are connected using both opposing edges of the SSFCE segment (or in some cases opposing edges of two or more SSFCE segments).
[0128] FIG. 3H is a side view of the segment of FIG. 3E .
[0129] FIG. 3I illustrates an embodiment of a SSFCE segment 300 , which includes an internal Relief port 370 attached to the inside of SSFCE segment 300 D with flanges 374 . Relief port 370 has an opening 371 at its top terminus and a closed bottom terminus 372 . Relief port 370 is installed below the maximum anticipated lower boundary depth of any accumulation of liquid and or emulsified hydrocarbon product.
[0130] The surface of SSFCE segment 300 D has a partitioned opening constructed to accommodate a One-way port 375 further comprising a slotted semi-flexible plate 376 shown in FIG. 3K and exterior attached membrane flaps 377 secured by battens 383 , attached to a flexible membrane material 382 both shown in FIG. 3L forming the completed assembly membrane flap 377 . FIG. 3J illustrates the placement of One-way port 375 with both an internal membrane 381 gasket panel and external membrane 380 gasket panel that is attached around the perimeter of One-way port 375 internally and externally and further secured to SSFCE segment 300 D.
[0131] Relief port 370 has at its lower terminus a closed bottom 372 with an access opening 378 that might further comprise an attached membrane flap 379 having an interior perimeter of a hook or loop closure material that creates a seal when secured to opposing hook or loop closure material 384 that is formed around outer exterior perimeter opening 378 .
[0132] Opening 378 of Relief port 370 is located below One-way port 375 and allows for the removal of precipitated material that might accumulate. This reduces the probability of obstructing the openings formed on slotted semi-flexible plate 376 . Variations in this design are possible. The terminus of Relief port 370 might have a different opening and access method. The geometry of Relief port 370 might vary. The embodiment might further include an exterior conduit or channel connected to One-way port 375 for other purposes.
[0133] Other variations on SSFCE segments 300 D might include an external port connection on the SSFCE segment side to connect an internal tube made partially buoyant ascending vertically to further reduce the probability of gaseous and liquid compromised emissions from entering downwardly into the tube and allowing for the relief to the exterior of excess water volume. A further variation might introduce to this side port a descending weighted tube to further disallow gaseous and liquid compromised emissions from descending into the external side port (as such materials are typically buoyant). This embodiment might further be revised to incorporate a channel constructed of panel material to replace the aforementioned internal and external tubes that interface with SSFCE segment 300 D side mounted port. This embodiment may further include a channel or tube connection continuing below the SSFCE segment 300 D side mounted port descending downward on the interior of the SSFCE segment 300 D for a distance to a separate port that might have a hook and flap arrangement for closure for the purpose of collecting any precipitated particulate having a density greater than the water media such that material is accumulated in the enclosed volume and is able to be removed at a later time, while primarily decreasing the probability that any descending material would interfere with the operation of the aforementioned glands membrane glands.
[0134] A further variation might incorporate a flexible membrane type gland comprising a number of slits operating like a valve attached to a frame of sufficient rigidity located at the SSFCE 300 D exterior side port and or further located along or at the end of the exterior channel or tube assemblage. A further variation might incorporate on the exterior side of the gland interface with said slits a number of strips of a lesser tension or more elastic yielding gland material of sufficient width to overlap and cover the slits further disallowing the ingress of fluid from exterior to the interior of the gland thereby creating a form of a check valve.
[0135] The embodiment might further include and is not limited to the number of ports, placement or orientation around or within the perimeter of SSFCE Segment 300 D.
[0136] FIG. 4 comprises FIGS. 4A-4F , and shows detailed views of various hook-and-loop connections between segments. FIG. 4A is a side view of I-shaped hook flap 305 of a first embodiment of the connection, while FIG. 4B is a side view of V-shaped loop flaps 303 . Hook flap 305 has hook material 306 disposed on both sides. Loop flaps 303 have loop material 304 disposed on the inside surfaces. In use, hook flap 305 is inserted between loop flaps 303 and hook material 306 engages loop material 304 . Water must follow a circuitous path in order to leak though the connection thus formed.
[0137] In one preferred embodiment, loop material 304 is disposed at the top of segment 300 and hook material 306 is disposed at the bottom of segment 300 , as this configuration has been found to permit the least amount of leakage. With the oil and gas migrating upward there is only an upward shear, with downward travel essentially non-existent.
[0138] FIGS. 4C and 4D show a second embodiment of a hook-and-loop connection similar to that shown in FIGS. 4A and 4B , but wherein loop flaps 303 A and hook flap 305 A further comprise membrane materials 330 and 332 that provide a barrier that is compressed by the adjacent hook and loop material providing an enhanced liquid and gas seal. Interior membrane 330 might consist of a pliable elongated silicon bead/tubular member, while exterior membrane 332 might consist of a pliable rectangular silicone strip member.
[0139] FIGS. 4E and 4F show a third embodiment of a hook-and-loop connection. Loop flaps 303 B form a V-shape having loop material disposed on all four sides. Hook flaps 305 B form a W-shape having hook material on all six surfaces. Engaging flaps 303 B and 305 B thus forces water to follow an even more circuitous path in order to leak through this connection. Those skilled in the art will appreciate various other configurations of hook flaps 305 and loop flaps 303 that could form similar connections between SSFCE 502 segments 300 .
[0140] FIG. 5 comprises FIGS. 5A and 5B which illustrate a deployment configuration of SSFCE 500 . FIG. 5 shows how SSFCE 500 connects a hydrocarbon leak to floating platform 100 Rigid Enclosure 200 . SSCFE 500 is a self-supporting flexible containment enclosure providing the conveyance method between subsea terminator assembly 600 or canopy terminator 300 C and floating platform 100 at sea surface 502 . There may be other variations and numbers of SSFCE subsea terminators connected to the SSFCE 500 .
[0141] FIG. 5A shows a side view of the deployment. FIG. 5B shows the connection between a PONBAD and a strap termination point.
[0142] FIG. 5A shows an example of an SSFCE 500 having five SSFCE segments 300 connected in a manner such as those shown in FIG. 4 in order to form a 2500 foot (in this example) tube to direct a hydrocarbon leak 550 from the sea floor 504 (or other leak source) to floating platform 100 rigid enclosure 200 , where gaseous and liquid products are separated and directed as required. In general, floating platform 100 is located at the waterline 500 , though it may be semi-submerged when necessary. SSFCE 500 may be connected at seafloor 504 via a compromised emissions terminator interface such as subsea terminator interface assembly 600 shown in FIG. 6 or Canopy Terminator 300 C shown in FIG. 7C . Subsea buoys 520 are attached (for example) at terminators 314 between segments 300 . Various mooring lines 510 stabilize SSFCE 502 and attach to anchorage point(s) 516 .
[0143] Other rode mooring or structural support points (not shown) may be attached as well. e.g. a Floating Platform Storage and Offloading (FPSO) vessel, Floating Storage and Offloading (FSO) Vessel, Drill Rig, or other structures like a Catenary Anchor Leg Mooring (CALM) buoy system.
[0144] Any entrapped air in SSFCE 500 during the deployment rises to the surface, leaving SSFCE 500 essentially collapsed and ready to engage the containment of the compromised emissions after it is partially filled with seawater.
[0145] FIG. 5B shows an example of how subsea buoys 520 are attached to connection points 314 via tethered cable connection lanyards 518 attached at eyehooks 522 . The purpose of subsea buoys 520 is to create neutral or slightly positive buoyancy with respect to final anticipated loads being applied.
[0146] Subsea buoys 520 might comprise PONBADs—Positive Offset Neutral Buoyancy Attachment Devices, formed, for example, of Syntactic Foam. Different sizes and densities of material are chosen according to the desired outcome. PONBAD performance may also be fine tuned by the additional or subtractive application of the desired buoyancy equivalent offset weight using removable or attachable modules/members.
[0147] FIG. 6 comprises FIGS. 6A , 6 B, 6 C, and 6 D, illustrates subsea terminator interface assembly 600 which connects between SSFCE 500 and leak sources 550 . Interface assembly 600 comprises frustum panel enclosure section 605 and terminator section 625 , connected via connector plate 616 . Frustum panel enclosure section 605 comprises panels 302 , support straps 308 and eyelets 310 constructed in a frustum shape and is part of and transitions the terminator to SSFCE 500 .
[0148] One example of a preferred embodiment of a subsea terminator interface assembly 600 interfacing with a compromised well-head or Blow out preventer BOP (not shown) is illustrated in FIG. 6A . The wellhead or BOP riser assembly is cut off, leaving a short riser stub. The operator 958 places the lower conduit section 607 over the stub using handles 608 , and secures lower conduit section 607 by tightening the tapered pointed set bolts 610 onto the riser stub section.
[0149] FIG. 6B is a side view of terminator section 625 . Terminator plate 606 , lower conduit section 607 , handles 608 , eyebolts 609 , tapered pointed set bolts 610 and bolt strip 611 form terminator section 625 . FIG. 6C is a top view of connector plate 616 , comprising split plates 614 and compression straps 615 , forming mounting positions 612 . A variation on terminator section 625 might include a tapered annulus within the ingress end of lower conduit section 607 . A further variation on terminator section 625 might include a lower flange at the lower conduit section 607 ingress to accommodate the attachment of other flanged connections for termination to various pipe diameters and geometry using reducers or other mechanically attached interfaces.
[0150] Subsea terminator interface assembly 600 is assembled by lowering terminator section 625 through frustum panel enclosure section 605 until panel terminator plate 606 is blocked by the narrower opening formed at the apex of lower Frustum panel enclosure section 605 , such that the attachment of split plates 614 and compression straps 615 secure Frustum panel enclosure section 605 to the lower portion of panel terminator plate 606 .
[0151] Compression straps 615 with Split plates 614 form a seal with panel terminator plate 606 against the lower surface Panel terminator plate of 606 . Fasteners 613 attach connector plate 616 to enclosure section 605 and terminator plate 606 . Terminator plate 606 is smooth with rounded edges to limit wear and chaffing.
[0152] Upper eyebolts 609 provide for the attachment of guy lines 620 between terminator interface assembly 600 and termination points 604 to SSFCE 502 , to reduce strain between lower conduit section 607 and panel enclosure section 605 . Lower section eye bolts 609 provide for the attachment of safety or backup guy lines 622 between the lower conduit section 607 and the object that the terminator is connected to, such as a BOP riser stub (not shown) or other structures, and may reinforce and reduce the vertical shear load on the tapered pointed set bolts 610 . In general, subsea interface terminator assembly 600 would be constructed topside and would be the first to be deployed in the succession of components comprising SSFCE 500 .
[0153] FIG. 6D is a side view of a dual subsea terminator interface assembly 600 A, configured to connect to dual SSFCE segments 300 . It basically comprises two subsea terminator interfaces similar to interfaces 600 connected by horizontal manifold tee section 652 to a terminator section 625 . Valves 654 control the flow of leaking hydrocarbons to SSFCE 502 (via enclosure sections 605 and conduit sections 607 ) and to flanged ports 658 . This arrangement might be used to direct the compromised emissions to more than one Floating Platform 100 . The flanged ports 658 provide connections to jump line conduits or hose to introduce product into other nearby distribution systems or may be used in reverse to introduce materials into the SSFCE system.
[0154] A variation on subsea terminator 600 might have a number of multiple size flanged ports, valves and manifolds connected to a lower single section of conduit section 607 .
[0155] Optionally, the Process control system 950 may have full duplex communication capabilities and power extended to further monitor characteristics of the flow emanating from the source, such as temperature, flow rates, material content, etc.
[0156] A further variation on the Terminator section 625 and Frustum panel enclosure section 605 might include items such as attached instrumentation 780 or sensors 750 to measure internal and external temperature, emission flow rate and or operate valves by motorized actuators.
[0157] FIG. 7 comprises FIGS. 7A , 7 B and 7 C.
[0158] FIG. 7A is an external side view of SSFCE tee assembly 300 B.
[0159] FIGS. 7A , 7 B illustrate use of an SSFCE tee assembly 300 B. FIG. 7A is an external side view of assembly 300 B with Frustum panel segment 302 C that allow assembly 300 B to attach to dual SSFCE segments 300 . Frustum Panel Segment 302 C is shaped like a clipped pyramid or trapezoid. Guy Lines 622 are broken to illustrate that in a preferred embodiment these would be of a variable length, preferably being shorter than the mechanical length or height of the 300 B enclosure, thus reducing the strain or tension forces acting upon 300 B and inherently providing some slack or a ruffle/ripple/frill/gathering for tee assembly 300 B. The other broken lines for the fabric panels are to indicate variability in size as well. Tee assembly 300 B includes connection portions at the top and bottom (such as loop flap 303 and hook flap 305 ).
[0160] FIG. 7B is a bottom isometric view of tee assembly 300 B with Guy lines 622 removed for clarity. It shows how liquid and gaseous material flows from more than one SSFCE Segment 300 and combine to form one flow within standard SSFCE segment 300 above. Tee assembly 300 B might be employed in an opposite configuration to divide into separate flows.
[0161] SSFCE Tee assembly 300 B might further include additional internal arrangements of panels such as louvers and or meshed panels for enhanced directional control of the individual or combined components comprising the hydrocarbon material flow.
[0162] FIG. 7C shows an outer side view of a single Canopy terminator 300 C that might be used to cover, straddle, envelop or tent a subsea floor fissure, a horizontal pipe-transport leaking assemblage or other leak source 550 . A Canopy terminator 300 C might be fabricated to various sizes to cover areas that show evidence of leaks. It may have one or more panels or frustums that may be symmetrical or asymmetrical in geometry.
[0163] Canopy terminator 300 C might also have attached to its lower perimeter Hook flaps 305 skirt assembly 345 as shown in side view in FIG. 7D . Skirt assembly 345 is attached with Loop flaps 303 and might contain within the formed lateral Sleeve 344 a suitable weighted material like sand, gravel or chain to ensure the Canopy terminator 300 C sufficiently interfaces with seafloor bottom 504 .
[0164] Switchable Magnet 352 or other connecting or clamping device attaches to weighted anchoring object 354 (such as a mass of Ferrous material) or other structures to provide anchorage upon seafloor surface 504 . Anchoring object 354 may be embedded into the seafloor surface with engagement protrusions.
[0165] If a number of deployed canopy terminators 300 C are combined, a collection method can be employed for gross widespread emissions of gaseous and liquid hydrocarbons in thermally unstable seafloors or with seafloor emissions emanating from unstable or underlying fractured strata below the seafloor. A blown out or compromised well casing or bore hole below the seabed might also cause subsea floor fissures. Combining multiple canopy terminators 300 C each connected to SSFCE 300 segments and connected using one or more SSFCE Tee Assemblies 300 B further directed to a single SSFCE 300 Segment forms a multi-segmented complete SSFCE 500 system.
[0166] FIG. 8 comprises FIGS. 8A-8E and illustrates an autonomously operated floating flare platform according to the present invention. FIG. 8A is an isometric view of floating flare platform 800 , FIG. 8B is a side view of floating flare platform 800 , FIG. 8C is a stern side isometric view of floating flare platform 800 , FIG. 8D is a bottom isometric view of the floating flare assembly and FIG. 8E is a detailed hidden isometric view of thermal blocks 822 used to isolate the radiant heat conducted from the radiant panels 820 on floating flare platform 800 . Floating flare platform 800 is used to burn off gaseous hydrocarbons delivered to it from floating platform 100 . The embodiment shown here is located on a separate platform, and the gaseous hydrocarbons provided via a tethered Flexible marine hose 701 (not shown) or the like.
[0167] Floating flare platform 800 provides for an integrated apparatus to flare (burn off) gaseous emissions from floating platform 100 that are directed from gaseous product ports 126 (See FIG. 1 ) via tethered Flexible marine hose 701 (not shown) to gaseous product port 126 on floating flare platform 800 . Flexible marine hose 701 might comprise a flexible marine hose suitable for transporting liquid and gaseous hydrocarbon products. Flexible marine hose 701 may also have attached to it “winker lights” (not shown) for collision avoidance and other transport lines (not shown) to convey liquid, air, gas, electricity, and/or means for electrically grounding the conduit to minimize static and to provide lightning protection. A preferred Flexible marine hose 701 would have a grounding conductor included as part of the construction from the manufacturer.
[0168] Floating flare platform 800 may be structured similarly to floating platform 100 in FIG. 1 , including flotation vessels 102 for supporting the structure, mooring points 101 , support blocks 105 , cleats 103 , etc. Solar panels 252 may be provided to generate electricity. The vertically suspended Solar panel 252 in FIG. 8A has been removed in FIG. 8C for clarity. In this embodiment Floating flare platform 800 obtains its power for operation from a plurality of Deep discharge batteries 781 (not shown) charged by Watertight solar panels 252 . This powers condensate collection enclosure 804 chemical pump 805 (not shown) to remove accumulated condensate liquid for injection into the flare assembly gas stream, flashback enclosure 806 water pump 807 (not shown), and including such items (not shown) as sensors 750 , liquid level detectors 753 and 767 (not shown), solenoid operated valves 787 (not shown), process control system computer 850 (not shown), ground radio digital link transceivers 980 (not shown) for communications to and from Floating platform 100 , and a flare ignition controller system 852 (not shown) comprising a Flare ignition Controller 852 , Flare igniter 854 , Flare ignition fuel 856 and Flare ignition purge gas 858 . Condensate collection enclosure 804 is also known as a “knockout” box or drum used in the collection of any condensates from the gas stream.
[0169] Structurally speaking, Vertical corner support assemblies 810 are secured to an arrangement of Flotation vessels 102 . They form inside corners to secure Upper horizontal beam assembly 812 , which is constructed in a horizontal framework as seen in FIGS. 8A , 8 B, 8 C, and 8 D. Exterior horizontal single support assembly 814 and Exterior horizontal corner support assembly 816 are secured to Upper horizontal beam assembly 812 . Radiant panels 820 mount Thermal blocks 822 with fasteners and isolate them from assemblies 812 , 814 and 816 . FIG. 8C illustrates two bolted split plates 821 attached to radiant panel 820 surrounding the lower portion of flare barrel 832 , providing access to flare barrel 832 flange connection (not shown) to Flashback enclosure 806 .
[0170] Flare assembly 830 comprises Barrel 832 , Arms 834 and Orifice 836 and is secured to the top of Flashback enclosure 806 with a flanged pipe connection (not shown). Also not shown in FIG. 8A are examples of orifice 836 tip outlets that may be used. Various other designs might be supplied by different manufacturers. Flashback enclosure 806 is secured by flanges at two locations at the bottom of Upper horizontal structural beam assembly 812 . Flashback enclosure 806 is also secured to Lower structural beam assembly 801 by flanges at four locations, as shown in FIGS. 8C , and 8 D.
[0171] Lower horizontal structural beam assemblies 801 are also secured to the Flotation vessels 102 and secure Floating flare upper deck 802 , Condensate collection enclosure 804 , Flashback enclosure 806 , Watertight solar panels 252 , Watertight equipment enclosures 140 , fuel gas tanks (not shown) for the ignition of flare assembly 830 , and Purge gas tanks (not shown) for purging explosive gas from Flare assembly 830 .
[0172] Flare ignition system 852 is conventional and is not shown or described in detail. Briefly, a flare igniter 854 is typically secured to Flare assembly 830 , and is fueled by a flare ignition fuel 856 tank containing fuel such as propane or LNG and operated by a flare ignition controller 852 . The flare ignition purge gas 858 tank contains pressurized nitrogen or other like purge gas and is operated by the flare ignition controller 852 , which is controlled by the Process Control System 850 shown in FIG. 12 .
[0173] Other conventional equipment 780 and sensors 750 might further include components such as chemical pumps, water pumps, liquid level sensors, Ground radio data link 980 providing communication for control options along with operational information such as pressure levels, flow rates, temperatures, etc.
[0174] Floating flare platform 800 supports Upper deck 802 , upright assembly 810 , Condensate collection enclosure 804 , and flashback enclosure 806 . Vertical corner support assembly 810 , supports Flare assembly 830 and Radiant panels 820 via exterior single support assemblies 814 and exterior corner support assemblies 816 .
[0175] FIG. 8B shows suspended counterweight 840 attached to platform 800 via cables 842 . The purpose of the counterweight is to assist in the reduction of vessel heave, pitch and roll by damping platform 800 motion, thus improving the platform's overall stability.
[0176] Thermal blocks 822 isolate conductive heat from Radiant panels, preventing heat radiated from the Flare Assembly from affecting Floating flare platform 800 . These are better shown in FIG. 8E .
[0177] FIG. 8E shows a detailed view of thermal blocks 822 . Each thermal block 822 is preferably formed of a thermal block base material 824 bonded by High temperature and high strength bonding material 826 to Thermal block insulator material 828 .
[0178] Thermal blocks 822 form base material Countersunk fastener holes for insulating material 829 for attaching thermal blocks 822 to radiant panels 820 . Thermal blocks 822 also form Countersunk fastener holes for base material 825 for attaching Thermal blocks 822 to upper horizontal structural beam assembly 812 , exterior single support assemblies 814 , and exterior corner support assemblies 816 . Thermal block insulator material 828 might consist of high temperature ceramic composite material.
[0179] In this embodiment radiant panels 820 might be constructed of stainless steel panels with associated stainless steel fasteners to withstand the radiant energy and shield the vessel and structure below. Radiant panels 820 might further include an insulative material secured to the underside to further reduce downwardly emanating radiant energy.
[0180] Watertight equipment enclosures 140 are provided to enclose and safeguard various equipment (not shown). For example, Floating flare platform 800 preferably includes a flare ignition controller system 852 as described above located within a watertight equipment enclosure 140 . Other watertight equipment enclosures 140 might contain equipment 780 and sensors 750 such as deep discharge batteries 781 , a charge controller and regulator 782 , the Process Control System 850 shown in FIG. 12 , Ground radio data link 980 , a condensate collection enclosure chemical pump 805 , a flashback seal enclosure water pump 807 , multiple liquid level sensors 750 and other sensors 750 , and various other process equipment 780 .
[0181] Floating Flare 800 Process Control System 850 (see FIG. 11 ) provides for the autonomous operation and monitoring of activities such as the flare ignition controller system 852 , operation of solenoid valves 787 for flare ignition fuel 856 and purge gas 858 , and other process equipment described above. Floating Flare 800 obtains its power for operation from batteries 781 charged by the Watertight solar panels 252 .
[0182] FIG. 9 illustrates a portion of the buoyancy control logic for floating platform 100 . FIG. 9 is primarily a logic drawing, but it does include a cutaway side view of one flotation vessel 102 to illustrate the submergence and surfacing processes. The components that comprise Buoyancy control system 935 is a part of operations performed by the Process Control System 950 .
[0183] Flotation vessel 102 in FIG. 9 includes two ports: Water port 908 (along bottom interior surface 904 ) having a short interior vertical conduit orientated toward the bottom; and Air port 906 (along top interior surface 902 ) having a short interior vertical conduit orientated toward the top. Both ports 906 , 908 are located on the exterior vertical surface of Flotation vessel 102 facing the interior perimeter of Flotation vessels 102 . Electronic liquid level sensor 920 might be located on the same surface as Air port 906 and Water port 908 .
[0184] In the preferred embodiment, there are four Water pumps 918 , acting in two pairs operating as two pumps in parallel. One pair of pumps provides operation for an opposing pair of Flotation vessels 102 , while the second pair provides operation for the adjacent opposing pair of Flotation vessels 102 . This arrangement provides for a uniform and symmetrical distribution of introduced liquid ballast and additionally provides redundancy and increased reliability. This preferred pairing arrangement is also used to provide and control air in a uniform and symmetrical distribution which again provides redundancy and increased reliability. All hose lengths are preferably of equal diameter and length, resulting in equivalent flow rates and pressure drops for the corresponding liquid and air media types.
[0185] This arrangement may be simplified to one pair of water pumps 918 in parallel providing control to Aft position 100 A and Bow position 100 B, while the other pair in parallel provides control to Port position 100 P and Starboard position 100 S as shown in FIG. 1A .
[0186] Solenoid valves 922 , 924 , 926 , and 928 are normally closed with the logic condition being 0 or not enabled.
[0187] Buoyancy system 935 (in turn controlled by Process Control System 950 ) controls the process of surfacing (or decreasing the draft) by enabling logic function 921 (S 1 ) by simultaneous activation of solenoid valves 922 and 924 , egressing ballast water and displacing it with pressurized air to achieve the level of buoyancy required. Solenoid valve 922 is activated, permitting compressed air from compressed air tank array 130 to flow into regulator 132 and into flotation vessel 102 Air port 906 . Solenoid valve 924 opens to allow water to “blow out” ballast through Ballast blow out port and inline check valve 912 from Water port 908 . When the desired depth is achieved, logic 921 deactivates and solenoid valves 922 , 924 close.
[0188] The action and process of submergence (or increasing the draft) is performed by enabling logic function 925 (S 2 ) to cause simultaneous activation of solenoid valves 926 , 928 to displace air within Flotation vessel 102 and to replace the air with the ballast water. Solenoid valve 926 opens air vent outlet 910 to allow the air to escape from Air port 906 . Solenoid valve 928 controls pump 918 which causes inflow through gross/fine filter water inlet 914 to Water port 908 .
[0189] Electronic liquid level sensor 920 provides a liquid level measurement inside each buoyancy vessel 102 . Other sensors (not shown) provide data representing the actual draft or depth of Floating platform 100 . When the desired depth (or draft) is achieved logic condition 925 is disabled and valves 926 and 928 are deactivated or closed.
[0190] In a preferred embodiment ports 906 and 908 are mounted within the interior perimeter of Flotation vessels 102 and adjacent to Rigid enclosure 200 (e.g. air port 906 on top interior vertical surface 902 and waterport 908 on bottom interior vertical surface 904 ). Another port placement method (not shown) mounts both ports to gasketed bolt on flanges located on flotation vessel 102 , enabling access to both sides of the two ports.
[0191] In a preferred embodiment, flotation vessel 102 may have a number of transverse baffles or surge plates installed (not shown) to minimize longitudinal surge and slosh of ballast water due to ocean wave action. Sacrificial anodes (not shown) may be provided for corrosion control.
[0192] The achieved draft or resultant depth of floating platform 100 is based on many factors such as: volume and mass of the ballast seawater 503 contained in flotation vessel 102 ; total mass of floating platform 100 ; volume of crude oil 564 content within the upper SSFCE segment 300 and its potentially variable density value; volume of gaseous product 566 within Rigid enclosure 200 and the upper SSFCE segment 300 ; the vertical load of the total SSFCE assembly 500 as measured by strain gauges (not shown); horizontal and vertical loading of SSFCE assembly 500 by undersea transverse current velocities; amount and degree of emulsified products 564 and 566 contained and affecting the overall buoyancy; weather characteristics; and Global Positioning Satellite GPS location deviation from the target.
[0193] These and other variables are one of the reasons for an advanced Process Control System 950 to monitor and adjust the dynamics of this invention. The complexity and number of variables under consideration is preferably addressed by an autonomous Process Control System 950 which also enables digital communication for remote monitoring and control by operators 958 .
[0194] FIG. 10 shows a flow chart illustrating the product flow system 954 for both the gaseous hydrocarbon and liquid hydrocarbon material from origination to destination.
[0195] In one embodiment, SSFCE 500 has one input and one output. Floating platform 100 has multiple outputs, enabling flexibility and or changeouts in the presentation of product output for final disposition. For example, offloading liquid product requires time to disconnect and reconnect to tankers when vessels are changed out. Multiple liquid product ports reduce this time. To further extend the time required for product presentation to offload vessels, a number of conventional temporary storage Towable bladder bag 700 might be incorporated in the product flow configuration. This embodiment also supports routing the gaseous product to multiple outputs, for example to support two Floating flare platforms 800 .
[0196] FIG. 11 is a block diagram showing a majority of the Process Control System 950 operations performed on the Floating Platform 100 .
[0197] The operations performed start by loading and initializing the default program with initial parameters, enabling data logging; system functions, actuators and sensors are checked and communication links are established prior to starting operation. FIG. 11 illustrates a process flow of operations that are continuously monitored and adjusted as required.
[0198] To achieve control of Floating platform 100 , Process Control System 950 makes use of the inputs from various sensors 750 . Further the Process Control System 950 provides control functions to buoyancy control system 935 , product flow system 954 , and other equipment 780 . Product flow system 954 includes equipment such as Valve assemblies 120 , Other equipment 780 and sensors 750 might include various pumps, solenoid valves, solid state IGBT relays 783 , voltage and current sensors 773 , navigation aid lighting 255 , other electronic equipment, liquid to air heat exchanger system 785 , pulsed radar liquid level sensors 751 , laser liquid level sensors 752 , pressure sensors 768 , etc. A number of Sensors 750 might typically be located within watertight sensor enclosures which may additionally include an internal Video Camera 788 with LED lighting 789 . A number of sensors 750 preferably redundant are used, including pulsed radar liquid level sensor 751 , laser liquid level transmitters 752 and pressure sensors 768 providing information to control the flow rates and volumes preferably by digital control valve actuators 122 in conjunction with the autonomous draft functionality of the platform.
[0199] Other sensors 750 preferably are incorporated in the Floating Platform 100 such as ultrasonic liquid flow sensor 765 , an ultrasonic gas flow sensor 754 , multipoint liquid level sensor switch 767 , strain gauges 770 , moisture detection sensors 775 , temperature sensors 772 , pressure sensors 768 , pressure sensor switch 769 , and photoelectric cell sensor 774 . The Process Control System 950 additionally monitors, via sensors 750 , such events as external wave height, periods and impingements, internal liquid level heights and periods, internal and external hydrostatic pressures, flow rates, buoyancy forces and the overall mass loading of the SSFCE 500 , and GPS coordinates. Process Control Systems 950 autonomously performs specific functions based on continuously monitored sensor inputs and further communicates to a more specific and limited Process Control System 850 onboard the Floating flare platform 800 where additional parameters are monitored and functions performed.
[0200] Three related and important parameters are critical for sustained operation: (1) the need to establish, maintain and periodically adjust the Floating platforms 100 draft via buoyancy control system 935 ; (2) maintaining the gas flow and contained volume within the rigid enclosure via product flow system 954 ; and (3) maintaining the flow and contained volume of crude oil via product flow system 954 .
[0201] As an example, the process control system might use a pulsed radar liquid level sensor 751 and laser liquid level sensor 752 in combination, measurements may be obtained of the surface height and depth of the accumulated liquid hydrocarbon emissions 564 within the upper portion of the SSFCE 500 structure in conjunction to the location of the respective sensors.
[0202] A pulsed radar liquid level sensor 751 will provide a distance value by the time measured to make a round trip of a reflected signal from a material having a significantly different dielectric constant than the medium it is transmitting thru. Seawater having a higher dielectric constant in the area of 60 to 80 will reflect the signal with a strong contrast compared to hydrocarbon products having a relatively low dielectric constant in the area of 4.0 and below with methane gas having a dielectric constant less than 2.0. The laser liquid level sensor 752 measures the round trip time when the laser beam is reflected from a liquid or solid surface. The sensors 751 and 752 may each be duplicated for redundancy and used for backup purposes and to also allow for averaging of the data provided.
[0203] Process Control System 950 , along with power control equipment 780 ; is preferably located within Watertight Equipment Enclosures 140 and further includes items (not shown) such as a master process control system 950 computer, a redundant process computer, electronic modules 799 comprising for example, analog and digital input and output control modules, signal isolators, etc.; current sensors 773 , solid state IGBT relays 783 , a water to air heat exchanger 785 , a sensor arrangement providing for a tri-axial accelerometer, rate gyro and magnetometer 771 measuring x-y-z acceleration, pitch, roll, yaw rate and magnetometer data and communication links comprising ground radio data link 980 and satellite data link 988 . In a preferred embodiment of this invention, the Primary Process Control System 950 being the primary controller is located on board the Floating platform 100 while a secondary, smaller and more process specific Process Control System 850 illustrated in FIG. 12 is located on the Floating flare platform 800 . Process Control System 950 may be operated autonomously and located on floating platform 100 in communication with floating flare platform 800 , or may be operated in a remote location, or may be distributed among two or more of these locations.
[0204] In the preferred embodiment the remote Human Machine Interface HMI monitoring and control capability afforded to the Floating Platform 100 and Floating Flare Platform 800 is provided by a meshed digital communications link using ground radio data link 980 transceivers onboard both Floating Platform 100 and Floating Flare 800 enabling secure communication to operators 958 , such as the local Deployment operations manager. Depending on the range, communication to these platforms may be from land, sea or air. Communication between the Floating Platform 100 and Floating Flare is of a minimal distance. Communication via the HMI interface is further enhanced by the use of Satellite data links 988 between the Floating Platform 100 and providing a redundant link to the Local Site Deployment operations manager while extending communication to Remote Spill Management Engineering and Regulators enabling information to be readily available for other concerned parties such as other government regulators, corporate office and engineering locations as illustrated in FIG. 15 .
[0205] According to the present invention a Process Control System 950 provides autonomous monitoring and control performed in near real time better than the reaction times by a human operators reaction times is able to perform, while also enabling supervisory monitoring and control by a human operator 958 to remotely monitor and control the operation using a Human Machine Interface HMI via digital communication radio links that are accessible concurrently by ground radio and or satellite communication.
[0206] FIG. 12 is a block diagram showing a majority of the Process Control System 850 operations performed on the Floating Flare 800 . The operations performed start by loading and initializing the default program with initial parameters, enabling data logging and establishing the communication link. The system checks the operational functions, pumps, valves, actuators and sensors and the process starts. Process Control System 850 , along with other control equipment is preferably located within Watertight Equipment Enclosures 140 . The Process Control System 850 monitors by sensors such values as gas pressure, liquid levels and temperatures to operate specific functions and communicates the operation and status via a communication link.
[0207] FIG. 13 illustrates an example of the fluid flow control portion of the control system.
[0208] The Process Control System 950 uses Programmable Logic Controllers PLC and also Proportional Integral Derivative PID controllers to manage overall the Fluid flow out 977 rate based on the Fluid flow in 970 to the system. Desired liquid levels values are established with Set Points SP 971 with actual Liquid Level Process Variables PV 972 and Pressure Sensors Process Variables PV 976 are compared by the PID controllers 974 monitoring the values and establishing an offset 973 or change that is translated to a Manipulated Variable MV 975 to adjust the Fluid Flow Output 977 . The process is continuous with a preference in minimizing the need for constant adjustment by forecasting the rate of change in the processing algorithms. Multiple Process Variables PV, Set Points SP and Manipulated Variables MV are established for Process Control System 950 to monitor and control draft operations and product flow. Process Control System 950 uses a number of algorithms that interact with the PV's, SP's and MV's along with other parameters and heuristic based tables to control operation of Floating Platform 100 .
[0209] As an example, a forward looking cascade of Proportional Integral PI to Proportional Integral Derivative PID gain scheduling algorithms for non-linear flows might be used. It would be noted by those experienced in the art that the example illustrated is extensively interrelated and is concomitant in operation with the gaseous control and buoyancy control portion of the Process Control System 950 .
[0210] FIG. 14 illustrates a 4 phase solid, liquid and gas model of the Floating Platform 100 Rigid Enclosure 200 , Self-Supporting Flexible Containment Enclosure (SSFCE) 500 and Bubble Diverting Assembly 240 . The primary materials discussed are seawater, methane gas, methane hydrates and crude oil. Typically hydrocarbon emissions being both gaseous 566 and liquid 564 having a density less than Seawater 503 eventually rise to the surface and are constrained within the uppermost portion of the SSFCE 500 structure connected to Floating Platform 100 Rigid Enclosure 200 . An enclosed and controlled volume of Gaseous product 566 prevents Liquid product 564 from rising within the Floating Platform 100 Rigid Enclosure 200 above a predetermined level such as the Waterline 502 used as a reference in this example. As more Liquid Product 564 is accumulated an increasing buoyant upward pressure is created and forces the Liquid product 564 through the upwardly ascending conduit to the Liquid Product Port 124 by the adjustment of a flow control valve (not shown) to release the Liquid Product 564 . The gaseous product 566 bubbles ascend through the Seawater 503 and through the accumulated volume of Liquid product 564 contained within the uppermost portion of the SSFCE 500 structure and are deflected and diverted past the opening of the Liquid Product ascending conduit connected within the Bubble Diverting Assembly 240 lower portion. The Gaseous Product 566 bubbles continue their upward ascent and break through the upper surface of the accumulated Liquid Product 564 and continue to add to the maintained volume of Gas Product 566 that is released by the adjustment of flow control valve assembly 120 (not shown). When sufficient volumes have been established, the same inflow rate entering from the bottom of the SSFCE 500 will be removed from the SSFCE 500 enclosures uppermost section and Floating Platform 100 Rigid Enclosure 200 for both the Liquid product 564 and the Gaseous product 566 using adjustments of the flow control valve assemblies 120 .
[0211] The inherent function of the upper portion of the SSFCE 500 structure and the Floating Platform 100 Rigid enclosure provides for the accumulation of Liquid product 564 by creating a vertical Gun barrel separation method that is well known, and eventually aggregating like type materials by natural phase separation using the Seawater 503 as the transport medium. Hydrocarbon emissions may be found as heated deposits located by deep well drilling in the earths crust. The release of these heated deposits from a well bore or fissure can generate a large amount of thermal energy. Additionally these thermal emissions when released eventually create a thermosyphon effect and may be compared to a contemporary residential wall radiator heating system in this example and model.
[0212] Ascending material at an elevated temperature 570 and transitioning to a Lower temperature 572 from the compromised emission site will typically move upward within the center of the SSFCE while Cooler Seawater Descending 574 will flow downward along the interior perimeter. The thermal flows expected are also likened to that of a chimney and a convection cycle is initiated. The natural dynamics of convection flow loops known as thermosyphons circulate the liquid by the changes in the buoyant forces generated by the thermal gradients due to heat introduced into the system, thermal loss due to conduction and dilution. The exterior of the SSFCE 500 also provides a substantial heat sink for increasing thermal dissipation due to conduction.
[0213] Pressure points 576 , 577 and 578 are noted to indicate the relative gauge pressure is equal on both the interior and exterior surface and this equality is maintained irrespective of the depth.
[0214] In addition to normal occurring gaseous hydrocarbon emissions or Methane Gas 566 underground, there may be large deposits of Methane clathrates, typically called Methane hydrates 567 being a solid form of a large amount of methane trapped within a crystal structure of water forming a solid, very much like ice that can be found in underground reservoirs and even occur on the seafloor and on land at the appropriate temperature and pressures.
[0215] Methane hydrates 567 are often cited as problematic due to disruptions of oil and gas exploration and production operations in the obstructing or clogging of production lines or by the “kick” produced by the rapid sublimation from a solid to the release of methane gas 566 and water in a closed system such as a riser pipe section or from a well bore. Control to minimize or prevent these “kicks” is often accomplished by operations such as adjusting flow rates, the removal of water and the introduction of material like ethylene glycol or methanol, etc. Gaseous Hydrocarbon Emissions or Methane Gas 566 released from reservoirs and introduced into well bores and distribution lines may encounter lower temperatures and with high pressures may create the methane hydrates 567 . Additionally Methane hydrate bearing layers are sometimes formed within geological formations pressurized by the weight of the formation pressure and seawater.
[0216] A depressurization inside the well enables the methane hydrates to dissociate into methane gas and water. When solid methane material 567 is introduced into the SSFCE 500 it finds a significant boundary barrier enclosed volume, a relaxed pressure and elevated temperature to undergo a natural gas phase transition while providing the room for the significant volumetric expansion to a gas without the need for hydrate inhibiting solvents to be used.
[0217] Containment and presentation operations are based on a “Ocean within an ocean” model providing an effective boundary barrier to the environment.
[0218] FIG. 15 illustrates communication pathway options.
[0219] Although the Floating Platform 100 and Floating Flare 800 structures Process Control Systems 950 and 850 respectively may be operated autonomously and even communicate between each other using a hard-wired communication path, a design capability embodiment is incorporated providing wireless communication between the Floating Platform 100 and the Floating Flare 800 to further ensure appropriate functions are performed. This is further enhanced by enabling remote monitoring and operations by the Local Site Deployment Operators 982 via a ground radio data link 980 while communication is conducted concurrently between Floating Platform 100 and Floating Flare 800 using the same ground radio data link 980 .
[0220] If Local Site Deployment Operators 982 are out of range using Ground Radio Data Link 980 , a communication link may also be established using the Satellite Data Link 988 to communicate to the Floating Platform 100 via Satellite Network 990 . Furthermore, teams of Remote Spill Management, Engineering and Regulators 984 may access the operations globally via Satellite Data Link 988 and or Internet Network 986 via Satellite Network 990 and subsequently monitor, control and communicate directly to the Floating Platform 100 , Floating Flare 800 and communicate to the Local Site Deployment Operators 982 . With secured digital communication radio links using redundant ground radio data links 980 along with Satellite data links 988 providing access to a system such as the Inmarsat Broadband Global Area Network BGAN satellite system 990 , a Human Machine Interface HMI enables senior management, engineers, government regulators, on-site personnel and others to have near real-time access to data and specific user access to operational control functions. Digital communications enable authorized secure local and global interaction to a combined supervisory autonomous control system with the present invention.
[0221] While the exemplary preferred embodiments of the present invention are described herein with particularity, those skilled in the art will appreciate various changes, additions, and applications other than those specifically mentioned, which are within the spirit of this invention. For example, certain components of SSFCE 500 may also be used to collect or transport other liquids or gases, such as pumped or sumped products from subway and tunnel flooding, or hydrocarbon emissions collected from marshes and estuaries or for the gross collection of hydrate saturated areas. SSFCE 500 components may also be used to divert water to fight fires.
[0222] What is claimed is:
|
A rapidly deployable flexible enclosure system for the collection, containment and presentation of hydrocarbon emissions from compromised shallow or deepwater oil and gas well systems, pipelines, other structures, including subsea fissures. The flexible containment enclosure can accommodate various depths and collection terminator configurations. The flexible containment enclosure system is connected to a floating platform and supported by positive offset neutral buoyancy attachment devices. The floating platform with the flexible containment enclosure separates liquid and gaseous materials and directs them to separate ports for removal from a rigid enclosure cavity integrated within the floating platform. Gaseous emissions may optionally be directed to a tethered floating flare system. The system has the ability to partially or fully submerge for extended durations and resurface on demand manually or by transmitted signal. The system provides for operation by a combined tele-supervisory and autonomous control system.
| 4
|
FIELD OF INVENTION
The invention relates to spectroscopy, and in particular, to spectroscopes for detecting vulnerable plaques within a wall of a blood vessel.
BACKGROUND
Atherosclerosis is a vascular disease characterized by a modification of the walls of blood-carrying vessels. Such modifications, when they occur at discrete locations or pockets of diseased vessels, are referred to as plaques. Certain types of plaques are associated with acute events such as stroke or myocardial infarction. These plaques are referred to as “vulnerable plaques.” A vulnerable plaque typically includes a lipid-containing pool of necrotic debris separated from the blood by a thin fibrous cap. In response to elevated intraluminal pressure or vasospasm, the fibrous cap can become disrupted, exposing the contents of the plaque to the flowing blood. The resulting thrombus can lead to ischemia or to the shedding of emboli.
One method of locating vulnerable plaque is to peer through the arterial wall with infrared light. To do so, one inserts a catheter through the lumen of the artery. The catheter includes a delivery fiber that sends infrared light to a delivery mirror. Infrared light reflects off the delivery mirror toward a spot on the arterial wall. Some of this infrared light penetrates the wall, scatters off structures within the arterial wall, and re-enters the lumen. This re-entrant light falls on a collection mirror, which then guides it to a collection fiber. The collection mirror and the delivery mirror are separated from each other by a gap. Because the catheter must be narrow enough to fit through blood vessels, the collection mirror and the delivery mirror are typically separated in the axial direction.
To a great extent, the separation between the delivery mirror and the collection mirror controls the depth from which most of the light gathered by the collection mirror is scattered. To gather more light from scattered from deep within the wall, one increases the gap between the collection mirror and the delivery mirror.
The collection mirror and the delivery mirror are mounted in a rigid housing at the distal tip of the catheter. To enable the catheter to negotiate sharp turns, it is desirable for the rigid housing to be as short as possible. This places an upper limit on the extent of the gap between the two mirrors, and hence an upper limit on the depth from which scattered light can be gathered.
SUMMARY
The invention is based on the recognition that one can increase the effective separation distance between a collection-beam redirector and a delivery-beam redirector by controlling the directions in which those redirectors direct light.
In one aspect, the invention provides a spectroscope having first and second fibers. First and second beam redirectors are in optical communication with the first and second fibers respectively. The first and second beam redirectors are oriented to illuminate respective first and second areas. The second area is separated from the first area by a separation distance that exceeds a separation distance between the first and second beam redirectors.
In one embodiment, the first beam redirector includes a mirror. However, the first beam redirector can also be a lens system or a diffracting element. Alternatively, by bending the first fiber to illuminate the first area, the first beam redirector becomes the distal end of the first fiber.
In another embodiment, the extent to which the second separation distance exceeds the separation distance between the first and second beam redirectors is chosen to enhance collection of light scattered from a target located at a selected distance from the first area.
In another aspect, the invention provides a method for collecting light scattered from behind an arterial wall by illuminating an illumination spot on the arterial wall, pointing a collection-beam redirector away from the illumination spot, and recovering scattered light incident on the collection-beam redirector.
In some practices of the invention, pointing a collection-beam redirector includes orienting a collection mirror to collect light from a direction away from the illumination spot. In other practices of the invention, pointing a collection beam redirector includes providing a lens to direct light received from a direction away from the illumination spot, or orienting an end of an optical fiber to receive light from a direction away from the illumination spot.
In other practices of the invention, pointing a collection-beam redirector includes selecting a depth from which to receive the scattered light, and pointing the collection-beam redirector in a direction that enhances the amount of light received from that depth.
Another aspect of the invention provides a method for collecting light scattered from behind an arterial wall. This method includes pointing a collection-beam redirector at a collection spot on the wall, pointing a delivery-beam redirector at the wall in a direction away from the collection spot, passing light through the delivery-beam redirector, and recovering scattered light incident on the collection-beam redirector.
In some practices of the invention, pointing a delivery-beam redirector includes orienting a delivery mirror to direct light along a direction away from the collection spot. Other practices include pointing a delivery-beam redirector by providing a lens to direct light along a direction away from the collection spot, or by orienting an end of an optical fiber to direct light along a direction away from the collection spot.
In yet other practices, the method includes selecting a depth from which to collect the scattered light, and pointing the delivery-beam redirector in a direction that enhances the amount of light received from the selected depth.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.
Other features and advantages of the invention will be apparent from the following detailed description, and from the claims.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic of a system for identifying vulnerable plaque in a patient.
FIG. 2 is a cross-section of the catheter in FIG. 1 .
FIG. 3 is a view of an optical bench at the tip assembly of the catheter in FIG. 1 .
FIG. 4 is a schematic of the paths traveled by light from the delivery fiber of FIG. 1 .
FIG. 5 is a cross-section of the spatial light distribution shown in FIG. 4 .
FIGS. 6-10 are schematics of different embodiments of beam redirectors.
FIG. 11 is a contour plot of mean penetration depth as a function of separation and orientation of beam redirectors.
FIG. 12 is a schematic of a pair of beam redirectors for generating the contour plot of FIG. 11 .
DETAILED DESCRIPTION
System Overview
FIG. 1 shows a diagnostic system 10 for identifying vulnerable plaque 12 in an arterial wall 14 of a patient. The diagnostic system features a catheter 16 to be inserted into a selected artery, e.g. a coronary artery, of the patient. A delivery fiber 18 and a collection fiber 20 extend between a distal end 22 and a proximal end 24 of the catheter 16 .
As shown in FIG. 2 , the catheter 16 includes a sheath 26 surrounding a rotatable torque cable 28 . The delivery fiber 18 extends along the center of a torque cable 28 , and the collection fiber 20 extends parallel to, but radially displaced from, the delivery fiber 18 . The rotatable torque cable 28 spins at a rate between approximately 1 revolution per second and 400 revolutions per second.
At the distal end 21 of the catheter 16 , a tip assembly 30 coupled to the torque cable 28 directs light traveling axially on the delivery fiber 18 toward an illumination spot 32 on the arterial wall 14 . The tip assembly 30 also collects light from a collection spot 34 on the arterial wall 14 and directs that light into the collection fiber 20 .
The tip assembly 30 is typically a rigid housing that is transparent to infra-red light. To enable the catheter 16 to negotiate turns as it traverses the vasculature, it is desirable for the tip assembly 30 to extend only a short distance in the axial direction.
A multi-channel coupler 36 driven by a motor 38 engages the proximal end 24 of the torque cable 28 . When the motor 38 spins the multi-channel coupler 36 , both the coupler 36 , the torque cable 28 , and the tip assembly 30 spin together as a unit. This feature enables the diagnostic system 10 to circumferentially scan the arterial wall 14 with the illumination spot 32 .
In addition to spinning the torque cable 28 , the multi-channel coupler 36 guides light from a laser 40 (or other light source such as a light-emitting diode, a super-luminescent diode, or an arc lamp) into the delivery fiber 18 and guides light emerging from the collection fiber 20 into one or more detectors (not visible in FIG. 1 ).
The detectors provide an electrical signal indicative of light intensity to an amplifier 42 connected to an analog-to-digital (“A/D”) converter 44 . The A/D converter 44 converts this signal into digital data that can be analyzed by a processor 46 to identify the presence of a vulnerable plaque 12 hidden beneath the arterial wall 14 .
Optical Bench
FIG. 3 shows an optical bench 48 in which are seated the collection fiber 20 and the delivery fiber 18 . The optical bench 48 is seated in a recess 50 between first and second side walls 52 A-B of the distal end of a housing 54 . The housing 54 is in turn coupled to the distal end of the torque cable 28 . The recess 50 is just wide enough to enable the collection fiber 20 and the delivery fiber 18 to nestle adjacent to each other. A floor 56 extending between the first and second side walls 52 A-B and across the recess 50 supports both the collection and delivery fibers 18 , 20 .
Just distal to the end of the delivery fiber 18 , a portion of the optical bench 48 forms a frustum 58 . The frustum 58 extends transversely only half-way across the optical bench 48 , thereby enabling the collection fiber 20 to extend distally past the end of the delivery fiber 18 .
The frustum 58 has an inclined surface facing the distal end of the delivery fiber 18 and a vertical surface facing the distal end of the optical bench 48 . The inclined surface forms a 135 degree angle relative to the floor 56 . However, other angles can be selected depending on the direction in which light from the delivery fiber 18 is to be directed. A reflective material coating the inclined surface forms a beam redirector, which in this case is a delivery mirror 60 . When light exits axially from the delivery fiber 18 , the delivery mirror 60 intercepts that light and redirects it radially outward to the arterial wall 14 . Examples of other beam redirectors include prisms, lenses, diffraction gratings, and combinations thereof.
The collection fiber 20 extends past the end of the delivery fiber 18 until it terminates at a plane that is coplanar with the vertical face of the frustum 58 . Just beyond the distal end of the collection fiber 20 , a portion of the optical bench 48 forms an inclined surface extending transversely across the optical bench 48 and making an angle greater than 135 degrees relative to the floor 56 . A reflective material coating the inclined surface forms a collection mirror 82 .
A delivery-fiber stop 86 molded into the optical bench 48 proximal to the frustum 58 facilitates placement of the delivery fiber 18 at a desired location proximal to the delivery mirror 60 . Similarly, a collection-fiber stop 88 molded into the optical bench 48 just proximal to the collection mirror 82 facilitates placement of the collection fiber 20 at a desired location proximal to the collection mirror 82 .
Spatial Distribution of Scattered Light
Referring to FIG. 4 , light travels radially outward from the delivery mirror 60 toward the illumination spot 32 on the arterial wall 14 . As the light does so, it encounters the blood that fills a lumen 68 . Because of scattering by particles in the blood, many photons never reach the wall 14 . This loss of energy is shown schematically by a progressive narrowing of the beam as it nears the wall 14 . The remaining photons 61 eventually reach the arterial wall 14 . Some of these photons are reflected from the wall 14 . These specularly reflected photons 62 carry little or no information about structures 64 behind the arterial wall 14 and are therefore of little value. Of those photons 63 that penetrate the wall, many others are absorbed. The remainder 66 are scattered by structures 64 behind the wall 14 . After having been scattered, a few of these remaining photons 66 again pass through the arterial wall 14 and re-enter the lumen 68 . This remnant of the light 61 originally incident on the wall, which is referred to herein as the “re-entrant light 66 ,” carries considerable information about the structures 64 behind the arterial wall 14 . It is therefore this re-entrant light 66 that is to be guided into the collection fiber 20 .
As suggested by FIG. 4 , re-entrant light 66 tends to re-enter the lumen along concentric annular regions 70 A-F that are radially separated from the specularly reflected light 62 . Each re-entrant such annular region 70 C, best seen in FIG. 5 , is a region through which light scattered from a particular depth within the wall 14 is most likely to re-enter the lumen 68 . Light that has penetrated only superficially into the wall 14 before being scattered generally re-enters the lumen 68 through the innermost 70 D-F such annular regions. Light that has penetrated more deeply into the wall 14 before being scattered tends to re-enter the lumen 68 through one of the outer re-entrant zones 70 A-B.
FIGS. 4-5 indicate that to collect deeply-scattered light, it is desirable to collect light from a collection spot 34 that lies in an annular region 70 C that is relatively far from the illumination spot 32 . One way to achieve this is to extend the separation distance between the delivery mirror 60 and the collection mirror 82 . However, doing so results in a longer tip assembly 30 . As an alternative, the delivery mirror 60 can be angled relative to the collection mirror 82 , as shown in FIG. 6 .
In FIG. 6 , the delivery mirror 60 is oriented to direct light radially away from the catheter, thereby delivering that light to an illumination spot 32 directly under the mirror 60 . The collection mirror 82 , however, is angled to collect light from a collection spot 34 that is further from the illumination spot 32 than the separation distance between the collection mirror 82 and the delivery mirror 60 .
The collection spot 34 and the illumination spot 32 can be made further apart in ways other than by orienting the collection mirror 82 . For example, in FIG. 7 , a refracting system 83 in the optical path between the collection fiber 20 and the collection spot 34 causes the collection spot 34 to be further from the illumination spot 32 than the separation distance between the collection mirror 82 and the delivery mirror 60 . Other optical elements, such as a diffracting system, can be used in place of a refracting system 83 . The refracting system 83 can be a discrete lens, as shown in FIG. 7 , a collection of lenses, or a lens integrally formed with the collection fiber 20 .
Alternatively, either the collection spot 34 , the illumination spot 32 , or both, can be shifted relative to each other by bending the collection fiber 20 and the delivery fiber 18 , as shown in FIG. 8 .
Separation of the collection spot 34 and the illumination spot 32 can also be achieved by orienting the delivery mirror 60 , as shown in FIG. 9 , or by orienting both the delivery mirror 60 and the collection mirror 82 , as shown in FIG. 10 . In both FIGS. 9 and 10 , the movement of the illumination spot 32 can be achieved using a refracting system 83 , by using a diffracting system, or by bending the fibers 18 , 20 as described above.
In all the foregoing cases, there exists a delivery-beam redirector, through which light leaves the catheter, and a collection-beam redirector, through which scattered light enters the catheter. Whether the beam redirectors are mirrors, lenses, or ends of a bent fiber, the fact remains that they will be spatially separated from each other.
FIGS. 6-10 show embodiments in which there is only one collection fiber 20 and one delivery fiber 18 . However, a catheter can also have several collection fibers 20 and/or several delivery fibers 18 , each with its associated beam-redirecting element. The beam re-directing elements associated with different delivery fibers and/or collection fibers are oriented at different angles to permit collection of light from different depths. In embodiments having multiple collection and/or delivery fibers, the spacing between fibers is between 50 and 2500 micrometers. The beam re-directing elements are oriented at angles separated by one-fourth of the numerical aperture of the fiber having the smallest numerical aperture.
For a particular choice of fibers, the distance between the illumination spot 32 and the collection spot 34 determines the average penetration depth of light incident on the collection mirror 82 . This distance depends on two independent variables: the distance separating the collection mirror 82 and the delivery mirror 60 ; and the angular orientation of the collection mirror 82 relative to that of the delivery mirror 60 . For the geometry shown in FIG. 12 , the contour plot of FIG. 11 shows the relationship between the average penetration depth of light received at the collection mirror 82 , the separation between the collection fiber 20 and the delivery fiber 18 and the angle θ as shown in FIG. 12 .
In FIG. 12 , a delivery mirror 60 is oriented to direct an illumination beam radially away from the catheter. A collection mirror 82 is oriented at an angle θ relative to a line normal to the wall 14 . Positive values of θ are those in which the collection mirror 82 is oriented to receive light from a collection spot 34 that is closer to the illumination spot 32 than the separation between the collection-beam redirector and the delivery-beam redirector. Conversely, negative values of θ, such as that shown in FIG. 12 , are those in which the collection mirror 82 is oriented to receive light from a collection spot 34 that is further from the illumination spot 32 than the separation between the collection mirror 82 and the delivery mirror 60 .
It is apparent from FIG. 11 that for a given separation between the collection mirror 82 and the delivery mirror 60 , one can collect light from deeper within the wall 14 by increasing the angle θ in the negative direction. This makes possible the collection of light scattered from deep inside the wall 14 without necessarily increasing the separation between the collection mirror 82 and the delivery mirror 60 . As a result, the tip assembly 30 can be made smaller without necessarily compromising the ability to detect light scattered from deep inside the wall 14 . A suitable choice for the angle θ (also referred to as the pitch angle), depends on the numerical apertures of the collection fiber and the delivery fiber. One suitable choice is that in which the angle θ is the sum of the arcsines of the numerical apertures.
FIGS. 11 and 12 are discussed in the context of mirrors as collection and delivery-beam redirectors. However, it will be apparent that similar principles apply to other types of collection-beam redirectors, such as those disclosed herein.
In addition, in the discussion of FIGS. 11 and 12 , only the angle of the collection mirror 82 is changed. However, similar effects can be achieved by properly orienting the delivery mirror 60 , or by orienting both the delivery and collection mirrors 60 , 82 together.
In some embodiments, the radian angle included between the longitudinal axes of the delivery and collection fibers 18 , 20 (hereafter referred to as the “pitch angle”) is between 0 radians and π radians. In this case, the axial separation between the delivery fiber and the collection fiber 18 , 20 is slightly greater than the average fiber diameter but less than 3 millimeters. As used herein, “slightly greater than” means “approximately 0.1 millimeters greater than,” and “average fiber diameter” means the average of the diameters of the collection fiber 20 and the delivery fiber 18 .
In other embodiments, the pitch angle is between π/2 and the smaller of the numerical apertures of the delivery fiber 18 and the collection fiber 20 . In this case, the axial separation between the delivery fiber 18 and the collection fiber 20 is slightly greater than the average fiber diameter but less than 1.5 millimeters.
In other embodiments, the pitch angle is within a 0.5 radian window having a lower bound defined by the greater of the numerical apertures of the delivery fiber 18 and the collection fiber 20 . In this case, the axial separation distance between the delivery fiber 18 and the collection fiber 20 is within a 0.5 millimeter window having a lower bound defined by a distance slightly greater than the average fiber diameter.
In yet other embodiments, the pitch angle is within a 0.1 radian window centered at the sum of the numerical apertures of the collection and delivery fiber 18 . In this case, the axial separation between the delivery and collection fibers 18 , 20 is within a 0.1 millimeter interval having a lower bound that is 0.35 millimeters greater than the average fiber diameter.
Additional embodiments include those in which the pitch angle is between 0 and π/2 radians and the axial separation between the delivery and collection fibers 18 , 20 is between 0.25 millimeters and 3 millimeters; those in which the pitch angle is between 0.12 radians and π/2 radians and the axial separation between the delivery and collection fibers 18 , 20 is between 0.25 millimeters and 1.5 millimeters, and those in which the pitch angle is between 0.25 and 0.75 radians and the axial separation between the delivery and collection fibers 18 , 20 is between 0.25 millimeters and 0.75 millimeters.
Suitable fibers for use as a delivery fiber 18 include those having a numerical aperture of 0.12 radians and core diameters of 9 micrometers, 100 micrometers, and 200 micrometers. Suitable fibers for use as a collection fiber 20 include those having a numerical aperture of 0.22 radians and core diameters of 100 micrometers or 200 micrometers. Also suitable for use as a collection fiber 20 are fibers having a numerical aperture of 0.275 radians and a core diameter of 62.5 micrometers.
The surfaces of the delivery and collection mirrors 60 , 82 can be coated with a reflective coating, such as gold, silver or aluminum. These coatings can be applied by known vapor deposition techniques. Alternatively, for certain types of plastic, a reflective coating can be electroplated onto those surfaces. Or, the plastic itself can have a reflective filler, such as gold or aluminum powder, incorporated within it.
The optical bench 48 is manufactured by injection molding a plastic into a mold. In addition to being simple and inexpensive, the injection molding process makes it easy to integrate the elements of the optical bench 48 into a single monolith and to fashion structures having curved surfaces. Examples of suitable plastics include liquid crystal polymers (LCPs), polyphenylsulfone, polycarbonate, acrylonitrile butadiene-styrene (“ABS”), polyamide (“NYLON”), polyethersulfone, and polyetherimide. Alternatively, the optical bench can be manufactured by micro-machining plastic or metal, by lithographic methods, by etching, by silicon optical bench fabrication techniques, or by injection molding metal. Materials other than plastics can be used to manufacture the housing 54 and the optical bench 48 . Such materials include metals, quartz or glass, and ceramics.
The floor 56 in the illustrated embodiment is integral to the housing 54 . However, the floor 56 can also be made part of the optical bench 48 .
As described herein, the housing 54 and the optical bench 48 are manufactured separately and later joined. However, the housing 54 and the optical bench 48 can also be manufactured together as a single unitary structure.
Using the Catheter
In use, the distal tip assembly 30 is inserted into a blood vessel, typically an artery, and guided to a location of interest. Light is then directed into the delivery fiber 18 . This light exits the delivery fiber 18 at its distal tip, reflects off the delivery mirror 60 in a direction away from the plane containing the delivery and collection fibers 18 , 20 , and illuminates an illumination spot 32 on the wall of the artery. Light penetrating the arterial wall 14 is then scattered by structures within the wall. Some of this scattered light re-enters the blood vessel and impinges on the plane and onto the collection mirror 82 . The collection mirror 82 directs this light into the collection fiber 20 .
Alternatively, light incident on the wall 14 can stimulate fluorescence from structures on or within the wall 14 . The portion of this fluorescent light that is incident on the collection mirror 82 is directed into the collection fiber 20 .
OTHER EMBODIMENTS
It is to be understood that while the invention has been described in conjunction with the detailed description thereof, the foregoing description is intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims. Other aspects, advantages, and modifications are within the scope of the following claims.
|
A spectroscope includes first and second beam redirectors in optical communication with first and second fibers respectively. The first and second beam redirectors are oriented to illuminate respective first and second areas. The second area is separated from the first area by a separation distance that exceeds the separation distance between the first and second beam redirectors.
| 0
|
BACKGROUND OF THE INVENTION
The present invention concerns a method of feeding substantially rectangular laundry articles to a laundry processing apparatus, such as an ironing roller, comprising alignment of the laundry article to a predetermined angle with respect to the direction of feed of the laundry article on a conveyor face on which the laundry article is conveyed with the rear edge stretched, seen with respect to the direction of feed, as well as lateral displacement of the laundry article on the conveyor face to a desired position transversely to the direction of feed. The invention also concerns an apparatus for performing the method.
These apparatuses are primarily used in big laundries in which they are used for smoothing and spreading large laundry articles, such as sheets, table-cloths, slips for eiderdowns, etc. for subsequent insertion of the laundry article into e.g. an ironing roller, it being important that these feeding devices spread and smooth the laundry articles effectively so that undesired creases will not occur after the ironing roller. Most frequently, the laundry articles are inserted into the apparatus by a laundry article being taken from a pile of laundry articles in a wrinkled state and optionally wet or damp, following which the laundry article is inserted into the machine, which subsequently processes the laundry article so that it can be transferred to e.g. an ironing roller in a spread and smoothened state.
Even though the laundry article is thus transferred to an optional ironing roller in a spread and smoothened state, unintentional creases in the laundry article may occur, however, after the ironing roller, if the laundry article is inserted askew into the ironing roller. These unintentional creases are produced in that, in this case, the ironing roller first pulls a corner of the laundry article forwardly, thereby forming creases on the laundry article. It is therefore important e.g. in connection with such ironing rollers that the laundry article is oriented such that the entire one edge of the laundry article is moved into the ironing roller approximately in parallel with the axis of rotation of the ironing roller.
Therefore, feeders are frequently provided with a device capable of orienting the laundry article such that when inserted into a subsequent optional ironing roller the laundry article has the desired orientation.
Numerous proposals for the construction of devices capable of performing the above-mentioned processes are known today. Thus, EP Patent Application 266 820 discloses a feeder comprising a roller capable of rotating about its own axis, the laundry article being so positioned across said roller as to extend down on both sides of the roller. The laundry article will then frequently be disposed askew on the roller, which is therefore adapted so as to be twistable about its longitudinal axis such that the laundry article may be aligned with respect to the roller. This alignment takes place by positioning the laundry article with respect to a plurality of optical sensors arranged in a horizontal plane with respect to each other so that these can detect an edge on the part of the laundry article which hangs down on one side of the roller. The roller can then be rotated and twisted in sequence, so that the edge of the laundry article precisely covers the row of optical sensors, said laundry article having thereby been aligned with respect to the feed direction of the roller.
Further, EP Patent Application 424 290 discloses a feeder having a short and wide conveyor belt across which the laundry article is hung so as to hang down on each side of the conveyor belt. Sensors are provided here too, detecting the position of the rear edge of the laundry article on the conveyor belt with a view to aligning the laundry article with respect to this conveyor belt. In this device, the alignment takes place by retaining the part of the laundry article hanging down on one side, while causing the laundry article to be moved with respect to the conveyor belt. This is effected by pressing an elongate rod toward the laundry article between the location where the laundry article is retained and the conveyor belt, whereby the laundry article is displaced on the conveyor belt, thereby making it possible to align the laundry article with respect to the conveyor belt.
In certain situations, e.g. when a folding-up machine capable of automatically folding-up the laundry articles is mounted after the ironing roller, it is moreover important that the laundry articles are positioned precisely in a lateral direction with respect to the direction of feed of the laundry article prior to optional folding-up so that the folding-up will be neat and uniform. For this purpose, there are folding-up machines which can displace the laundry article transversely prior to the folding-up. However, these folding-up machines require that the laundry article is displaced transversely before the folding-up is begun, which reduces the production rate of these machines. It is therefore desirable that such transverse displacement can be performed already in the feeder.
In both of the above-mentioned known devices the laundry article is inserted in that the laundry article is pulled from the side across the roller or the conveyor belt by a gripper, thereby enabling initial positioning of the laundry articles on the roller or the conveyor belt. However, the subsequent alignment of the laundry article on the roller or the conveyor belt may cause the initial positioning to be destroyed.
Accordingly, the object of the present invention is to provide a method of feeding and a machine for performing this method, by means of which the lateral positioning may be performed precisely in a simple manner.
SUMMARY OF THE INVENTION
This object is achieved by providing a method of feeding substantially rectangular laundry articles to a laundry processing apparatus, such as an ironing roller, comprising alignment of the laundry article to a predetermined angle with respect to the direction of feed of the laundry article on a conveyor face on which the laundry article is conveyed with the rear edge stretched with respect to the direction of feed, and lateral displacement of the laundry article on the conveyor face to a desired position transversely to the direction of feed, characterized in that the lateral displacement is performed after the laundry article has been aligned.
Also provided is an apparatus for feeding substantially rectangular laundry articles to a laundry processing apparatus, such as an ironing roller, comprising a conveyor face on which the laundry articles are fed so that the rear edge of the laundry article, seen in the direction of feed, is stretched in any angle with respect to the direction of feed, and means for aligning the rear edge to a predetermined angle with respect to the direction of feed as well as means for laterally displacing the laundry article on the conveyor face to a desired position transversely to the direction of feed, characterized in that the means for transverse displacement of the laundry article are adapted to displace the laundry article laterally after the laundry article has been aligned.
Since the lateral positioning of the laundry article according to the invention is performed after the alignment of the laundry article with respect to the direction of feed, it is ensured that this positioning is not destroyed subsequently in the feeder. In addition, it is simple to position the laundry article since the laundry article has already been aligned in the feeder.
BRIEF DESCRIPTION OF THE DRAWINGS
An expedient embodiment of the invention will be described more fully below with reference to the drawing, in which
FIG. 1 is a perspective view of an apparatus according to the invention and of an operator,
FIG. 2a is schematic sectional view of a detail in the apparatus of FIG. 1,
FIG. 2b is a view of the detail of FIG. 2a in another process position,
FIG. 3 is a view of the apparatus of FIG. 1 with a laundry article transferred in the machine with a crease, and
FIG. 4 shows the apparatus of FIG. 3 where the laundry article is smoothed out,
FIG. 5 shows the apparatus of FIG. 3 where the laundry article has been partly braked at its rear edge,
FIG. 6 is a schematic view of the mode of operation of the invention in an expedient embodiment, and
FIG. 7 is a view similar to FIG. 5 but with the beam broken away to reveal the senors and rollers.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic and perspective view of an embodiment of a feeder apparatus according to the invention. The apparatus 1 is provided with two end gables 3 and 4 between which two conveyor belts 5 and 6 are located. The conveyor belt 6 extends partly below the conveyor belt 5, and the conveyor belt 6 is tightened by the rollers 8 and 10. A bar 11 whose function will be described more fully below, is located below and straight in front of the rollers 7 and 8.
An operator-operated insertion device is positioned at one end of the bar 11, as shown; the insertion device here consists of an underlying runway 12, above which two parallel conveyor belts 13 and 14 are positioned so as to be in firm engagement with the runway 12. The conveyor belt 6 is formed by a row of ribbons which are arranged with mutual spaces 19, and a gripper device shown as a beam 20, which will be described more fully with reference to FIG. 6, is arranged across the conveyor belt 6.
The operator starts the process by inserting the laundry article 2 between the conveyor belts 13 and 14 and the underlying runway 12, so that one corner 15 of the laundry article is positioned laterally of the conveyor belts 13 and 14, and so that a small portion of the edge of the laundry article 2 is stretched between the conveyor belts 13 and 14 and the underlying runway 12. The conveyor belts 13 and 14 are then activated to pull the laundry article 2 up to the bar 11.
The function and mode of operation of the feeder 1 will be described now as a series of individual processes according to the method of the invention.
FIG. 2a thus shows that the laundry article 2 is pulled across the bar 11, which is positioned below the rollers 7 and 8 that tighten the conveyor belts 5 and 6. This is done through the provision of a narrow conveyor belt 16 which extends in the entire length of the bar, and which can thus pull the entire laundry article 2 into position on the bar 11. When the laundry article 2 is introduced at the end of the bar with one of the corners 15 of the laundry article 2, as stated above, the laundry article 2 hangs across the bar 11 with a minor flap 18 bent across the bar 11. The bar 11 additionally comprises a slidable plate element 17 which extends in the entire length of the bar 11. It is thus shown in FIG. 2b how the slidable plate element 17 is moved by means (not shown) up toward the rollers 7 and 8 with the conveyor belts 5 and 6, the conveyor belt 5 being caused to move in the direction of the arrow A, the conveyor belt 6 being correspondingly caused to move in the direction of the arrow B. The movements of the conveyor belts 5 and 6 will thus cause the laundry article 2 with the bent flap 18 to be pulled by the slidable plate element 17, which is moved up between the rollers 7 and 8.
The movements of the conveyor belts 5 and 6 will then bring the laundry article 2 with the bent flap 18 into a position in which the laundry article 2 is positioned, as shown in FIG. 3, on top of the conveyor belt 6. Since the laundry article 2 has now been removed from the bar 11, the operator can insert a new laundry article 2 already now and begin the process once more. Final smoothing of the laundry article 2 then takes place, as shown in fig. 4, in that the continued movement of the conveyor belt 6 in the direction B shown in FIG. 2b causes the laundry article 2 to be moved toward the edge on the conveyor belt 6 which is defined by the roller 10, following which the bent flap 18 on the laundry article 2 drops beyond the edge, and the laundry article has hereby been completely straightened and smoothed.
The beam 20 of the gripper device, as shown in detail in FIG. 6 includes aligning means and lateral displacement means and comprises a transverse conveyor belt 23 which extends across the conveyor belt 6, said transverse conveyor belt 23 being provided with a rack 21 which can drive the transverse conveyor belt 23 transversely across the conveyor belt 6 by means of a gear wheel 22 located on the drive shaft of a suitable drive means such as an electric motor. The transverse conveyor belt 23 is supported by a support 26 at the face directed toward the underlying conveyor belts 6. A plurality of clamping faces or rollers 27 are provided in the spaces 19 between the conveyor belts 6 and are displaceable upwards from the position shown in the drawing to engage the transverse conveyor belts 23, said rollers 27 being capable of rolling on said transverse conveyor belt 23 during the movement thereof. Electric actuators 28 at each of the rollers 27 are used here for activating this up and down movement of the rollers 27.
Photocells or sensors 29 (see FIG. 7) of a detection device are located in front of the rollers 27, seen in the direction of feed of the conveyor belt 6, said photocells registering or detecting the position of the rear edge 24 of the laundry article 2 when it passes by, following which the rollers 27 are activated according to the invention by means of the electric actuators to engage the transverse conveyor belt 23 so that the rear edge of the laundry article 2 is grouped and retained against movement, the continued forward movement of the conveyor 6 thereby aligning the article, as shown in FIG. 5 shows how the rear edge 24 of the laundry article is braked locally from one corner 25 of the article towards the other corner 25A as the rollers 27 are sequentially activated by the actuators 28. After the entire laundry article 2 has been aligned, the electric motor provided for the gear wheel 22 is activated, following which the laundry article 2 may be displaced laterally.
Thus the laundry article is gripped solely at its edge and is transversely displaced solely by transverse displacement of the rear edge, which allows a particularly simple and thereby inexpensive structure.
Further, by performing the alignment and the transverse displacement with the same gripper device, this increases the efficiency of the feeder, since the laundry article does not have to be stopped more than once in the feeder to achieve both alignment and transverse displacement.
The laundry article 2 has hereby been aligned and laterally displaced in a simple manner with respect to the direction of feed B of the conveyor 6, following which the rollers 27 are retracted, and the laundry article 2 may be passed further on in the apparatus and optionally be transferred to a subsequent ironing roller. The shown embodiment of the invention is unique in being a particularly simple and inexpensive structure, while providing a high degree of operational reliability in the apparatus. Clearly, it will be evident to a skilled person to provide sequence controls and drive devices, etc. so that the feeder 1 can automatically perform the above-mentioned functions. Accordingly, such sequence controls and drive devices, etc. are not described in detail here.
|
A method and an apparatus for feeding substantially rectangular laundry articles to a laundry processing apparatus, such as an ironing roller, comprising alignment of the laundry article to a predetermined angle with respect to the direction of feed of the laundry article on a conveyor face on which the laundry article is conveyed with the rear edge stretched, seen with respect to the direction of feed, as well as lateral displacement of the laundry article on the conveyor face to a desired position transversely to the direction of feed, said lateral displacement being performed after the laundry article has been aligned. This provides a more precise positioning of the laundry article.
| 3
|
FOREIGN PRIORITY INFORMATION
[0001] This application claims priority under 35 U.S.C. § 119 to a Korean Patent Application, Serial No. 2002-63070, filed in the Korean Intellectual Property Office on Oct. 16, 2002, to Korean Patent Application Serial No. 2002-84575, filed in the Korean Intellectual Property Office on Dec. 26, 2002, and to Korean Patent Application, Serial No. 2002-88235 filed in the Korean Intellectual Property Office on Dec. 31, 2002, the contents of all three said applications being incorporated herein by reference
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an improved head drum assembly for use in a tape recorder such as a compact size camcorder of a digital video camera (DVC).
[0004] 2. Description of the Related Art
[0005] Generally, in a tape recorder such as a compact size camcorder of a digital video camera or a video cassette recorder (VCR), in order to scan magnetic tape and thus record video data thereon and/or reproduce video data therefrom, a tape recorder deck includes a head drum assembly having a magnetic head rotatable at high speed.
[0006] Referring to FIGS. 1A and 1B, a conventional head drum assembly 100 for a tape recorder includes a rotary drum 110 , a stationary drum 120 and a drum cover 130 . The rotary drum 110 supports a magnetic head (h), which scans a moving magnetic tape (not shown) to record/reproduce video data thereon/therefrom, and is rotatably mounted on the shaft 140 . The stationary drum 120 and the drum cover 130 are press-fitted to be placed on the lower and the upper parts of the shaft 140 , respectively, with the rotary drum 110 being interposed therebetween.
[0007] The drum cover 130 includes a conductive bushing member 131 in a form of a flange which is press-fitted in the shaft 140 so as to be positioned on the rotary drum 110 , a cover member 132 formed by a resin molding and joined with the bushing member 131 by a pair of screws (s), and a conductive earth plate 133 supported by one of the screws (s) to be exposed through the upper surface of the cover member 132 and electrically connected to the sub circuit board 153 .
[0008] Between the drum cover 130 and the rotary drum 110 , a rotary transformer 152 and a stationary transformer 151 facing the rotary transformer 152 are disposed to transmit the signals recorded/reproduced on/from tape by the magnetic head (h). In order to connect the magnetic head (h) and the coil (c) of the rotary transformer 152 through soldering, a terminal 155 is preferably interconnected therebetween as a medium because direct soldering is not easy. Accordingly, in order to enable easy soldering of the coil (c) first, terminal 155 is attached to the lower part of the rotary transformer 152 . Next, a hole 115 is defined in the rotary drum 110 , and the upper part of the terminal pin 111 is attached to the terminal 115 . Next, one end of the coil (c) is soldered to the connecting area between the terminal 155 and the terminal pin 111 . As shown in FIG. 2A, the lower end of the terminal pin 111 is soldered to a fine patter coil (FPC) 117 which is disposed at the lower part of the rotary drum 110 . Of course, the FPC 117 is connected to the magnetic head (h) by soldering.
[0009] To the lower part of the rotary drum 110 is provided a motor rotor 160 which has a donut-shaped magnet 162 disposed within a ring-type rotor casing 161 thereof, and to the upper part of the stationary drum 120 , a motor stator 170 is mounted. The motor stator 170 is formed in a type in which the so-called FP coil (fine pattern coil) is formed into a disc pattern and disposed to face the donut-type magnet 162 to obtain a result of a more compact-sized head drum assembly 100 . Such motor stator 170 usually has the three-layered structure consisting of first substrate 171 , a second substrate 172 and a third substrate 17 which are stacked on one another in turn.
[0010] With regard to the motor stator 170 , there is a torque generation coil pattern (A) formed on the first and second substrates 171 , 172 , while a frequency generation coil pattern (B) for speed control and a phase generation coil pattern (C) for phase control is formed on the third substrate 173 .
[0011] As shown in FIG. 2C, the first substrate 171 is formed of a structure in which a copper membrane 171 b in fine pattern is formed on an epoxy substrate 171 a , i.e., on a base plate, and a protective layer 171 c is formed thereon. The second and the third substrates 172 and 173 are formed in the same structure.
[0012] In the head drum assembly 100 constructed as above, the rotary drum 110 is rotated by the electromagnetic interaction between the motor rotor 160 and the motor stator 170 . As the rotary drum 110 is rotated, the magnetic head (h) mounted in the rotary drum 110 is also subsequently rotated, thereby scanning the tape and recording/reproducing data on/from the magnetic tape. The data obtained from the scanning of the magnetic head (h) is transmitted to the rotary transformer 152 and the stationary transformer 151 via the terminal pin 111 and the coil (c), and then to the camcorder system via the sub circuit board 153 , which is connected to the stationary transformer 151 . The data is then processed at the camcorder system. Reference numerals 140 a and 140 b denote bearings, and 141 an elastic member, respectively.
[0013] However, the conventional head drum assembly 100 constructed as above for use in the tape recorder is accompanied with the following drawbacks:
[0014] First, because the cover member 132 is formed of an insulating resin through a molding process, the conductive bushing member 131 and the screws (s) are required to ensure stable electric connection between the sub circuit board 153 and the earth plate 133 for a stable earthing of the head drum assembly 100 .
[0015] Additionally, because the drum cover 130 requires various components such as the bushing member 131 , the cover member 132 , the earth plate 133 , and a pair of screws (s) to connect the related parts, the number of manufacturing steps such as soldering of the earth plate 133 with respect to the sub circuit board 153 , or bonding of the cover member 132 to the bushing member 131 , are also increased. As a result, due to increased number of necessary parts and manufacturing steps, productivity deteriorates while the manufacturing costs increase.
[0016] Second, a significant amount of components and manufacturing steps are also required in order to connect the magnetic head (h) and the coil (c) of the rotary transformer 152 . The terminal 155 has to be attached to, and the hole 115 has to be formed in, the rotary drum 110 , so that the upper part of the terminal pin 111 , the terminal 155 and the coils (c), can be connected through the hole 115 . Then, the lower part of the terminal pin 111 is attached to the FPC 117 which is disposed at the lower part of the rotary drum 110 , and the FPC 117 is connected to the magnetic head (h) by soldering.
[0017] Furthermore, because signal connection between the rotary transformer 152 and the magnetic head (h) can be achieved only after a plurality of processes, signal transmission rate is degraded, and thus performance of the product deteriorates.
[0018] Third, because the motor stator 170 is formed in the three-layered structure having the first substrate 171 , the second substrate 172 and the third substrate 173 , each of which are bonded to one another in turn, the number of parts and manufacturing steps increase and manufacturing costs increase. Furthermore, the copper patterning on the respective substrates also causes decreased productivity.
SUMMARY OF THE INVENTION
[0019] Accordingly, it is an aspect of an embodiment of the present invention to provide a head drum assembly for a tape recorder, which provides an improved productivity at a reduced manufacturing cost through an improvement to the structure of a drum cover thereof.
[0020] It is another aspect of an embodiment of the present invention to provide a head drum assembly for a tape recorder, which is improved in a connecting structure for a rotary transformer and a magnetic head.
[0021] It is yet another aspect of an embodiment of the present invention to provide a head drum assembly for a tape recorder, which provides improved manufacturing processes at a reduced manufacturing cost through an improvement to the structure of a motor stator.
[0022] In order to achieve the above aspects, an embodiment of present invention provides a head drum assembly for a tape recorder, including a rotary drum supporting a magnetic head thereon and being rotatably disposed on a shaft, a stationary drum and a drum cover secured to the shaft to be positioned respectively on lower and upper parts of the rotary drum with the rotary drum being interposed therebetween, a sub circuit board. The embodiment of the invention further includes a stationary transformer and a rotary transformer, each being disposed between the stationary drum and the rotary drum for signal transmission with the magnetic head, a motor stator mounted on the stationary drum, and a motor rotor disposed in the rotary drum to oppose the motor stator and rotate.
[0023] The drum cover is formed of a conductive material and is press-fitted to contact with the shaft, and a connecting member is disposed on the conductive body of the drum cover for supporting and electrically connecting the sub circuit board with the conductive body.
[0024] The drum cover is formed of the same or similar material as that of the rotary drum and the stationary drum.
[0025] The connecting member is a screw fastened to coupling holes which are respectively formed in the drum cover and in the sub circuit board to correspond to each other.
[0026] The rotary drum has a linking hole vertically penetrating therein, and a coil of the rotary transformer is passed through the linking hole and directly connected to the magnetic head by soldering.
[0027] An entry part and an exit part at the upper and the lower parts of the linking hole are rounded, or may be tapered.
[0028] The linking hole is formed symmetrically with respect to the magnetic head.
[0029] The motor stator is formed in a two-layered structure having a lower substrate and an upper substrate stacked on the lower substrate. Combinations of a torque generation coil pattern, a frequency generation coil pattern for speed control and a phase generation coil pattern for phase control are formed on the upper and the lower substrates, respectively.
[0030] The torque generation coil pattern is formed dispersely on the upper and the lower substrates, and the phase generation coil pattern for phase control is formed on one of the upper and the lower substrates, and the frequency generation coil pattern for speed control is formed on the other.
[0031] The torque generation coil pattern and the phase generation coil pattern are formed dispersely on the upper and the lower substrates, and the frequency generation coil pattern is formed on the lower substrate.
[0032] Each of the upper and the lower substrates has a copper layer in a predetermined pattern which is formed on a base plate, and a protective layer formed on the copper layer, and the copper layers of the upper and the lower substrates are connected with each other through a passing hole formed in the upper substrate.
[0033] The copper layer is formed in width from about 10 μm to about 20 μm, and a pitch between the respective copper layers ranges from about 90 μm to about 100 μm.
[0034] With the head drum assembly for a tape recorder constructed as described above in accordance with an embodiment of the present invention, the conductive bushing members and earth plate, which were respectively provided to the insulating drum cover, can be replaced by a single conductive drum cover. Accordingly, the number of necessary parts and manufacturing steps is reduced, and the manufacturing cost decreases while the productivity increases.
[0035] Further, because the coil is directly connected to the magnetic head, many parts become unnecessary, and as a result, the number of manufacturing steps decreases. Also, as the signal transmission rate increases due to direct connection between the coil and the magnetic head, the performance of the product is improved.
[0036] Furthermore, because the motor stator adopts a two-layered structure of an upper and lower substrates, i.e., omitting one layer from the conventional structure, the number of necessary parts is reduced, and subsequently, the manufacturing costs are also decreased. Additionally, because the process of forming copper pattern on the respective substrate layers can be shortened, productivity is increased.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] The above objects and other features of the present invention will become more apparent by describing in detail a preferred embodiment thereof with reference to the attached drawings, in which:
[0038] [0038]FIG. 1A is a schematic sectional view of a conventional head drum assembly;
[0039] [0039]FIG. 1B is an exploded perspective view of the head drum assembly of FIG. 1A;
[0040] [0040]FIG. 2A is a bottom view illustrating the rotary drum of FIG. 1A;
[0041] [0041]FIG. 2B is a schematic perspective view illustrating the motor stator of FIG. 1A being disassembled;
[0042] [0042]FIG. 2C is a schematic sectional view taken on line II-II of FIG. 2B;
[0043] [0043]FIG. 3A is a schematic sectional view illustrating a head drum assembly according to a preferred embodiment of the present invention;
[0044] [0044]FIG. 3B is an exploded perspective view of the head drum assembly of FIG. 3A;
[0045] [0045]FIG. 4A is a bottom view of the rotary drum of FIG. 3A;
[0046] [0046]FIG. 4B is a schematic perspective view illustrating the motor stator of FIG. 3A being disassembled; and
[0047] [0047]FIG. 4C is a schematic sectional view taken on line IV-IV of FIG. 4B.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings.
[0049] Referring to FIGS. 3A and 3B, a head drum assembly 200 for a tape recorder according to the present invention includes a rotary drum 210 which rotatably supports a magnetic head (h) thereon to scan and thus record/reproduce data on/from a magnetic tape (not shown), a stationary drum 220 and a drum cover 230 press-fitted to be positioned on the lower and the upper parts of a shaft 240 , respectively, with the rotary drum 210 being interposed therebetween. Here, the shaft 240 is disposed in a center axis hole of the rotary drum 210 .
[0050] The drum cover 230 receives the shaft 240 which is press-fitted in a shaft hole defined therein, to be disposed on the rotary drum 210 . The drum cover 230 can be formed by shaping a conductive material such as an aluminum alloy. More preferably, the drum cover 230 is made of the same material as that of the rotary drum 210 and the stationary drum 230 .
[0051] According to an embodiment of the present invention, the drum cover 230 and the sub circuit board 253 are each provided with connecting holes 230 a , 230 b , respectively, that corresponds to each other. Accordingly, as the screws (s) are fastened into the connecting holes 230 a , 230 b , the drum cover 230 and the sub circuit board 253 are supported in an electric connection.
[0052] As described above, because the drum cover 230 is formed of a conductive material, the drum cover 230 and the sub circuit board 253 can be electrically connected simply by the screws (s), and the drum cover 230 itself can function as the earth plate.
[0053] By the above-described structure, the need for a conductive bushing member and an earth plate which were usually required in the drum cover 230 can be omitted, and the number of screws (s) for connecting these parts is also reduced. As a result, the conductive drum cover 230 can be provided as one simple element.
[0054] Stationary transformer 251 and rotary transformer 252 (which faces the stationary transformer 251 ), are provided to the upper part of the rotary drum 210 and to the lower part of the drum cover 230 , respectively. The transformers 251 , 252 provide signal transmission between the magnetic head (h) and the sub circuit board 253 .
[0055] The rotary transformer 252 is attached to the upper part of the rotary drum 210 . On the rotary drum 210 , there is the drum cover 230 fixed to the shaft 240 . The stationary transformer 251 is attached to the lower part of the drum cover 230 to face the rotary transformer 252 . The rotary transformer 252 sends and receives signals with the stationary transformer 251 in a non-contact manner. Accordingly, data reproduced or to be recorded by the magnetic head (h) can be transmitted through the respective transformers 251 , 252 .
[0056] To this end, the coil (c) of the rotary transformer 252 has to be connected to the magnetic head (h), and accordingly, there is a linking hole 215 vertically penetrating the rotary drum 210 . As shown in FIG. 3A, a pair of linking holes 215 are symmetrically formed at the right and the left sides with respect to the magnetic head (h). The coil (c) is passed through the linking holes 215 and is directly connected to the magnetic head (h) by soldering. As a result, in the case where there is a pair of magnetic heads (h) employed, a total of four soldering steps are performed: two soldering steps for each coil (c) of each magnetic head (h). Generally, the surface of the coil (c) is coated with enamel for the purpose of insulation. In order to prevent the coating from peeling off by contact with the rotary drum 210 , the upper/lower entry/exit parts 215 a , 215 b of the linking holes 215 are preferably rounded. By having the entry and exit parts 215 a , 215 b rounded, instead of angular, the peel-off of the coating layer of the coil (c) by the contact can be prevented.
[0057] In addition, a motor stator 270 is disposed in the upper part of the stationary drum 220 , and a motor rotor 260 is disposed in the lower surface of the rotary drum 210 to oppose the motor stator 270 and rotate. The motor rotor 260 has a donut-shaped magnet 262 disposed inside a ring-type rotor casing 261 .
[0058] The motor stator 270 , which is one of the main features of an embodiment of the present invention, is formed of the type in which the so-called “FP coil (fine pattern coil)” is formed into a disc pattern and disposed to face the donut-type magnet 162 , to obtain a more compact-sized head drum assembly. As shown in FIG. 4B, the motor stator 270 has the two-layered structure which consists of a lower substrate 261 and an upper substrate 262 stacked on the lower substrate 261 . In the upper and the lower substrates 262 , 261 , there are a torque generation coil pattern (A), a frequency generation coil pattern (B) for speed control and a phase generation coil pattern (C) for phase control formed in various shapes and in combination with one another.
[0059] According to a preferred embodiment of the present invention, as shown in FIG. 4B, the torque generation coil pattern (A) and the phase generation (PG) coil pattern (C) for phase control are formed dispersely on the upper and the lower substrates 262 , 261 , while the frequency generation (FG) coil pattern (B) for speed control is formed on the upper substrate 262 .
[0060] According to another aspect of an embodiment of the present invention, albeit not shown, a predetermined torque generation coil pattern may be formed dispersely on the upper and the lower substrates 262 , 261 , while there is the PG coil pattern (C) on one of the upper substrate and lower substrate 262 , 261 and the FG coil pattern (B) on the other substrate 262 , 261 . Additionally, various other combinations of the patterns are also possible.
[0061] According to yet another aspect of an embodiment of the present invention, as shown in FIG. 4C, preferably, each of the upper and the lower substrates 262 , 261 is formed by coating a copper membrane 261 b of a predetermined fine pattern on an epoxy substrate 261 a , i.e., on a base plate, and forming a protective layer 261 c thereon. The copper layer 261 b may be formed in width (W) from at or about 10 μm to at or about 20 μm , and the pitch (P) between the respective copper layers 261 b ranges from at or about 90 μm to at or about 100 μm .
[0062] Although a few preferred embodiments of the present invention have been described, it will be understood by those skilled in the art that the present invention should not be limited to the described preferred embodiments, but various changes and modifications can be made within the spirit and scope of the present invention as defined by the appended claims.
|
A head drum assembly for a compact-size camcorder such as a digital video camera comprised of a drum cover, stationary and rotating drum, a subcircuit board, a stationary and rotating transformer and a motor stator and rotor. By forming the drum cover, which is attached to the shaft of the rotary drum above the rotary drum, with a conductive material such as an aluminum alloy, the need for a conductive bushing member and earthing plate for the insulating drum cover of the head drum assembly can be omitted, resulting in an overall simpler. As the number of components and manufacturing steps decreases, the manufacturing costs decrease and productivity increases.
| 6
|
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to currently co-pending U.S. Provisional Patent Application Ser. No. 61/369,681, filed Jul. 31, 2010, for “Multi-Purpose, Small-Garment Bag Structure”. The entire content of this provisional application is hereby incorporated herein by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
This invention pertains to a multi-purpose, small-garment bag structure, and more particularly, to such a structure which may be used in singular, or co-attached plural-bag, forms, to furnish useful, convenient organizational handling and management control for various small, personal garments such as socks and underwear. The utility of this structure presents itself especially well in laundering, post-laundering drying, at-home storing, and traveling situations, as will become apparent.
The proposed bag structure (or bag), for and in these various settings, offers a number of combinational functionalities including, as illustrations, (a) receiving small garments, such as socks and underwear, and containing them neatly organized for machine (or hand) laundering as well as for machine (or non-machine) drying, (b) holding dried, laundered garments within the bag for storage, (c) collecting dirtied garments in preparation for laundering, (d) hanging garments within the bag structure on an otherwise conventional clothing hanger for pre-use storage display (or for other reasons), etc., if desired (as in a closet), and (e) containing “bagged” garments for travel purposes. The bag structure of the invention includes appropriate, releasably interengageable interconnection structures, such as matable zipper structures, adjacent opposite top and bottom edges enabling roll-folding, and holding of the bag structure in a roll-folded condition for, as an example, garment-contained compactness in a travel situation.
To meet these purposes, and to offer these features, the basic bag structure of the invention includes a principal bag formed of, for example, an open-mesh nylon fabric, such as the material known as laundry mesh, having front and back sides, and including an openable/closable closure structure, such as a regular zipper structure, extending laterally generally centrally across the front side of the bag. This central, lateral zipper structure furnishes access to the bag's inside, wherein reinforcing-band-anchored (and thus basically positionally stabilized), clothing-article-holding clips, such as alligator-like clips, are furnished, pivotally mounted, in laterally extending rows (preferably, though not necessarily, two rows) for the purpose of gripping and selectively releasing small garments for containment in and retraction from the bag. The reinforcing band mentioned may be formed of the material known as belting tape. The laterally extending openable/closable closure structure provided for access to the inside of the bag is conveniently located positionally adjacent the locations of the preferred two rows of clips. The clips preferably are pivotally mounted on the mentioned reinforcing band material, with the pivot axes for these clips being substantially normal to the “plane” of the bag under circumstances wherein the bag's confronting front and back sides are in conditions essentially flattened adjacent each other.
The mentioned zipper structures that are disposed adjacent the top and bottom edges of the bag, made, for example from what is known as “matable”, separating zipper structures, enable plural bag structures to be connected for various purposes and conditions, such in a “vertical stack” for collective hanging as a plural-bag-structure unit, or for other reasons.
The upper edge of the proposed bag is reinforced with the same belting-type material mentioned above. Additionally, provided laterally centrally in this upper edge is a small access opening allowing for the passage of the hanging hook of a conventional clothing hanger whose main body may be disposed within the top of the bag to hold it and its contents for hanging purposes.
These and other features of the invention will become more fully apparent as the detailed description of it which now follows is read in conjunction with the accompanying drawings.
DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is a top, frontal isometric view of a single bag structure made in accordance with the present invention. A portion of the front of this structure has been broken away in order to illustrate details of internal construction.
FIG. 2 , which has been drawn on a slightly larger scale than that employed in FIG. 1 , is a front elevation of the bag of FIG. 1 , here, also, with a portion broken away to illustrate internal construction.
FIG. 3 presents a reduced-scale view of an assembly of three bag structures, each having the construction illustrated in FIGS. 1 and 2 , zipped together, top-edge to bottom-edge, for storage-hanging purposes. The upper bag is shown associated with a conventional clothing hanger to enable hanging of the bag assembly for storage purposes, as in a closet. Selected portions of the bags illustrated in this figure have been shown only fragmentarily in order to illustrate details of construction.
FIG. 4 is a simplified cross section taken generally along the line 4 - 4 in FIG. 3 , and drawn on a scale which is slightly larger than that employed in FIG. 3 .
FIG. 5 , which has been drawn on about the same scale as that employed in FIG. 4 , illustrates the bag pictured in the FIG. 4 roll-folded upon itself, and retained in that condition by engaged, complementary components which form parts in an included matable zipper structure. These zipper structure components are provided adjacent the upper and lower edges of the bag.
DETAILED DESCRIPTION OF THE INVENTION
Turning attention now to the drawings, and referring first of all to FIGS. 1 , 2 and 4 , indicated generally at 10 is a combined laundry, travel, storage/display bag structure made in accordance with a preferred and best-mode embodiment of the present invention. Bag structure 10 , which, generally speaking, is floppy and flexible in nature, includes, as its main body, an open-mesh, fabric bag 12 formed in any suitable fashion of a conventional machine-washable, machine-dryable, nylon laundry-mesh material. The bag illustrated herein is shaped generally in the form of an elongate rectangle, having a width W of about 18-inches between its lateral edges 12 a , 12 b , and a top-to-bottom height H of about 24-inches between its upper (or top) edge 12 c and its bottom edge 12 d . Bag 12 has front and back sides 12 e , 12 f , respectively, an inside 12 g (seen especially well through a break-away opening in front side 12 e in FIGS. 1 and 2 marked by a dash-double-dot line 14 ), and a nominal flattened condition, which is generally seen in the edge-view of it presented in FIG. 4 , in which condition the bag can be thought of as occupying a plane, such as that shown for it by a dash-dot line 12 A in FIG. 4 .
The dimensions just stated are convenient and practical for most applications, but not in any sense critical.
At four locations in the bag structure pictured there are provided vertically spaced, laterally extending, narrow, reinforcing strips 16 , 18 , 20 , 22 formed preferably of the conventional fabric material known as belting tape.
Attached across the bag's top edge 12 c , immediately above reinforcing strip 16 , is one complementary side 24 a of a conventional matable zipper structure 24 , the other complementary side, 24 b , of which is attached across the bag's bottom edge 12 d . The functions of zipper sides, or components, 24 a , 24 b will be explained shortly in relation to FIGS. 3 and 5 . Components 24 a , 24 b are referred to collectively herein as selectively matable, releasably and complementarily interengageable, interconnection structures.
Openable and closeable access to the inside 12 g of bag 12 is provided through a substantially full-width, laterally extending separation existing between upper and lower portions of the mesh fabric which forms front side 12 e , and by operation of an appropriately there attached, conventional, regular zipper, or openable/closable closure structure, 26 which is disposed generally centrally between the top and bottom edges of the bag. This access feature, by way of which small garments are passed into and out of the bag during use, is located preferably, though not necessarily, about midway between the top and bottom edges of the bag.
Another, relatively small, somewhat slit-like opening into bag 12 is furnished laterally centrally at 28 adjacent the top edge of the bag, immediately above reinforcing strip 16 (as seen in FIG. 1 ). This opening is also referred to herein as a clothing-hanger hook-passage access opening, for a reason which will become immediately apparent from a look at FIG. 3 . More will be said shortly about this structure.
Suitably pivotally attached to each of previously mentioned material strips 18 , 20 , at five locations on each strip, and spaced laterally along these strips, are five each, conventionally available, alligator-like clips, such as clips 30 , which can pivot, or rotate, about axes, such as those shown 30 a . Clips 30 are also referred to herein as plural, clothing-article holding structures.
Turning attention now to FIGS. 3 and 5 in conjunction with the other drawing figures, one will notice that, with respect to the specific locations illustrated for the alligator clips, these clips are conveniently positioned generally centrally (relative to the top and bottom of the bag) near the bag's front opening to furnish easy and direct access for the attachment and detachment of small garments, such as the two pairs of socks that are shown in FIG. 3 , for example, clipped inside the upper one of the three zipper-attached bags pictured in this figure. An upper pair of socks 32 is shown clipped into place, and dangling by gravity, by one of the alligator clips attached to material strip 18 , and another, similar pair of socks 34 is shown likewise clipped into place, and likewise dangling by gravity, by one of the alligator clips attached to material strip 20 .
With regard to typical use of but a single bag made in accordance with the present invention, small garments, such as socks, like socks 32 , 34 , underwear, and other kinds of pieces (not specifically shown), in a ready-to-wash condition, are put into place and clipped within the bag which has been opened by manipulation of zipper 26 for that purpose (see broad, double-headed arrow 35 in FIG. 3 ). The bag is then re-closed, and the entire assemblage of bag and held garments is placed in a washing machine, or otherwise placed for hand laundering, in a condition where the held garments are retained in place, and neatly organized, during this process. Pairs of socks, for example, are kept together, and all garments in a bag may have been placed there for identification convenience on a person-specific basis.
When washing is completed, the bag and held-garments assemblage may then typically either be placed in a dryer, or alternatively, hung for air drying by using a conventional clothing hanger, such as the hanger which is illustrated at 36 in FIG. 3 . When such a hanger is employed, its main body is disposed inside and near the top of the bag as shown, with the stem, or neck, of the hook in the hanger, such as that of the hook shown at 36 a , extending upwardly through previously mentioned bag opening 28 .
When the held garments are dry and ready for use, they may either be easily removed from the bag for conventional storage, or they may simply be stored and held in place inside the receiving bag, with the bag either hung for storage and display of the held garments as pictured in FIG. 3 , or perhaps stored on a shelf or in a drawer in an otherwise conventional manner except that the held garments are bag-retained in a separated and easily identified manner.
Garments which are held in a bag and which are clean and ready (inside the bag) for storage, may readily be packed for travel in a very convenient manner.
At any point during the washing, drying and storing procedures just described, it is possible for a single bag, if desired, to be rolled and folded upon itself, as indicated in FIG. 5 , and held in this condition simply by connecting the complementary components 24 a , 24 b in the associated matable zipper structure 24 .
Another very convenient and sometimes useful manner of employing a bag of the present invention is illustrated effectively by what is shown in FIG. 3 , where a plurality of bags becomes unified in a chain of bags through inter-bag connections of the matable zipper components. Such a chain of bags may also be rolled upon itself in the same manner illustrated for the single bag in FIG. 5 .
The fact that attachment and support for bag-held garments is furnished through clips which are pivotally mounted, as explained, results in garments, particularly during storage and/or display after washing, neatly self-organizing because of the fact that they tend to dangle by gravity as pictured for the two pairs of socks shown in FIG. 3 .
Accordingly, a unique, multi-function, combined laundry, travel, storage/display bag structure has been illustrated and described herein. Numerous features of the proposed bag structure have been discussed and are quite evident, but I recognize that other features and advantages are also available, and may be discovered by those generally skilled in the art. Accordingly, it is my intention that all claims to invention will be read to incorporate such additional features and advantages.
|
A combined, flexible and floppy laundry, travel, storage/display bag structure for socks and like small clothing articles, including (a) a machine-launderable/dryable, open-mesh, fabric bag having front and back sides, and spaced top, bottom and lateral edges, (b) located intermediate the bag's top and bottom edges, an elongate openable/closeable closure structure joined to and extending laterally across the bag's front side and between its lateral edges, and furnishing user-selective access to the inside of the bag, and (c) plural, releasable, clothing-article-holding structures mounted inside the bag on its back side, made manually accessible, via the closure structure, for operative gripping and releasing, within the bag, of user-selected clothing articles.
| 3
|
PRIORITY CLAIM
This application claims priority to U.S. Provisional Application No. 61/307,262 filed Feb. 23, 2010 which claims priority to U.S. Provisional Patent Application No. 60/970,445, filed on Sep. 6, 2007, entitled, “Morinda Citrifolia Based Formulations for Regulating T Cell Immunomodulation in Neonatal Stock Animals,” is a continuation in part of U.S. patent Ser. No. 11/034,505, filed Jan. 13, 2005, entitled “Profiles of Lipid Proteins and Inhibiting HMG-COA Reductase,” which claims priority to Provisional Application No. 60/536,663, filed Jan. 15, 2004 and claims priority to Provisional Application No. 60/552,144, filed Mar. 10, 2004, is a continuation-in-part of U.S. Pat. No. 6,737,089, filed Apr. 17, 2001, entitled “Morinda Citrifolia (Noni) Enhanced Animal Food Product”, and is a continuation-in-part of U.S. Pat. No. 7,244,463, filed Oct. 18, 2001, entitled “Garcinia Mangostana L. Enhanced Animal Food Product” and is a continuation-in-part of U.S. patent application Ser. No. 10/396,868, filed Mar. 25, 2003 now abandoned, entitled “Preventative And Treatment Effects Of Morinda Citirifolia As An Aromatase Inhibitor” and claims priority to U.S. Provisional Patent Application Ser. No. 60/458,353, filed Mar. 28, 2003, entitled “The Possible Estrogenic Effects Of Tahitian Noni Puree Juice Concentrate-Dry Form”, and is a continuation-in-part of U.S. patent application Ser. No. 11/360,550 filed Feb. 23, 2006, entitled “Preventative and Treatment Effects of Morinda Citrifolia on Osteoarthritis and Its Related Conditions” which is a divisional of U.S. patent application Ser. No. 10/285,359, now U.S. Pat. No. 7,033,624, filed Oct. 31, 2002, entitled “Preventative and Treatment Effects of Morinda Citrifolia on Osteoarthritis and Its Related Conditions” which claims priority to U.S. Provisional Patent Application No. 60/335,343 filed Nov. 2, 2001, entitled, “Methods for Treating Osteoarthritis” and is a continuation-in-part of U.S. patent application Ser. No. 10/006,014 filed Dec. 4, 2001, entitled “Tahitian Noni Juice On Cox-1 And Cox-2 And Tahitian Noni Juice As A Selective Cox-2 Inhibitor”, which claims priority to U.S. Provisional Patent Application Ser. No. 60/251,416 filed Dec. 5, 2000, entitled “Cox-1 and Cox-2 Inhibition Study on TNJ” and is a continuation-in-part of U.S. patent application Ser. No. 11/553,323, filed Oct. 26, 2006, entitled “Preventative and Treatment Effects of Morinda Citrifolia on Diabetes and its Related Conditions” which is a divisional of U.S. patent application Ser. No. 10/993,883, now U.S. Pat. No. 7,186,422 filed Nov. 19, 2004, entitled “Preventative And Treatment Effects Of Morinda Citrifolia On Diabetes And Its Related Conditions” which is a divisional of U.S. application Ser. No. 10/286,167, now U.S. Pat. No. 6,855,345 filed Nov. 1, 2002, entitled “Preventative And Treatment Effects Of Morinda Citrifolia On Diabetes And Its Related Conditions,” which claims priority to U.S. Provisional Application Ser. No. 60/335,313, filed Nov. 2, 2001, and entitled, “Methods for Treating Conditions Related to Diabetes.”
BACKGROUND
1. Field of Invention
Embodiments of the invention relate to fortified food and dietary supplement products which may be administered to produce desirable physiological improvement. In particular, embodiments of the invention relates to the administration of products enhanced with Morinda citrifolia and iridoids.
2. Background
Nutraceuticals may generally be defined as dietary products fortified to provide health and medical benefits, including the prevention and treatment of disease. Nutraceutical products include a wide range of goods including isolated nutrients, dietary supplements, herbal products, processed foods and beverages. With recent breakthroughs in cellular-level nutraceuticals agents, researchers, and medical practitioners are developing therapies complimentary therapies into responsible medical practice and maintenance of good health. Generally, nutraceutical include a product isolated or purified from foods, and are generally sold in forms that demonstrate a physiological benefit or provide protection against chronic disease.
There are multiple types of products that fall under the category of nutraceuticals. Nutraceuticals may be manufactured as dietary supplements, functional foods or medical product. A dietary supplement is a product that contains nutrients derived from food products that are concentrated in liquid, powder or capsule form. A dietary supplement is a product taken by mouth that contains a dietary ingredient intended to supplement the diet. Dietary ingredients in these products may include: vitamins, minerals, herbs or other botanicals, and substances such as enzymes and metabolites. Dietary supplements can also be extracts or concentrates, and may be found in many forms such as tablets capsules, softgels, gelcaps, liquides or powders.
Functional foods include ordinary food that has components or ingredients added to give it a specific medical or physiological benefit, other than a purely nutritional effect. Functional foods may be designed to allow consumers to eat enriched foods close to their natural state, rather than by taking dietary supplements manufactured in liquid or capsule form. Functional foods may be produced in their naturally-occurring form, rather than a capsule, tablet, or powder, can be consumed in the diet as often as daily, and may be used to regulate a biological process in hopes of preventing or controlling disease.
SUMMARY OF THE INVENTION
Some embodiments relate to formulations that provide a specific physiological benefit. Some embodiments relate to formulations designed to prevent or control disease. Some embodiments comprise a processed Morinda citrifolia products and a source of iridoids and methods for manufacturing the same.
Some embodiments provide a processed Morinda citrifolia product selected from a group consisting of: extract from the leaves of Morinda citrifolia , leaf hot water extract, processed Morinda citrifolia leaf ethanol extract, processed Morinda citrifolia leaf steam distillation extract, Morinda citrifolia fruit juice, Morinda citrifolia extract, Morinda citrifolia dietary fiber, Morinda citrifolia puree juice, Morinda citrifolia puree, Morinda citrifolia fruit juice concentrate, Morinda citrifolia puree juice concentrate, freeze concentrated Morinda citrifolia fruit juice, Morinda citrifolia seeds, Morinda citrifolia seed extracts, extracts from defatted Morinda citrifolia seeds and evaporated concentration of Morinda citrifolia fruit juice, in combination with an amount of iridoids sourced from at least one of a variety of plants.
Preferred embodiments are formulated to provide a physiological benefit. For example some embodiments may selectively inhibit COX-1/COX-2, regulate TNF and Nitric oxide and 5-LOX, increases IFN- secretion, inhibit histamine release, inhibit human neutrophils, regulate elastase enzyme activity, inhibit the complement pathway, inhibits the growth microbials including gram − and gram + bacteria, inhibit DNA repair systems, inhibit cancer cell growth & cytotoxic to cancer cells, inhibits platelets aggregations, provide DPPH scavenging effects, provide antiviral activity including anti-HSV, anti-RSV, and anti-VSV activity, provide antispasmodic activity, provide wound-healing and neuroprotective activities.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the matter in which the above-recited and other advantages of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 depicts the structural formula for common iridoids according to some embodiments of the invention;
FIG. 2 depicts the structural formula for common iridoids according to some embodiments of the invention;
FIG. 3 depicts results from studies demonstrating the DNA protective activity of iridoid containing plant products according to some embodiments of the invention;
FIG. 4 depicts the chemical structures of deacetylasperulosidic acid and asperulosidic acid;
FIG. 5 depicts HPLC chromatograms of iridoid analysis in the different parts of noni plant; and
FIG. 6 depicts a comparison of iridoid contenst in the methanolic extracts of noni fruits collected from different tropical areas worldwide.
DETAILED DESCRIPTION OF THE INVENTION
It will be readily understood that the components of the present invention, as generally described herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of embodiments of the compositions and methods of the present invention is not intended to limit the scope of the invention, as claimed, but is merely representative of the presently preferred embodiments of the invention. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
Embodiments of the present invention feature methods and compositions designed to provide a physiological benefit comprising a combination of a processed Morinda citrifolia product and a source of iridoids. The physiological benefit arising from the synergistic combination of a component derived from the Indian Mulberry or Morinda citrifolia L. plant and a source of iridoids.
Embodiments of the present invention comprise Morinda citrifolia compositions, each of which include one or more processed Morinda citrifolia L. products. The Morinda citrifolia product preferably includes Morinda citrifolia fruit juice, which juice is preferably present in an amount capable of maximizing the desired physiological benefit without causing negative side effects when the composition is administered to a mammal. Products from Morinda citrifolia may include one more parts of the Morinda citrifolia L. plant, including but not limited to the: fruit, including the fruit juice and fruit pulp and concentrates thereof, leaves, including leaf extract, seeds, including the seed oil, flowers, roots, bark, and wood.
Some compositions of the present invention comprise Morinda citrifolia extracts present between about 1 and 5 percent of the weight of the total composition. Other such percentage ranges include: about 0.1 and 50 percent; about 85 and 99 percent; about 5 and 10 percent; about 10 and 15 percent; about 15 and 20 percent; about 20 and 50 percent; and about 50 and 100 percent.
In some Morinda citrifolia compositions of the present invention, Morinda citrifolia fruit juice evaporative concentrate is present, the evaporative concentrate having a concentration strength (described further herein) between about 8 and 12 percent. Other such percentage ranges include: about 4 and 12 percent; and about 0.5 and 12 percent.
In some Morinda citrifolia compositions of the present invention, Morinda citrifolia fruit juice freeze concentrate is present, the freeze concentrate having a concentration strength (described further herein) between about 4 and 6 percent. Other such percentage ranges include: about 0.5 and 2 percent; and about 0.5 and 6 percent.
One or more Morinda citrifolia extracts can be further combined with other ingredients or carriers (discussed further herein) to produce a pharmaceutical Morinda citrifolia product or composition (“pharmaceutical” herein referring to any drug or product designed to improve the health of living organisms such as human beings or mammals, including nutraceutical products) that is also a Morinda citrifolia of the present invention. Examples of pharmaceutical Morinda citrifolia products may include, but are not limited to, orally administered solutions and intravenous solutions.
Methods of the present invention also include the obtaining of Morinda citrifolia compositions and extracts, including Morinda citrifolia fruit juice and concentrates thereof. It will be noted that some of the embodiments of the present invention contemplate obtaining the Morinda citrifolia fruit juice pre-made. Various methods of the present invention shall be described in more detail further herein.
The following disclosure of the present invention is grouped into subheadings. The utilization of the subheadings is for convenience of the reader only and is not to be construed as limiting in any sense.
General Description of the Morinda citrifolia L. Plant
The Indian Mulberry or Morinda citrifolia plant is known scientifically as Morinda Citrifolia L. The plant is native to Southeast Asia and has spread in early times to a vast area from India to eastern Polynesia. It grows randomly in the wild, and it has been cultivated in plantations and small individual growing plots. Although the fruit has been eaten by several nationalities as food, the most common use of the Morinda citrifolia plant has traditionally been as a red and yellow dye source.
The Morinda citrifolia plant is rich in natural ingredients including: (from the leaves): alanine, anthraquinones, arginine, ascorbic acid, aspartic acid, calcium, beta-carotene, cysteine, cystine, glycine, glutamic acid, glycosides, histidine, iron, leucine, isoleucine, methionine, niacin, phenylalanine, phosphorus, proline, resins, riboflavin, serine, beta-sitosterol, thiamine, threonine, tryptophan, tyrosine, ursolic acid, and valine; (from the flowers): acacetin-7-o-beta-d(+)-glucopyranoside, 5,7-dimethyl-apigenin-4′-o-beta-d(+)-galactopyranoside, and 6,8-dimethoxy-3-methylanthraquinone-1-o-beta-rhamnosyl-glucopyranoside; (from the fruit): acetic acid, asperuloside, butanoic acid, benzoic acid, benzyl alcohol, 1-butanol, caprylic acid, decanoic acid, (E)-6-dodeceno-gamma-lactone, (Z,Z,Z)-8,11,14-eicosatrienoic acid, elaidic acid, ethyl decanoate, ethyl hexanoate, ethyl octanoate, ethyl palmitate, (Z)-6-(ethylthiomethyl) benzene, eugenol, glucose, heptanoic acid, 2-heptanone, hexanal, hexanamide, hexanedioic acid, hexanoic acid (hexoic acid), 1-hexanol, 3-hydroxy-2-butanone, lauric acid, limonene, linoleic acid, 2-methylbutanoic acid, 3-methyl-2-buten-1-ol, 3-methyl-3-buten-1-ol, methyl decanoate, methyl elaidate, methyl hexanoate, methyl 3-methylthio-propanoate, methyl octanoate, methyl oleate, methyl palmitate, 2-methylpropanoic acid, 3-methylthiopropanoic acid, myristic acid, nonanoic acid, octanoic acid (octoic acid), oleic acid, palmitic acid, potassium, scopoletin, undecanoic acid, (Z,Z)-2,5-undecadien-1-ol, and vomifol; (from the roots): anthraquinones, asperuloside (rubichloric acid), damnacanthal, glycosides, morindadiol, morindine, morindone, mucilaginous matter, nor-damnacanthal, rubiadin, rubiadin monomethyl ether, resins, soranjidiol, sterols, and trihydroxymethyl anthraquinone-monomethyl ether; (from the root bark): alizarin, chlororubin, glycosides (pentose, hexose), morindadiol, morindanigrine, morindine, morindone, resinous matter, rubiadin monomethyl ether, and soranjidiol; (from the wood): anthragallol-2,3-dimethylether; (from the tissue culture): damnacanthal, lucidin, lucidin-3-primeveroside, and morindone-6beta-primeveroside; (from the plant): alizarin, alizarin-alpha-methyl ether, anthraquinones, asperuloside, hexanoic acid, morindadiol, morindone, morindogenin, octanoic acid, and ursolic acid.
Processing Morinda citrifolia Leaves
The leaves of the Morinda citrifolia plant are one possible component of the Morinda citrifolia plant that may be present in some compositions of the present invention. For example, some compositions comprise leaf extract and/or leaf juice as described further herein. Some compositions comprise a leaf serum that is comprised of both leaf extract and fruit juice obtained from the Morinda citrifolia plant. Some compositions of the present invention comprise leaf serum and/or various leaf extracts as incorporated into a nutraceutical product (“nutraceutical” herein referring to any product designed to improve the health of living organisms such as human beings or mammals).
In some embodiments of the present invention, the Morinda citrifolia leaf extracts are obtained using the following process. First, relatively dry leaves from the Morinda citrifolia L. plant are collected, cut into small pieces, and placed into a crushing device—preferably a hydraulic press—where the leaf pieces are crushed. In some embodiments, the crushed leaf pieces are then percolated with an alcohol such as ethanol, methanol, ethyl acetate, or other alcohol-based derivatives using methods known in the art. Next, in some embodiments, the alcohol and all alcohol-soluble ingredients are extracted from the crushed leaf pieces, leaving a leaf extract that is then reduced with heat to remove all the liquid therefrom. The resulting dry leaf extract will herein be referred to as the “primary leaf extract.”
In some embodiments, the primary leaf extract is subsequently pasteurized. The primary leaf extract may be pasteurized preferably at a temperature ranging from 70 to 80 degrees Celsius and for a period of time sufficient to destroy any objectionable organisms without major chemical alteration of the extract. Pasteurization may also be accomplished according to various radiation techniques or methods.
In some embodiments of the present invention, the pasteurized primary leaf extract is placed into a centrifuge decanter where it is centrifuged to remove or separate any remaining leaf juice therein from other materials, including chlorophyll. Once the centrifuge cycle is completed, the leaf extract is in a relatively purified state. This purified leaf extract is then pasteurized again in a similar manner as discussed above to obtain a purified primary leaf extract.
Preferably, the primary leaf extract, whether pasteurized and/or purified, is further fractionated into two individual fractions: a dry hexane fraction, and an aqueous methanol fraction. This is accomplished preferably in a gas chromatograph containing silicon dioxide and CH2Cl2-MeOH ingredients using methods well known in the art. In some embodiments of the present invention, the methanol fraction is further fractionated to obtain secondary methanol fractions. In some embodiments, the hexane fraction is further fractionated to obtain secondary hexane fractions.
One or more of the leaf extracts, including the primary leaf extract, the hexane fraction, methanol fraction, or any of the secondary hexane or methanol fractions may be combined with the fruit juice of the fruit of the Morinda citrifolia plant to obtain a leaf serum (the process of obtaining the fruit juice to be described further herein). In some embodiments, the leaf serum is packaged and frozen ready for shipment; in others, it is further incorporated into a nutraceutical product as explained herein.
Processing Morinda citrifolia Fruit
Some embodiments of the present invention include a composition comprising fruit juice of the Morinda citrifolia plant. In some embodiments the fruit may be processed in order to make it palatable for human consumption and included in the compositions of the present invention. Processed Morinda citrifolia fruit juice can be prepared by separating seeds and peels from the juice and pulp of a ripened Morinda citrifolia fruit; filtering the pulp from the juice; and packaging the juice. Alternatively, rather than packaging the juice, the juice can be immediately included as an ingredient in another product, frozen or pasteurized. In some embodiments of the present invention, the juice and pulp can be pureed into a homogenous blend to be mixed with other ingredients. Other processes include freeze drying the fruit and juice. The fruit and juice can be reconstituted during production of the final juice product. Still other processes may include air drying the fruit and juices prior to being masticated.
In a currently preferred process of producing Morinda citrifolia fruit juice, the fruit is either hand picked or picked by mechanical equipment. The fruit can be harvested when it is at least one inch (2-3 cm) and up to 12 inches (24-36 cm) in diameter. The fruit preferably has a color ranging from a dark green through a yellow-green up to a white color, and gradations of color in between. The fruit is thoroughly cleaned after harvesting and before any processing occurs.
The fruit is allowed to ripen or age from 0 to 14 days, but preferably for 2 to 3 days. The fruit is ripened or aged by being placed on equipment so that the fruit does not contact the ground. The fruit is preferably covered with a cloth or netting material during aging, but the fruit can be aged without being covered. When ready for further processing the fruit is light in color, such as a light green, light yellow, white or translucent color. The fruit is inspected for spoilage or for excessive green color and firmness. Spoiled and hard green fruit is separated from the acceptable fruit.
The ripened and aged fruit is preferably placed in plastic lined containers for further processing and transport. The containers of aged fruit can be held from 0 to 30 days, but preferably the fruit containers are held for 7 to 14 days before processing. The containers can optionally be stored under refrigerated conditions prior to further processing. The fruit is unpacked from the storage containers and is processed through a manual or mechanical separator. The seeds and peel are separated from the juice and pulp.
The juice and pulp can be packaged into containers for storage and transport. Alternatively, the juice and pulp can be immediately processed into a finished juice product. The containers can be stored in refrigerated, frozen, or room temperature conditions. The Morinda citrifolia juice and pulp are preferably blended in a homogenous blend, after which they may be mixed with other ingredients, such as flavorings, sweeteners, nutritional ingredients, botanicals, and colorings. The finished juice product is preferably heated and pasteurized at a minimum temperature of 181° F. (83° C.) or higher up to 212° F. (100° C.). Another product manufactured is Morinda citrifolia puree and puree juice, in either concentrate or diluted form. Puree is essentially the pulp separated from the seeds and is different than the fruit juice product described herein.
The product is filled and sealed into a final container of plastic, glass, or another suitable material that can withstand the processing temperatures. The containers are maintained at the filling temperature or may be cooled rapidly and then placed in a shipping container. The shipping containers are preferably wrapped with a material and in a manner to maintain or control the temperature of the product in the final containers.
The juice and pulp may be further processed by separating the pulp from the juice through filtering equipment. The filtering equipment preferably consists of, but is not limited to, a centrifuge decanter, a screen filter with a size from 1 micron up to 2000 microns, more preferably less than 500 microns, a filter press, a reverse osmosis filtration device, and any other standard commercial filtration devices. The operating filter pressure preferably ranges from 0.1 psig up to about 1000 psig. The flow rate preferably ranges from 0.1 g.p.m. up to 1000 g.p.m., and more preferably between 5 and 50 g.p.m. The wet pulp is washed and filtered at least once and up to 10 times to remove any juice from the pulp. The resulting pulp extract typically has a fiber content of 10 to 40 percent by weight. The resulting pulp extract is preferably pasteurized at a temperature of 181° F. (83° C.) minimum and then packed in drums for further processing or made into a high fiber product.
The filtered juice and the water from washing the wet pulp are preferably mixed together. The filtered juice may be vacuum evaporated to a brix of 40 to 70 and a moisture of 0.1 to 80 percent, more preferably from 25 to 75 percent. The resulting concentrated Morinda citrifolia juice may or may not be pasteurized. For example, the juice would not be pasteurized in circumstances where the sugar content or water activity was sufficiently low enough to prevent microbial growth.
Processing Morinda citrifolia Seeds
Some Morinda citrifolia compositions of the present invention include seeds from the Morinda citrifolia plant. In some embodiments of the present invention, Morinda citrifolia seeds are processed by pulverizing them into a seed powder in a laboratory mill. In some embodiments, the seed powder is left untreated. In some embodiments, the seed powder is further defatted by soaking and stirring the powder in hexane—preferably for 1 hour at room temperature (Drug:Hexane-Ratio 1:10). The residue, in some embodiments, is then filtered under vacuum, defatted again (preferably for 30 minutes under the same conditions), and filtered under vacuum again. The powder may be kept overnight in a fume hood in order to remove the residual hexane.
Still further, in some embodiments of the present invention, the defatted and/or untreated powder is extracted, preferably with ethanol 50% (m/m) for 24 hours at room temperature at a drug solvent ratio of 1:2.
Processing Morinda citrifolia Oil
Some embodiments of the present invention may comprise oil extracted from the Morinda Citrifolia plant. The method for extracting and processing the oil is described in U.S. patent application Ser. No. 09/384,785, filed on Aug. 27, 1999 and issued as U.S. Pat. No. 6,214,351 on Apr. 10, 2001, which is incorporated by reference herein. The Morinda citrifolia oil typically includes a mixture of several different fatty acids as triglycerides, such as palmitic, stearic, oleic, and linoleic fatty acids, and other fatty acids present in lesser quantities. In addition, the oil preferably includes an antioxidant to inhibit spoilage of the oil. Conventional food grade antioxidants are preferably used.
Iridoids
Embodiments of the present invention comprise a source of iridoids compositions, each of which include one or more processed plant or naturally occurring. Iridoids are a class of secondary metabolites found in a wide variety of plants and in some animals. Iridoids represent a large and still expanding group of cyclopenta[c]pyran monoterpenoids found in a number of folk medicinal plants used as bitter tonics, sedatives, hypotensives, antipyretics, cough medicines, remedies for wounds and skin disorder. Typical structural formulas for common iridoids are depicted in FIGS. 1 and 2 . There are at least three different types of Iridoids: Glycosidic iridoids with a sugar molecule attach to the monoterpene cyclic ring; Non-Glycosidic Iridoids without a sugar molecule attach to the monoterpene cyclic ring; and Secoiridoid iridoids known for its bitterness and function as deterrence for herbivores but it is simply a class of Iridoids derived from deoxyloganic acid via oxidation to carboxyl at C 11 .
The iridoid source may be selected from a variety of plant families and species including (referred to as “List A” below in the formulations section of this application): Scrophylariaceae, Rubiaceae, Gentianaceae, Apocynaceae, Adoxaceae, Lamiaceae, Bignoniaceae, Oleaceae, Verbenaceae, Hydrangeaceae, Orobancaceae, Eucommiaceae, Scrophulariaceae, Acanthaceae, Galium verum, Morinda officinalis, Galium melanantherum, Pyrola calliatha, Radix Morindae, Pyrola xinjiangensis, Pyrola elliptica, Coussarea platyphylla, Craibiodendron henryi, Crotalaria emarginella, Cranberry, Saprosma scortechinii, Galium rivale, Arbutus andrachne, G. humifusum, G. paschale, G. mirum, G. macedonicum, G. rhodopeum, G. aegeum, Galium aparine, Vaccinium myrtillus, Vaccinium bracteatum, Bilberry, Blueberry, Olive, Morinda lucida, Lingonberries, Morinda parvifolia, Saprosma scortechinii, Arbutus andrachne, Cornus Canadensis, Cornus suecica, Galium species, Liquidambar formasans, Arbutus andrachne, Rhododendron luteum, Arbutus unedo, Subfamily Rubioideae, S. sagittatum, S. convolvulifolium, Arctostaphylos uva-ursi, Andromeda polifolia, Tripetaleia paniculata, Asperula adorata, Randia canthioides, Tecomella undulate, Thunbergia alata, Thunbergia fragrans, Mentzelia albescens, Deutzia scabra, Verbascum lychnitis, Mentzelia linleyi, Mentzelia lindleyi, Mentzelia lindbeimerii, Mentzelia involucrate, Randia canthioides, Lamiastrum galeobdolon, Teucrium bircanicum, Teucrium arduini, Betonica officinalis, Barleria prionitis, Harpagophytum procumbens, Ajuga decumbens, Anarrhinum orientale, Linaria clementei, Kickxia spuria, Veronicastrum sibiricum, Physostegia virginiana, Betonica officinalis, Clerodendrum thomsonae, Rebmannia glutinosa, Ajuga reptans, Rebmannia glutinosa, Penstemon nemorosus, Capraria biflora, Rogeria adenophylla, Ajuga spectabilis, Avecennia officinalis, Plantago asiatica, Vitex negundo, Penstemon cardwellii, Tecoma cbrysantha, Odontites verna, Verbascum sinuatum, Verbascum nigrum, Verbascum laxum, Buddleja globosa, Vitex agnuscastus, Penstemon eriantberus, Vitex rotundifolia, Euphrasia rostkoviana, Tecoma beptaphylla, Plantago media, Castilleja wightii, Rebmannia glutinosa, Tecoma beptaphylla, Castilleja rbexifolia, Utricularia australis, Verbascum saccatum, Verbascum sinuatum, Verbascum georgicum, Premna odorata, Premana japonica, Verbascum pulverulentum, Scrophularia scopolii, Scropbularia ningpoensis, Veronica officinalis, Besseya plantaginea, Veronicastrum sibiricum, Catalpa speciosa, Tabebuia rosea, Picrorbiza kurrooa, Veronica bellidioides, Penstemon nemorosus, Globularia alypum, Pinguicula vulgaris, Globularia Arabica, Antirrbinum orontium, Retzia capensis, Pbaulopsis imbricate, Macfadyena cynancboides, Paulownia tomentosa, Asystasia bella, Rebmannia glutinosa, Erantbemum pulcbellum, Hygropbila difformis, Boscbniakia rossica, Linaria cymbalaria, Satureja vulgaris, Lamium amplexicaule, Viburnum betulifolium, Viburnum bupebense, Tecoma stans, Plantago arenaria, Campsidium valdivianum, Campsis chinensis, Tecoma capensis, Penstemon pinifolius, Eupbrasia salisburgensis, Clerodendrum incisum, Clerodendrum incisum, Clerodendrum ugandense, Lamourouxia multifida, Nepeta cataria, Argylia radiate, Linaria cymbalaria, Monocbasma savatieri, Veronica anagallis-aquatica, Avicennia offinalis, Avicennia marina, Gentian, pedicellata, Alangium platanifolium, Lonicera coerulea, Swertica japonica, Melampyrum cristatum, Monochasma savatieri, Vitex negundo, Avicennia marina, Tarenna graveolens, Argylia radiate, Veronica anagallis-aquatica, Castilleja integra, Galium verum, Arbutus unedo, Galium mollugo, Andromeda polifolia, Gelsemium sempervirens, Verbena brasiliensis, Gelsemium sempervirens, Randia dumetorum, Penstemon barbatus, Odontites verna, Gentiana verna, Erytbraea centaurium, Gentiana pyrenaica, Desfontainia spinosa, Lonicera periclymenum, Strycbnos roborans, Pedicularis palustris, Penstemon nitidus, Citbarexylum fruticosum, Fouquieria diguetii, Nyctantbes arbortristis, Mussaenda, Besseya plantaginea, Stacbytarpbeta jamaicensis, Cantbium subcordatum, Barleria lupulina, Barleria prionitis, Plectronia odorata, Salvia digitaloides, Stacbytarpbeta mutabilis, Penstemon strictus, Duranta plumeri, Sesamum angolense, Rebmannia glutinosa, Parentucellia viscose, Melampyrum arvense, Gardenia jasminoides, Randia Formosa, Oldenlandia diffusa, Castilleja integra, Eupbrasia rostkoviana, Fouquieria diguetii, Penstemon nitidus, Feretia apodantbera, Randia cantbioides, Asystasia bella, Viburnum urceolatum, Gentiana depressa, Syring a reticulate, Deutzia scabra, Eccremocarpus scaber, Cistanche salsa, Rebmannia glutinosa, Catalpa ovate, Myoporum deserti, Teucrium marum, Gelsemium sempervirens, Viburnum urceolatum, Argylia radiate, Morinda lucida, Thunbergia gandiflora, Thunbergia alata, Thunbergia laurifolia, Mentzelia cordifolia, Angelonia integerrima, Linaria genstifolia, Caryopteris mongholica, Linaria arcusangeli, Leonurus persicus, Tubebuia impetiginosa, Phyllarthron madagascariense, Phsostegia virginiana, Harpagophytum procumbens, Caryopteris clandonensis, Cymbalaria muralis, Scrophularia buergeriana, Caryopteris mongholica, Caryopteris clandonensis, Verbascum undulatum, Globularia dumulosa, Pedicularis artselaeri, Utricularia vulgaris, Pedicularis chinensis, Verbascum phlomoides, Plantago subulata, Clerodendrum inerme, Scrophularia lepidota, Globularia davisiana, Globularia cordifolia, Holmskioldia sanguine, Gmelina philippensis, Scrophularia nodosa, Picrorhiza kurroa, Gmelina arborea, Penstemon newberryi, Asystasia intrusa, Catalpa fructus, Scrophularia scorodonia, Premna subscandens, Catalpa ovate, Verbascum spinosum, Scrophularia auriculata, Scrophularia lepidota, Veronica hederifolia, Tabebuia impetiginosa, Veronica pectinata var. glandulosa, Baleria strigosa, Pedicularis procera, Crescentia cujete, Thunbergia grandiflora, Thunbergia laurifolia, Viburnum suspensum, Pedicularis kansuensis, Nepeta Cilicia, Euphrasia pectinata, Penstemon parryi, Penstemon barrettiae, Tecoma capensis, Pedicularis plicata, Vitex altissima, Veronica anagallis-aquatica, Clerodendrum ineinie, Vitex agnus-castus, Dipsacus asperoides, Chioccoca alba, Alangium lamarckii, Cornus capitata, Strychnos nux-vomica, Alangium platanifolia var. trilobum, Gentiana linearis, Swertia franchetiana, Picconia excels, Clerodendrum inerme, Verbenoxylum reitzii, Leonurus persicus, Avicennia germinans, Canthium berberidifolium, Clerodendrum inerme, Avicennia officinalis, Lippia graveolens, Ajuga pseudoiva, Barleria lupulina, Calycophyllum spruceanum, Phlomis capitata, Phlomis nissolii, Premna barbata, Plantago alpine, Avicennia marina, Galium humifusum, Morinda coreia, Saprosma scortechinii, Plantago atrata, P. maritime, P. subulata, Erinus alpines, Paederia scandens, Tocoyena Formosa, Fagraea blumei, Hedyotis chrysotricha, Paederia scandens, Jasmium hemsleyi, Eucnide bartonioides, Rauwolfia serpentine, Picconi, excels, Gentiana kurroo, Nepeta cadmea, Gmelina philippensis, Penstemon mucronatus, Citharexylum caudatum, Phlomis aurea, Eremostachys glabra, Phlomis rigida, P. tuberose, Pedicularis plicata, Duranta erecta, Bouchea fluminensis, Phlomis brunneogaleata, Barleria lupulina, Zaluzianskya capensis, Thevetia peruviana, Plantago lagopus, Gardenoside (and its acid hydrolysis product), Asperuloside (and its acid hydrolysis product), Canthium schimperianum, Plantago arborescens, P. ovate, P. webbii, Plantago cornuti, Plantago hookeriana, Plantago altissima, Penstemon secudiflorus, Viburnum luzonicum, Galium lovcense, Nyetanthes arbor-tristis, Rothmania macrophylla, Myxopyrun smilacifolium, Nepeta racemosa, Linaria japonica, Viburnum ayavacense, Viburnum tinus, Viburnum rhytidophyllum, Viburnum lantana var. discolor, Viburnum prunifolium, Centranthus longiflorus, Viburnum sargenti, Plumeria obtuse, Dunnia sinensis, Morinda morindoides, Caryopteris clandonensis, Vitex rotundifolia, Globularia dumulosa, Pedicularis artselaeri, Cymbaria mongolica, Pedicularis kansuensis f. albiflora, Phlomis umbrosa, Dunnia sinensis, Gelsemium sempervirens, Verbena littoralis, Syringia afghanica, Tabebuia impetiginosa, Patrinia scabra, Catalpa fructus, Scrophularia lepidota, Lasianthus wallichii, Crescentia cujete, Kickxia elatine, K. spuria, K. commutate, Linaria arcusangeli, L. flava, Coelospermum billardieri, Randia spinosa, Asperula maximowiczii, Wulfenia carinthiaca, Fagraea blumei, Daphniphyllum calycinum, Penstemon ricbardsonii, Nardostachys chinensis, Sambucus ebulus, Penstemon confertus, Sambucus ebulus, Penstemon serrulatus, Penstemon birsutus, Viburnum furcatum, Viburnum betulifolium, Viburnum japonicum, Allamanda neriifolia, Plumeria acutifolia, Allamanda catbartica, Alstonia boonei, Actinidia polygama, Patrinia villosa, Patrinia gibbosa, Posoqueria latifolia, Strycbnos spinosa, Kigelia pinnata, Centrantbus ruber, Cerbera mangbas, Mentzelia spp., Teucrium marum, Eucommia ulmoides, Aucuba japonica, Gelsemium sempervirens, Syring a amurensis, Strychnos spinosa, Lonicera alpigena, Nauclea diderrichii, Olea europaea, Ligustrum japonicum, Swertia japonica, Swertia mileensis, Crucksbanksia verticillata, Gentiana asclepiadea, Jasminum multiflorum, Menyantbes trifoliate, Jasminum mesnyi, Jasminum azoricum, Jasminum sambac, Centaurium erythraea, Centaurium littorale, Gentiana gelida, Gentiana scabra, Jasmium burnile var. revolutum, Syring a vulgaris, Osmantbus ilicifolius, Ligustrum ovalifolium, Ligustrum obtusifolium, Gentiana pyrenaica, Isertia baenkeana, Olea europaea, Osmantbus fragrans, Exacum tetragonum, Hydrangea macrophylla, Hydrangea scandens, Abelia grandiflora, Dipsacus laciniatus, Scaevola racemigera, Erytbraea centaurium, Lisiantbus jefensis, Alyxia reinwardtii, Desfontainia spinosa, Patrinia saniculaefolia, Plantago asiatica, Plantago species, Gentiana species, Hapagophytum species, Pterocephalus perennis subsp. Perennis, Morinda citrifolia , Campsis grandiflora, Heracleum rapula, Syring a dilatata, Bartsia alpine, Hedyotis diffusa, Sickingia williamsii, Buddleja cordobensis, Borreria Verticillata and combinations thereof.
Some embodiments may utilize an iridoid source from any of the parts of the listed plants plant alone, in combination with each other or in combination with other ingredients. For example the leaves including leaf extracts, fruit, bark, seeds including seed oil, roots, oils, juice including the fruit juice and fruit pulp and concentrates thereof, or other product from the list of plants may be utilized as an iridoid source. Thus, while some of the parts of the plants are not mentioned above, some embodiments may use of one or more parts selected from all of the parts of the plant.
Some compositions of the present invention comprise a source of iridoids present between about 1 and 5 percent of the weight of the total composition. Other such percentage ranges include: about 0.01 and 0.1 percent; about 0.1 and 50 percent; about 85 and 99 percent; about 5 and 10 percent; about 10 and 15 percent; about 15 and 20 percent; about 20 and 50 percent; and about 50 and 100 percent.
In some embodiments the source of iridoids may be combined with other ingredients or carriers (discussed further herein) to produce a pharmaceutical grade source of iridoids (“pharmaceutical” herein referring to any drug or product designed to improve the health of living organisms such as human beings or mammals, including nutraceutical products).
In some embodiments various extracts may be utilized from one or more of the plants listed above. In some embodiments the extracts may comprise 7b-Acetoxy-10-O-acetyl-8a-hydroxydecapetaloside (Compound 2),10-Acetoxymajoroside, 7-O-Acetyl-10-O-acetoxyloganin, 6-O-Acetylajugol, 6-O(2_-O-Acetyl-3_-O-cinnamoyl-4_-O-p-methoxy cinnamoyl-a-Lrhamnopyranosyl) catalpol, 6-O-(3_-O-Acetyl-2_-O-trans-cinnamoyl)-a-L-rhamnopyranosyl catalpol, 8-O-Acetylclandonoside, 8-O-Acetyl-6-O-(p-coumaroyl)harpagide, 8-O-Acetyl-6-O-trans-p-coumaroylshanzhiside, 6-Acetyl deacetylasperuloside, 8-O-Acetyl-1-epi-shanzhigenin methyl ester, Acetylgaertneroside, 10-O-Acetylgeniposidic acid, 10-O-Acetyl-8a-hydroxydecapetaloside, 8-O-Acetyl-6b-hydroxyipolamide, 2-O-Acetyllamiridoside, 3-O-Acetylloganic acid, 4-O-Acetylloganic acid, 6-O-Acetylloganic acid, 6b-Acetyl-7b-(E)-p-methoxycinnamoyl-myxopyroside, 6b-Acetyl-7b-(Z)-p-methoxycinnamoyl-myxopyroside, 10-O-Acetylmonotropein, 8-O-Acetylmussaenoside, 10-O-Acetylpatrinoside, 3-O-Acetylpatrinoside, 6-O-Acetylplumieride-p-E-coumarate, 6-O-Acetylplumieride-p-Z-coumarate, 6-O-Acetylscandoside, 8-O-Acetylshanzhigenin methyl ester, 8-O-Acetylshanzhiside, Acuminatuside, Agnucastoside A (6-O-Foliamenthoylmussaenosidic acid), Agnucastoside B (6-O-(6,7-Dihydrofoliamenthoyl)-mussaenosidic acid), Agnucastoside C (7-O-trans-p-Coumaroyl-6-O-trans-caffeoyl-8-epi-loganic acid), Alatoside, Alboside I, Alboside II, Alboside III, Alpinoside, Angeloside, 6-O-b-D-Apiofuranosylmussaenosidic acid, 2-O-Apiosylgardoside, Aquaticoside A (6-O-Benzoyl-8-epi-loganic acid), Aquaticoside B (6-O-p-Hydroxybenzoyl-8-epi-log-anic acid), Aquaticoside C (6-O-Benzoylgardoside), Arborescoside, Arborescosidic acid, Arborside D, Arcusangeloside, Artselaenin A, Artselaenin C, Artselaenin B, Asperuloide A, Asperuloide B, Asperuloide C, Asperulosidic acid ethyl ester, 6-O-a-L-(2-O-Benzoyl,3-O-trans-p-coumaroyl) rhamnopyranosylcatalpol, 10-O-Benzoyldeacetylasperulosidic acid, 6-O-Benzoyl-8-epi-loganic acid, 6-O-Benzoylgardoside, 10-O-Benzoylglobularigenin, 10-Bisfoliamenthoylcatalpol, Blumeoside A Blumeoside B, Blumeoside C, Blumeoside D, Boucheoside, Brunneogaleatoside, 3b-Butoxy-3,4-dihydroaucubin, 6-O-Butylaucubin, 6-O-Butyl-epi-aucubin, 6-O-Caffeoylajugol, 10-O-Caffeoylaucubin, 6-O-trans-Caffeoylcaryoptosidic acid, 10-O-trans-p-Caffeoylcatalpol, 10-O-E-Caffeoylgeniposidic acid, 2-Caffeoylmussaenosidic acid, 6-O-trans-Caffeoylnegundoside, Caryoptosidic acid, Caudatoside A, Caudatoside B, Caudatoside C, Caudatoside D, Caudatoside E, Caudatoside F, Chlorotuberoside, 10-O-(Cinnamoyl)-6-(desacetyl-alpinosidyl)catalpol, 10-O-E-Cinnamoylgeniposidic acid, 8-O-Cinnamoylmussaenosidic acid, 8-Cinnamoylmyoporoside, 7b-Cinnamoyloxyugandoside (Serratoside A), 7-O-trans-p-Coumaroyl-6-O-trans-caffeoyl-8-epi-loganic acid, 6-O-a-L-(2-O-trans-Cinnamoyl)-rhamnopyranosylcatalpol, 6-O-a-L-(3-O-trans-Cinnamoyl)-rhamnopyranosylcatalpol, 6-O-a-L-(4-O-trans-Cinnamoyl)-rhamnopyranosylcatalpol, Citrifolinin A, Citrifolinoside A, Clandonensine, Clandonoside, Clandonoside II, Coelobillardin, 6-O-trans-p-Coumaroyl-8-O-acetylshanzhiside methyl ester, 6-O-cis-p-Coumaroyl-8-O-acetylshanzhiside methyl ester, 6-O-(p-Coumaroyl)antirrinoside, 10-O-cis-p-Coumaroylasystasioside E, 10-O-trans-p-Coumaroylasystasioside E, 6-O-p-Coumaroylaucubin, 6-O-p-trans-Coumaroylcaryoptosidic acid, 6-O-cis-p-Coumaroylcatalpol, 10-O-cis-p-Coumaroylcatalpol, 6-O-trans-p-Coumaroyl-7-deoxyrehmaglutin A, 6-O-cis-p-Coumaroyl-7-deoxyrehmaglutin A, 2-trans-p-Coumaroyldihydropenstemide, 2-O-Coumaroyl-8-epi-tecomoside, 10-O-trans-Coumaroyleranthemoside, 10-O-E-p-Coumaroylgeniposidic acid, 7-O-Coumaroylloganic acid, Crescentin I, Crescentin II, Crescentin III, Crescentin IV, Crescentin V, 6-O-trans-p-Coumaroylloganin, 6-O-cis-p-Coumaroylloganin, 7-O-p-Coumaroylpatrinoside, 2-O-Coumaroylplantarenaloside, 6-O-(4-O-p-Coumaroyl-b-D-xylopyranosyl)-aucubin, 7b-Coumaroyloxyugandoside, Crescentoside A, Crescentoside B, Crescentoside C, Cyanogenic glycoside of geniposidic acid, Daphcalycinosidine A, Daphcalycinosidine B, Davisioside, Deacetylalpinoside (Arborescosidic acid), Dehydrogaertneroside, Dehydromethoxygaertneroside, 5-Deoxyantirrhinoside, 4-Deoxykanokoside A, 4-Deoxykanokoside C, 6-Deoxymelittoside, 5-Deoxysesamoside, Desacetylhookerioside, Des-p-hydroxybenzoylkisasagenol B, 2,3-Diacetylisovalerosidate, 2,3-Diacetylvalerosidate, 6-O-a-L-(2-O-,3-O-Dibenzoyl,4-O-cis-p-coumaroyl) rhamnopyranosylcatalpol, 6-O-a-L-(2-O-,3-O-Dibenzoyl,4-O-trans-p-coumaroyl) rhamnopyranosylcatalpol, 6-O-a-L-(2-O-,3-O-Dibenzoyl)rhamnopyranosylcatalpol, 6a-Dihydrocornic acid, 6b-Dihydrocornic acid, 6-O-(6,7-Dihydrofoliamenthoyl)-mussaenosidic acid, 3,4-Dihydro-3a-methoxypaederoside, 3,4-Dihydro-3b-methoxypaederoside, 3,4-Dihydro-6-O-methylcatalpol, 5,6b-Dihydroxyadoxoside, 2-(2,3-Dihydroxybenzoyloxy)-7-ketologanin, 5b,6b-Dihydroxyboschnaloside, Dimer of paederosidic acid, Dimer of paederosidic acid and paederoside, Dimer of paederosidic acid and paederosidic acid methyl ester, 6-O-(3,4-Dimethoxybenzoyl)crescentin IV 3-O-b-D-glucopyranoside, 10-O-(3,4-Dimethoxy-(E)-cinnamoyl)-aucubin, 10-O-(3,4-Dimethoxy-(Z)-cinnamoyl)-catalpol, 10-O-(3,4-Dimethoxy-(E)-cinnamoyl)-catalpol, 6-O-[3-O-(trans-3,4-Dimethoxycinnamoyl)-a-L-rhamnopyranosyl]-aucubin, Dumuloside, Dunnisinin, Dunnisinoside, Duranterectoside A, Duranterectoside B, Duranterectoside C, Duranterectoside D, 6-epi-8-O-Acetylharpagide, 6-O-epi-Acetylscandoside, 6,9-epi-8-O-Acetylshanzhiside methyl ester, 8-epi-Apodantheroside, 1,5,9-epi-Deoxyloganic acid glucosyl ester, 5,9-epi-7,8-Didehydropenstemoside, (5a-H)-6a-8-epi-Dihydrocornin, 8-epi-Grandifloric acid, 7-epi-Loganin, 8-epi-Muralioside, 5,9-epi-Penstemoside, 3-epi-Phlomurin, 1-epi-Shanzhigenin methyl ester, 8-epi-Tecomoside (7b-Hydroxyplantarenaloside), 7b,8b-Epoxy-8a-dihydrogeniposide, 7,8-Epoxy-8-epi-loganic acid, 6b,7b-Epoxy-8-epi-splendoside, Epoxygaertneroside, Epoxymethoxygaertneroside, Erinoside, 8-O-Feruloylharpagide, 7-O-E-Feruloylloganic acid, 7-O-Z-Feruloylloganic acid, 6-O-E-Feruloylmonotropein, 10-O-E-Feruloylmonotropein, 6-O-trans-Feruloylnegundoside, 6-O-a-L-(4-O-cis-Feruloyl)-rhamnopyranosylcatalpol, 6-O-Foliamenthoylmussaenosidic acid, 2-O-Foliamenthoylplantarenaloside, Formosinoside, 10-O-b-D-Fructofuranosyltheviridoside, Gaertneric acid, Gaertneroside, 6-O-a-D-Galctopyranosylharpagoside, 6-O-a-D-Galactopyranosylsyringopicroside, Gelsemiol-6-trans-caffeoyl-1-glucoside, Globuloside A, Globuloside B, Globuloside C, 3-O-b-D-Glucopyranosylcatalpol, 6-O-(4-O-b-Glucopyranosyl)-trans-p-coumaroyl-8-O-acetylshanzhiside methyl ester, 6-O-a-D-Glucopyranosylloganic acid, 3-O-b-Glucopyranosylstilbericoside, 6-O-a-D-Glucopyranosylsyringopicroside, 3-O-b-D-Glucopyranosylsyringopicroside, 4-O-b-D-Glucopyranosylsyringopicroside, 3-O-b-D-Glucopyranosyltheviridoside, 6-O-b-D-Glucopyranosyltheviridoside, 10-O-b-D-Glucopyranosyltheviridoside, 4-O-Glucoside of linearoside (7-O-(4-O-Glucosyl)-coumaroylloganic acid), Glucosylmentzefoliol, Gmelinoside A, Gmelinoside B, Gmelinoside C, Gmelinoside D, Gmelinoside E, Gmelinoside F, Gmelinoside G, Gmelinoside H, Gmelinoside I, Gmelinoside J, Gmelinoside K, Gmelinoside L, Gmephiloside (1-O-(8-epi-Loganoyl)-b-D-glucopyranose), Grandifloric acid, GSIR-1, Hookerioside, 6a-Hydroxyadoxoside, 6-O-p-Hydroxybenzoylasystasioside, 2-O-p-Hydroxybenzoyl-6-O-trans-caffeoyl-8-epi-loganic acid, 2-O-p-Hydroxybenzoyl-6-O-trans-caffeoylgardoside, 6-0-p-Hydroxybenzoylcatalposide, 3-O-(4-Hydroxybenzoyl)-10-deoxyeucommiol-6-O-b-D-glucopyranoside, 2-O-p-Hydroxybenzoyl-8-epi-loganic acid, 6-O-p-Hydroxybenzoyl-8-epi-loganic acid, 2-O-p-Hydroxybenzoylgardoside, 6-O-p-Hydroxybenzoylglntinoside, 7-O-p-Hydroxybenzoylovatol-1-O-(6_-O-p-hydroxybenzoyl)-b-D-glucopyranoside, 8-0(−2-Hydroxycinnamoyl)harpagide, 5-Hydroxydavisioside, 10-Hydroxy-(5a-H)-6-epi-dihydrocornin, 1b-Hydroxy-4-epi-gardendiol, 6b-Hydroxy-7-epi-loganin, (5a-H)-6a-Hydroxy-8-epi-loganin, 7b-Hydroxy-11-methylforsythide, 6b-Hydroxygardoside methyl ester, 6a-Hydroxygeniposide, 4-Hydroxy-E-globularinin, 7b-Hydroxyharpagide, 5-Hydroxyloganin, 7b-Hydroxyplantarenaloside, Humifusin A, Humifusin B, Inerminoside A, Inerminoside A1, Inerminoside B, Inerminoside C, Inerminoside D, Ipolamidic acid, Iridoid dimer of asperuloside and asperulosidic acid, Iridolactone, Iridolinarin A, Iridolinarin B, Iridolinarin C, Iridolinaroside A, 6-O-Isoferuloyl ajugol, 10-O-trans-Isoferuloylcatalpol, Isosuspensolide E, Isosuspensolide F, Isounedoside, Isovibursinoside II, Isoviburtinoside III, Jashemsloside A, Jashemsloside B, Jashemsloside C, Jashemsloside D, Jashemsloside E (6S-7-O-{6-O-[b-D-apiofuranosyl-(1→6)-b-Dglucopyranosyl]menthiafolioyl}-loganin, Kansuenin, Kansuenoside, 7-Ketologanic acid, Kickxin, Lamidic acid, Lantanoside, Linearoside (7-O-Coumaroylloganic acid), Lippioside I (6-O-p-trans-Coumaroylcaryoptosidic acid), Lippioside II (6-O-trans-Caffeoylcaryoptosidic acid), Loganic acid-6-O-b-D-glucoside, Lupulinoside, Luzonoid A, Luzonoid B, Luzonoid C, Luzonoid D, Luzonoid E, Luzonoid F, Luzonoid G, Luzonoside A, Luzonoside B, Luzonoside C, Luzonoside D, Macedonine, Macrophylloside, 7-O-(6-O-Malonyl)-cachinesidic acid (Malonic ester of 8-hydroxy-8-epiloganic acid), Melittoside 3-O-b-glucopyranoside, 5-O-Menthiafoloylkickxioside, 6-O-Menthiafoloylmussaenosidic acid, Mentzefoliol, 6-O-(4-Methoxybenzoyl)-5,7-bisdeoxycynanchoside, 6-m-Methoxybenzoylcatalpol, 6-O-(4-Methoxybenzoyl)crescentin IV (3-O-b-D-glucopyranoside), 10-044-Methoxybenzoyl)impetiginoside A, 7-O-(p-Methoxybenzoyl)-tecomoside, 6-O-p-Methoxy-trans-cinnamoyl-8-O-acetylshanzhiside methyl ester, 6-O-p-Methoxy-cis-cinnamoyl-8-O-acetylshanzhiside methyl ester, 10-O-trans-p-Methoxycinnamoylasystasioside E, 10-O-cis-p-Methoxycinnamoyl asystasioside E, 10-O-cis-p-Methoxycinnamoylcatalpol, 10-O-trans-p-Methoxycinnamoylcatalpol, 8-O-Z-p-Methoxycinnamoylharpagide, 6-O-Z-p-Methoxycinnamoylharpagide, 8-O-E-p-Methoxycinnamoylharpagide, 6-O-E-p-Methoxycinnamoylharpagide, 1b-Methoxy-4-epi-gardendiol, 1b-Methoxy-4-epi-mussaenin A, 1a-Methoxy-4-epi-mussaenin A, Methoxygaertneroside, 1b-Methoxygardendiol, 4-Methoxy-Z-globularimin, 4-Methoxy-Z-globularinin, 4-Methoxy-E-globularimin, 4-Methoxy-E-globularinin, 6-O-[3-O-(trans-p-Methoxycinnamoyl)-a-L-rhamnopyranosyl]-aucubin, 1b-Methoxylmussaenin A, 6-O-Methyl-epi-aucubin, Muralioside (7b-Hydroxyharpagide), Myxopyroside, Nepetacilicioside, Nepetanudoside, Nepetanudoside B, Nepetanudoside C, Nepetanudoside D, Nepetaracemoside A, Nepetaracemoside B, Ningpogenin (revision of 1-dehydroxy-3,4-dihydroaucubingenin), Officinosidic acid (5-Hydroxy-10-O-(p-methoxycinnamoyl)-adoxosidic acid), Ovatic acid methyl ester-7-O-(6-O-p-Hydroxybenzoye-b-D-glucopyranoside, Ovatolactone-7-O-(6-O-p-hydroxybenzoyl)-b-D-glucopyranoside, 7-Oxocarpensioside, Paederoscandoside, Paederosidic acid methyl ester, Patrinioside, Pedicularis-lactone, Phlomiside, Phlomoidoside (6-O-(4-O-p-Coumaroyl-b-D-xylopyranosyl)-aucubin), Phlomurin, Phlorigidoside A (2-O-Acetyllamiridoside), Phlorigidoside B (8-O-Acetyl-6b-hydroxyipolamide), Phlorigidoside C (5-Deoxysesamoside), Picconioside 1, Picroside IV, Picroside V (6-m-Methoxybenzoylcatalpol), Pikuroside, Plicatoside A, Plicatoside B, Premnaodoroside D, Premnaodoroside E, Premnaodoroside F [isomeric mixture of A and B in ratio (1:1)], Premnaodoroside G (isomeric mixture of (C) and (D)), Premnosidic acid, Proceroside (7-Oxocarpensioside), Randinoside, Saletpangponoside A [6-O-(4-O-b-Glucopyranosyl)-trans-p-coumaroyl-8-O-acetylshanzhiside methyl ester], Saletpangponoside B, Saletpangponoside C, Sammangaoside C (Melittoside 3-O-b-glucopyranoside), Saprosmoside A, Saprosmoside B, Saprosmoside C, Saprosmoside D, Saprosmoside E, Saprosmoside F, Saprosmoside G, Saprosmoside H, Scorodioside (6-O-(3-O-Acetyl-2_-O-trans-cinnamoyl)-a-L-rhamnopyranosyl catalpol), Scrolepidoside, Scrophuloside A1, Scrophuloside A2, Scrophuloside A3, Scrophuloside A4, Scrophuloside A5, Scrophuloside A6, Scrophuloside A7, Scrophuloside A8, Scrophuloside B4 [6-O-(2_-O-Acetyl-3_-O-cinnamoyl-4_-O-p-methoxy cinnamoyl-a-L rhamnopyranosyl)catalpol], Scrovalentinoside, Senburiside III, Senburiside IV, Serratoside A, Serratoside B, Shanzhigenin methyl ester, 6-O-Sinapoyl scandoside methyl ester, Sintenoside, Stegioside I, Stegioside II, Stegioside III, Syringafghanoside, 7,10,2,6-Tetra-O-acetylisosuspensolide F, 7,10,2,3-Tetra-O-acetylisosuspensolide F, 7,10,2 — ,3_-Tetra-O-acetylsuspensolide F, Thunaloside, 7,10,2-Tri-O-acetylpatrinoside, 7,10, 2-Tri-O-acetylsuspensolide F, 6-O-a-L-(2-O-,3-O-,4-O-Tribenzoyl)-rhamnopyranosylcatalpol, 6-O-(3 — ,4 — ,5_-Trimethoxybenzoyl)ajugol, Unbuloside (6-O-[(2-O-trans-Feruloyl)-a-L-rhamnopyranosyl]-aucubin), Urphoside A, Urphoside B, Verbaspinoside (6-O-[(2_-O-trans-Cinnamoyl)-a-L-rhamnopyranosyl]-catalpol), Viburtinoside I, Viburtinoside II, Viburtinoside III, Viburtinoside IV, Viburtinoside V, Viteoid I, Viteoid II, Wulfenoside [(10-O-(Cinnamoylalpinosidyl)-6-(desacetyl-alpinosidyl)-catalpol)], Yopaaoside A, Yopaaoside B, Yopaaoside C, Zaluzioside (6b-Hydroxygardoside methyl ester), Abelioside A, Abelioside A dimethyl acetal, Abelioside B, 10-Acetoxyoleuropein, 2′-O-Acetyldihydropensternide, 2′-O-Acetylpatrinoside, 13-0-Acetylplurnieride, 7-O-Acetylsecologanol, 2′-O-Acetylswert˜amain1, 10-0-Acetylviburnalloside, Actinidialactone, Allarnancin I, Allarncidin A, Allarncidin B, Allamcidin B P-c-glucose, Allarncin, Allaneroside, Allodolicholactone, 3-0-AllosylcerberidoI, 3-O-Allosylcyclocerberidol, 3-0-Allosylepoxycerbeeridol, Alpigenoside, Arnarogentin, Amaroswerin, 6′-O-Apiosylebuloside m, Azoricin, 3, IO-Bis-O-allosylcerberidol, Boonein, 13-0-Caffeoylplurnieride, Centauroside, Cerberic acid, Cerberidol, Cerberinic acid, Cerbinal, Confertoside, 4′-O-cis-p-Cournaroyl-7a-rnorronisi, 4′-O-truns-p-Coumaroyl-7a-rnorronisi, 4′-O-cis-p-Cournaroyl-7P-rnorronisi, 4′-O-truns-p-Cournaroyl-7-morronisi, 13-O-Coumaroylplurnieride, Cyclocerberidol, Decentapicrin A, kentapicrin B, Decentapicrin C, Deglucoserrulatoside, Deglucosyl plumieride, Dehydroiridodialo-P-D-gentiobioside, Dehydroiridomyrrnecin, 5,6-Dehydrojasrninin, Demethyloleuropein, 1-Deoxyeucomrniol, 9′-hxyjasrninigenin, 10-Deoxyptrinoside, 10-Deoxyptrinoside aglycone, 10-Deoxypensternide, 13-Deoxyplumieride, Desacetylcentapicrin, Desfontainic acid, Desfontainoside, 2′,3′-O-Diacetylfurcatoside C, 8,9-Didehydro-7-hydroxydolichodial, Diderroside, 7,7-O-Dihydroebuloside, Dihydrcepinepetalactone, Dihydrofoliamenthin, 8.9-Dihydrojasrninin, Dihydropensternide, P-Dihydroplurnericinic acid glucosyl ester, Dihydroserruloside, Dolichodial, Dolicholactone, Ebuloside, 8-epi-Dihydropensternide, 7-epi-Hydrangenoside A, 7-epi-Hydrangenoside C, 7-epi-Hydrangenoside E, 8-epi-Kingiside, 8-epi-Valerosidate, 7-rpt-Vogeloside, Epoxycerberidol, 11-Ethoxyviburtinal, Eucommioside 1, Eucommioside II, Fliederoside 1,2′-O-Foliarnenthoyldihydropensternide, Furcatoside A, Furcatoside B, Furcatoside C, Gelidoside I, Gelserniol, Gelserniol-1-glucoside, Gelsemiol-3-glucoside, Gentiogenal, Gentiopicral, Gentiopicroside, 7-O-Gentiroylsecologanol, Gibboside, G′-O-˜-˜-Glucosylgentiopicrosid, (7iR)-Haenkeanoside I, (7S)-Haenkeanoside I, Hiiragilide, Hydrangenoside A Hydrangenoside B, Hydrangenoside C, Hydrangenoside D, Hydrangrnoside E, Hydrangenoside F, Hydrangenoside G, 9″-Hydroxyasrnesoside, 9″-Hydroxyjasrnesosldic acid, (7R)-IO-Hydroxyrnorroniside, (7s)-IO-Hydroxymorroniside, 10-Hydroxyoleoside dimethyl ester, 10-Hydroxyoleuropein, Ibotalactone A, Ibotalactone B, Iridodialo-P-D-gentiobioside, Lsoactinidialactone, lsoallarnandicin, lsodehydroiridornyrmecin, Isodihydroepinepetalacton, Isodolichodial, Isoepiiridomyrmecin, (7R)-lsohaenkeanoside, (7S)-lsohaenkeanoside, Lsoligustroside, isoneonepetalactone, Isonuezhenide, Lsooleuropein, 8-lsoplumieride, Isosweroside, Jasrnesoside, Jasminin-10″-O-glucoside, Jasminoside, Jasmisnyiroside, Jasmolactone A, Jasmolactone B, Jasmolactone B dimethylare, Jasmolactone C, Jasmolactone D, Jasmolactone D tetramethylare, Jasmoside, Jiofuran, Jioglutolide, Kingiside aglycone, Laciniatoside V, Latifonin, Ligustaloside A, Ligusraloside B, Ligusraloside B dimethyl acetal, Ligustrosidic acid, Ligustrosidic acid methyl ester, Lilacoside, Lisianthoside, Menthiafolin, Mentzerriol, 7a-Methoxysweroside, 3-0-Methylallamancin, 3-0-Mrthylallamcin, Methyl glucooleoside, Methylgrandifloroside, (7R)-O-Methylhaenkeanoside, (7S)-O-Methylhaenkeanoside, (7R)-O-Methylisohaenkeanosidel, (7S)-O-Mrthylisohaenkranoside, (7R)-O-Methylmorronisidr, (7S)-O-Methylmorroniside, Methyl syramuraldehydate, 6′-O-[(2R)-Methyl-3-veratroyloxypropanoyl, 6′-0-[(2R)-Methyl-3-veratroyloxypropanoyl, 7a-Morroniside, 7P-Morroniside, Nardosrachin, Neonuezhenide, Neooleuropein, 4aa,7a,7a-Nepetalactone, 4aa, 7a, 7a P-Nepetalactone, 4ap, 70,7a P-Nepetalactone, Nepetariasidc, Nepetaside, Norviburtinal, Oleoactcosidr, 7a-morroniside, 7P-morronisidr, Olebechinacoside, Olmnuezhenide, Oleoside dimethyl ester, Oleuropeinic acid, Oleuropeinic acid methyl ester, Oleuroside, Oruwacin, Oxysporone, Patrinalloside, Penstebioside, Penstemide aglycone, Plumenoside, Plumiepoxide, 1a-Plumieride, Plumieride coumarare, Plumieride coumarate glucoside, Plumieridine, Posoquenin, 1a-Protoplumericin A, Protoplumericin A, Protoplumericin B, Pulorarioside, Rehmaglutin, Sambacin, Sambacolignoside, Sambacoside A, Sambacoside E, Sambacoside F, Scabraside, Scaevoloside, Secologanin dimethyl acetal, Secologanol, Secologanoside, Secologanoside dimethyl ester, Secoxyloganin, Serrulatoloside, Serrulatoloside aglycon, Serrulatoside, Serruloside, Stryspinolactone, Suspensolide A, Suspensolide A aglycone, Suspensolide B, Suspensolide C, Swertiamarin, Syringalactonr A, Syringalactonr B, 6′-0-Vanilloyl-8-ept-kingiside, Viburnalloside, Villosol, Villosoloside, Adoxoside, Agnuside, Allarnnmdin, Allamdin, Amaropentin, Antirride, Antirrinoside, Asperuloside, Asperulosidic acid, Aucubin, Aucubin Acetate, Aucuboside, Aucubieenin-1-P-i˜onialtopidc, Haldrinal, Darlerin, Dartsioeide, Iloschnalosiile, Cantleyoside, Caryoptoeide, Catalpol, Catalpol Yonoacetate, Catalposide, Centapicrin, 7-Chlorodeutziol, Cornin, Uaphylloslde, Deacetyl-Asperuloside, Decaloside, Decapetaloside, 5-9 Dehydro-nepetalactcne, Deoxl-amaropentin, 10-Deoxy Aucubin, Deoxyloeanin, Deutziol, Didrovaltrate, Dihydrofoliamenthin, Dihydropenstemide, Dihydroplumericin, 8-Dihydro Plumericinic acid, Durantoride-I, Elenolide, Epoxydeculoside, Erythroccntaurine, IO-Ethylapodanthoside, Eucommiol, Eustomoruside, Eustomoside, Eustoside, Feretoside, Foliamenthin, Forsythide, Forsythide Methyl Ester, llethyl Grandiiloroside, 11-llethyl Isoside, Lllneroeide, Jlioporoeide, 3lononielittoeirle, 316notropein, Monotronein, Jlorroniside, 3luesaenoside, Saucledd, Seomatatabiol, Sepetalactcne, Suzhenide, Jdontoride, Odontosidc Aretate, I Jleuropein, Opulus Iridoid, Opului lridoid, Onin-arin, 7-Clxologanin, I'aederoelde, I'nederoaidic, I'atrinoside, I'lumericin, Lieptoside, Sarracenin, Scabroside, Scandoside, Scandoride, Srrophularioride, Cutellariosid, ecoealioside, Secologanir, Secolopanin, Ecoivloeanin, Shanzhiside llethyl Ester, Specioside, Stilberiecside, Strictoside, Sn-eroside 1, Swertiamnrin, S-lvestroside-I, yl-estroside-II, Svl-estroside-III, Svrineoside, TLretnoeide, Tecomoside, Tecoside, Teucrium, Teucriuni Lactone B, Teucrium Lactone C, Teucriuni Lactone D, Vaccinioside, Valechlorine, Valeridine, Valerosidate and Taltrate, Haqnlpol.
Methods of the present invention comprise the administration and/or consumption of a combination of a processed Morinda citrifolia product and a source of iridoids in an amount designed to produce a desirable physiological response. It will be understood that specific dosage levels of any compositions that will be administered to any particular patient will depend upon a variety of factors, including the patient's age, body weight, general health, gender, diet, time of administration, route of administration, rate of excretion, drug combination, and the severity of the particular diseases undergoing therapy or in the process of incubation.
Studies performed have revealed that Iridoids in combination with a processed Morinda citrifolia product exhibit unexpected synergistic bioactivity including; neuroprotective, anti-tumor, anti-inflammatory, anti-oxidant, cardiovascular, anti-hepatotoxic, choleretic, hypoglycemic, hypolipidemic, antispasmodic, antiviral, antimicrobial, immunomodulator, antiallergic, anti-leishmanial, and molluscicidal effect.
Preferred embodiments are formulated to provide a physiological benefit. For example, some embodiments may provide an anti-inflammatory activity selectively inhibit COX-1/COX-2 and/or by regulating regulate TNF□, Nitric oxide and 5-LOX; regulate immunomodulation by increases IFN- secretion; provide antiallergic activity by inhibiting histamine release; provide anti-arthritic activity by inhibiting human neutrophils, regulating elastase enzyme activity, inhibiting the complement pathway; provide antimicrobial activity by inhibiting the growth of various microbials including gram − and gram + bacteria; providing antifungal activity by inhibiting DNA repair systems; provide anticancer activity by inhibiting cancer cell growth and by being cytotoxic to cancer cells; provide anticoagulant activity by inhibiting platelets aggregations; provide antioxidant activity by providing DPPH scavenging effects; provide antiviral activity including anti-HSV, anti-RSV, and anti-VSV activity; provide antispasmodic activity; provide wound-healing activity by stimulating the growth of human dermal fibroblasts; and provide neuroprotective activities by blocking the release of lactate dehydrogenase (LDH), and enhancing Nerve Growth Factor-potentiating (NGF) activity.
Methods of the present invention also include manufacturing a composition comprising an iridoid source and/or extracts. Each of the methods described above in the discussion relevant to processing the Morinda citrifolia plant products may likewise be utilized to process the constitutive elements of plant being utilized as a source of iridoids.
For example the leaves of one or more of the plants listed above may be processed. For example, some compositions comprise leaf extract and/or leaf juice. Some compositions comprise a leaf serum that is comprised of both leaf extract and fruit juice obtained from one or more plants. Some compositions of the present invention comprise leaf serum and/or various leaf extracts as incorporated into a nutraceutical product (“nutraceutical” herein referring to any product designed to improve the health of living organisms such as human beings or mammals).
In some embodiments of the present invention, the leaf extracts are obtained using the following process. First, relatively dry leaves from the selected plant or plants are collected, cut into small pieces, and placed into a crushing device—preferably a hydraulic press—where the leaf pieces are crushed. In some embodiments, the crushed leaf pieces are then percolated with an alcohol such as ethanol, methanol, ethyl acetate, or other alcohol-based derivatives using methods known in the art. Next, in some embodiments, the alcohol and all alcohol-soluble ingredients are extracted from the crushed leaf pieces, leaving a leaf extract that is then reduced with heat to remove all the liquid therefrom. The resulting dry leaf extract will herein be referred to as the “primary leaf extract.”
In some embodiments, the primary leaf extract is subsequently pasteurized. The primary leaf extract may be pasteurized preferably at a temperature ranging from 70 to 80 degrees Celsius and for a period of time sufficient to destroy any objectionable organisms without major chemical alteration of the extract. Pasteurization may also be accomplished according to various radiation techniques or methods.
In some embodiments of the present invention, the pasteurized primary leaf extract is placed into a centrifuge decanter where it is centrifuged to remove or separate any remaining leaf juice therein from other materials, including chlorophyll. Once the centrifuge cycle is completed, the leaf extract is in a relatively purified state. This purified leaf extract is then pasteurized again in a similar manner as discussed above to obtain a purified primary leaf extract.
Preferably, the primary leaf extract, whether pasteurized and/or purified, is further fractionated into two individual fractions: a dry hexane fraction, and an aqueous methanol fraction. This is accomplished preferably in a gas chromatograph containing silicon dioxide and CH2Cl2-MeOH ingredients using methods well known in the art. In some embodiments of the present invention, the methanol fraction is further fractionated to obtain secondary methanol fractions. In some embodiments, the hexane fraction is further fractionated to obtain secondary hexane fractions.
One or more of the leaf extracts, including the primary leaf extract, the hexane fraction, methanol fraction, or any of the secondary hexane or methanol fractions may be combined with the processed Morinda citrifolia product to obtain a leaf serum. In some embodiments, the leaf serum is packaged and frozen ready for shipment; in others, it is further incorporated into a nutraceutical product as explained herein.
Some embodiments of the present invention include a composition comprising fruit juice from one or more of the listed plants. Each of the methods described above in the discussion relevant to processing the Morinda citrifolia juice products may likewise be utilized to process the fruit of the plant being utilized as a source of iridoids.
Some embodiments comprise the use of seeds from the list of plants provided. Each of the methods described above in the discussion relevant to processing seeds from the Morinda citrifolia plant may likewise be utilized to process the seeds of plant being utilized as a source of iridoids.
Some embodiments of the present invention may comprise oil extracted from the plant and/or plants selected as the source of iridoids. Each of the methods described above in the discussion relevant to processing the Morinda citrifolia plant to produce an oil extract may likewise be utilized to process the constitutive elements of plant being utilized as a source of iridoids.
Compositions and Their Use
The present invention features compositions and methods for providing a desirable physiological effect. Several embodiments of the Morinda citrifolia and iridoid compositions comprise various different ingredients, each embodiment comprising one or more forms of a processed Morinda citrifolia and a source of iridoids as explained herein.
Compositions of the present invention may comprise any of a number of Morinda citrifolia components such as: extract from the leaves of Morinda citrifolia , leaf hot water extract, processed Morinda citrifolia leaf ethanol extract, processed Morinda citrifolia leaf steam distillation extract, Morinda citrifolia fruit juice, Morinda citrifolia extract, Morinda citrifolia dietary fiber, Morinda citrifolia puree juice, Morinda citrifolia puree, Morinda citrifolia fruit juice concentrate, Morinda citrifolia puree juice concentrate, freeze concentrated Morinda citrifolia fruit juice, Morinda citrifolia seeds, Morinda citrifolia seed extracts, extracts taken from defatted Morinda citrifolia seeds, and evaporated concentration of Morinda citrifolia fruit juice in combination with a source of iridoids. Compositions of the present invention may also include various other ingredients. Examples of other ingredients include, but are not limited to: artificial flavoring, other natural juices or juice concentrates such as a natural grape juice concentrate or a natural blueberry juice concentrate; carrier ingredients; and others as will be further explained herein.
Any compositions having the leaf extract from the plant or plants being utilized a as source of iridoids and the Morinda citrifolia leaves, may comprise one or more of the following: the primary leaf extract, the hexane fraction, methanol fraction, the secondary hexane and methanol fractions, the leaf serum, or the nutraceutical leaf product.
In some embodiments of the present invention, active ingredients from the plant or plants being utilized as a source of iridoids and the Morinda citrifolia plant may be extracted out using various procedures and processes. For instance, the active ingredients may be isolated and extracted out using alcohol or alcohol-based solutions, such as methanol, ethanol, and ethyl acetate, and other alcohol-based derivatives using methods known in the art. These active ingredients or compounds may be isolated and further fractioned or separated from one another into their constituent parts. Preferably, the compounds are separated or fractioned to identify and isolate any active ingredients that might help to prevent disease, enhance health, or perform other similar functions. In addition, the compounds may be fractioned or separated into their constituent parts to identify and isolate any critical or dependent interactions that might provide the same health-benefiting functions just mentioned.
Any components and compositions of Morinda citrifolia and/or ingredients from the plant or plants being utilized as a source of iridoids may be further incorporated into a nutraceutical product (again, “nutraceutical” herein referring to any product designed to improve the health of living organisms). Examples of nutraceutical products may include, but are not limited to: topical products, oral compositions and various other products as may be further discussed herein.
Oral compositions may take the form of, for example, tablets, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsions, syrups, or elixirs. Such compositions may contain one or more agents such as sweetening agents, flavoring agents, coloring agents, and preserving agents. They may also contain one or more additional ingredients such as vitamins and minerals, etc. Tablets may be manufactured to contain one or more Morinda citrifolia components and ingredient(s) from the plant or plants being utilized as a source of iridoids in admixture with non-toxic, pharmaceutically acceptable excipients that are suitable for the manufacture of tablets. These excipients may be, for example, inert diluents, granulating and disintegrating agents, binding agents, and lubricating agents. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate may be used.
Aqueous suspensions may be manufactured to contain the Morinda citrifolia components and ingredient(s) from the plant or plants being utilized as a source of iridoids in admixture with excipients suitable for the manufacture of aqueous suspensions. Examples of such excipients include, but are not limited to: suspending agents such as sodium carboxymethyl-cellulose, methylcellulose, hydroxy-propylmethycellulose, sodium alginate, polyvinyl-pyrrolidone, gum tragacanth and gum acacia; dispersing or wetting agents such as a naturally-occurring phosphatide like lecithin, or condensation products of an alkylene oxide with fatty acids such as polyoxyethylene stearate, or condensation products of ethylene oxide with long chain aliphatic alcohols such as heptadecaethylene-oxycetanol, or condensation products of ethylene oxide with partial esters derived from fatty acids and a hexitol such as polyoxyethylene sorbitor monooleate, or condensation products of ethylene oxide with partial esters derived from fatty acids and hexitol anhydrides such as polyethylene sorbitan monooleate.
Typical sweetening agents may include, but are not limited to: natural sugars derived from corn, sugar beets, sugar cane, potatoes, tapioca, or other starch-containing sources that can be chemically or enzymatically converted to crystalline chunks, powders, and/or syrups. Also, sweeteners can comprise artificial or high-intensity sweeteners, some of which may include aspartame, sucralose, stevia, saccharin, etc. The concentration of sweeteners may be between from 0 to 50 percent by weight of the composition, and more preferably between about 1 and 5 percent by weight.
Typical flavoring agents can include, but are not limited to, artificial and/or natural flavoring ingredients that contribute to palatability. The concentration of flavors may range, for example, from 0 to 15 percent by weight of the composition. Coloring agents may include food-grade artificial or natural coloring agents having a concentration ranging from 0 to 10 percent by weight of the composition.
Typical nutritional ingredients may include vitamins, minerals, trace elements, herbs, botanical extracts, bioactive chemicals, and compounds at concentrations from 0 to 10 percent by weight of the composition. Examples of vitamins include, but are not limited to, vitamins A, B1 through B12, C, D, E, Folic Acid, Pantothenic Acid, Biotin, etc. Examples of minerals and trace elements include, but are not limited to, calcium, chromium, copper, cobalt, boron, magnesium, iron, selenium, manganese, molybdenum, potassium, iodine, zinc, phosphorus, etc. Herbs and botanical extracts may include, but are not limited to, alfalfa grass, bee pollen, chlorella powder, Dong Quai powder, Echinacea root, Gingko Biloba extract, Horsetail herb, Indian mulberry, shitake mushroom, spirulina seaweed, grape seed extract, etc. Typical bioactive chemicals may include, but are not limited to, caffeine, ephedrine, L-carnitine, creatine, lycopene, etc.
The ingredients to be utilized in a topical dermal product may include any that are safe for internalizing into the body of a mammal and may exist in various forms, such as gels, lotions, creams, ointments, etc., each comprising one or more carrier agents.
In one exemplary embodiment, a composition of the present invention comprises one or more of a processed Morinda citrifolia component present in an amount by weight between about 0.01 and 100 percent by weight, and preferably between 0.01 and 95 percent by weight in combination with a processed iridoid source present in an amount by weight between about 0.01 and 100 percent by weight, and preferably between 0.01 and 95 percent by weight. Several embodiments of formulations are included in U.S. Pat. No. 6,214,351, issued on Apr. 10, 2001, which are herein incorporated by reference. However, these compositions are only intended to be exemplary, as one ordinarily skilled in the art will recognize other formulations or compositions comprising the processed Morinda citrifolia product.
In another exemplary embodiment, the internal composition comprises the ingredients of: processed Morinda citrifolia fruit juice or puree juice present in an amount by weight between about 0.1-80 percent; a processed source of iridoids present in an amount by weight between about 0.1-20 percent; and a carrier medium present in an amount by weight between about 20-90 percent.
The processed Morinda citrifolia product and/or processed source of iridoids is the active ingredient or contains one or more active ingredients, such as quercetin, rutin, scopoletin, octoanoic acid, potassium, vitamin C, terpenoids, alkaloids, anthraquinones (such as nordamnacanthal, morindone, rubiandin, B-sitosterol, carotene, vitamin A, flavone glycosides, linoleic acid, Alizarin, amino acides, acubin, L-asperuloside, caproic acid, caprylic acid, ursolic acid, and a putative proxeronine and others. Active ingredients may be extracted utilizing aqueous or organic solvents including various alcohol or alcohol-based solutions, such as methanol, ethanol, and ethyl acetate, and other alcohol-based derivatives using any known process in the art. The active iridoid ingredients and/or quercetin and rutin may be present in amounts by weight ranging from 0.01-10 percent of the total formulation or composition. These amounts may be concentrated as well into a more potent concentration in which they are present in amounts ranging from 10 to 100 percent.
The composition comprising Morinda citrifolia and a source of iridoids may be manufactured for oral consumption. It may contain one or more agents selected from the group consisting of sweetening agents, flavoring agents, coloring agents, preserving agents, and other medicinal agents as directed.
The following compositions or formulations represent some of the preferred embodiments contemplated by the present invention.
Formulation One
% Range
Ingredient
30-90
Purified Water
1.0-60
Noni Fruit Juice
0.5-30
Grape Juice Concentrate
0.5-30
Blueberry Juice Concentrate
0.01-3
Olive Leaf Extract
0.1-35
Plant's Extract from List A
Formulation Two
% Range
Ingredients
40-80
Purified Water
1.0-50
Noni Fruit Juice
0.5-30
Apple Juice Concentrate
0.5-25
Mango Juice Concentrate
0.5-20
Passion Fruit Juice Concentrate
0.001-1.0
Natural Flavor
0.001-1.0
Natural Color
0.001-1.0
Oligofructose
0.001-1.0
Fructose
0.001-1.0
Konjac /Xanthan Gum
0.001-1.0
Vegetable Protein Isolate
0.1-35
Plant's Extract from List A
Formulation Three
% Range
B Version
Ingredients
1.0-90
1.0-50
Purified Water
1.0-90
1.0-50
Noni Fruit Juice
0.5-50
0.5-50
Noni Leaf Tea
Formulation Four
% Range
Ingredient
1.0-90
Purified Water
10.-50
Noni Fruit Juice
0.5-50
Noni Leaf Tea
0.1-35
Plants Extract from List A
Formulation Five
% Range
Ingredient
40-80
Purified Water
1.0-50
Noni Fruit Juice
0.5-35
Grape Juice Concentrate
0.5-35
Concord Grape Juice Concentrate
0.001-2
Natural Grape Type Flavor
0.001-3
Konjac /Xanthan Gum
0.1-35
Plant's Extract from List A
Formulation Six
% Range
Ingredient
1.0-90
Purified Water
1.0-90
Noni Fruit Juice
0.5-60
Grape Juice Concentrate
0.5-90
Concord Grape Juice Concentrate
0.001-2
Natural Grape Type Flavor
0.001-3
0.001-1.0
Formulation Seven
% Range
Ingredient
1.0-90
Purified Water
1.0-9
Noni Fruit Juice
0.5-60
Apple Juice Concentrate
0.5-60
Mango Juice Concentrate
0.5-60
Passion Fruit Juice Concentrate
0.001-1.0
Natural Flavor
0.001-1.0
Natural Color
0.001-1.0
Oligofructose
0.001-1.0
Fructose
0.001-1.0
Konjac /Xanthan Gum
0.001-1.0
Vegetable Protein Isolate
Formulation Eight
% Range
Ingredient
50-100%
Morinda citrifolia fruit nectar from pure noni puree from
French Polynesia
3-30%
Natural Grape Juice Concentrate
3-30%
Natural Blueberry Juice Concentrate
0-15%
Vitis vinifera (White Grape) Juice Concentrate
0-5%
Natural Flavors
0-15%
Olea europaea (Olive) Leaf Extract
0-15%
Vaccinium macrocarpum (Cranberry) Juice Concentrate
0-15%
Gum Arabic*
0-15%
Xanthan Gum*
*some sizes exclude these ingredients
Formulation Nine
% Range
Ingredient
50-100%
Morinda citrifolia Fruit Nectar From Pure Noni Puree From
French Polynesia
10-75%
Vitis labrusca (Concord Grape) Juice Concentrate
5-50%
Vitis vinifera (White Grape) Juice Concentrate
0-15%
Gum Arabic*
0-15%
Xanthan Gum*
0-5%
Natural Flavor
*some sizes exclude these ingredients
Formulation Ten
% Range
Ingredient
10-75%
Morinda citrifolia Fruit Nectar From Pure Noni Puree From
French Polynesia
10-75%
Malus pumila (Apple) Juice Concentrate
5-50%
Mangifera indica (Mango) Juice Concentrate
3-30%
Passiflora edulis (Passionfruit) Juice Concentrate
0-5%
Natural Flavor
0-15%
Natural Color or Concentrates (apple, cherry, radish, sweet
potato)
0-15%
Gum Arabic*
0-15%
Xanthan Gum*
0-15%
Oligofructose
0-15%
Fructose
0-15%
Vegetable Protein Isolate
*some sizes exclude these ingredients
Formulation Eleven
% Range
Ingredient
50-100%
Morinda citrifolia (Noni) Fruit Puree
10-75%
Morinda citrifolia (Noni) Leaf Tea
Formulation Twelve
% Range
Ingredient
50-100%
Morinda citrifolia Fruit Nectar From Pure Noni Puree From
French Polynesia
3-30%
Natural Grape Juice Concentrate
3-30%
Natural Blueberry Juice Concentrate
0-5%
Natural Flavors
0-15%
Gum Arabic*
0-15%
Xanthan Gum*
*some sizes exclude these ingredients
Formulation Thirteen
% Range
Ingredient
35-90%
Morinda citrifolia (Noni) Fruit Nectar from Pure Noni Puree
and from Juice Concentrate from French Polynesia
15-60%
Cornus mas (Cornelian Cherry) Puree
5-50%
Cornus officinalis Reconstituted Juice
5-50%
Vitis vinifera (White Grape) Juice Concentrate
5-50%
Vaccinium corymbosum (Blueberry) Juice from Concentrate
0-15%
Prunus cerasus (Red Sour Cherry) Juice Concentrate
0-15%
Vitis labrusca (Concord Grape) Juice Concentrate
0-5%
Natural Flavor
0-15%
Olea europea (Olive) Leaf Extract
0-15%
Vaccinium macrocarpum (Cranberry) Juice Conc.
*some sizes exclude these ingredients
Formulation Fourteen
% Range
Ingredient
35-90%
Morinda citrifolia Fruit Nectar From Pure Noni Puree From
French Polynesia
5-50%
Vitis vinifera (White Grape) Juice Concentrate
3-30%
Malus domestica (Apple) Juice Concentrate
0-15%
Ribes nigrum (Black Currant) Juice Concentrate
0-15%
Vitis labrusca (Concord Grape) Juice Concentrate
0-15%
Vaccinium corymbosum (Blueberry) Juice Concentrate
0-5%
Natural Flavors
0-15%
Rubus idaeus (Red Raspberry) Juice Concentrate
Formulation Fifteen
% Range
Ingredient
50-95%
Water (Aqua/Eau)
0-15%
Polymethylsilsesquioxane
0-20%
Glycerin
0-20%
Propanediol
0-20%
Cyclopentasiloxane
0-20%
Cyclotetrasiloxane
0-20%
Caprylic/Capric Triglyceride
0-20%
Sodium Polyacrylate
0-20%
Dimethicone
0-15%
Hydrogenated Polydecene
0-15%
Butylene Glycol
0-15%
Cyclohexasiloxane
0-15%
Phenoxyethanol
0-15%
Morinda citrifolia (Noni) Leaf Juice
0-15%
PEG/PPG-14/4 Dimethicone
0-15%
Dimethiconol
0-15%
Avena sativa (Oat) Kernel Extract
0-15%
Tropaeolum majus Flower Extract
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Caprylyl Glycol
0-15%
Aminomethyl Propanol
0-15%
Sodium PCA
0-15%
Ethylhexylglycerin
0-15%
Panthenol
0-5%
Trideceth-6
0-5%
Hexylene Glycol
0-5%
Tetrasodium EDTA
0-5%
Fragrance (Parfum)
0-5%
Carbomer
0-5%
Polysorbate 20
0-5%
Sodium Hyaluronate
0-5%
Methylparaben
0-5%
Ethylparaben
0-5%
Propylparaben
0-5%
Butylparaben
0-5%
Isobutylparaben
0-5%
Vegetable Oil
0-5%
Tocopherol
0-5%
Palmitoyl Oligopeptide
0-5%
Palmitoyl Tetrapeptide-7
0-5%
Phospholipids
0-5%
Rosmarinus officinalis (Rosemary) Leaf Extract
0-5%
Tocopheryl Acetate
0-5%
Retinyl Palmitate
0-5%
Ascorbyl Palmitate
0-5%
Quaternium-15
0-5%
EDTA
Formulation Sixteen
% Range
Ingredient
50-95%
Water (Aqua/Eau)
3-30%
Aloe barbadensis Leaf Juice
0-15%
Caprylic/Capric Triglyceride
0-15%
Sinorhizobium meliloti Ferment Filtrate
0-15%
Propanediol
0-15%
Carthamus tinctorius (Safflower) Seed Oil
0-15%
Prunus armeniaca (Apricot) Kernel Oil
0-15%
Glycerin
0-15%
Cetyl Alcohol
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-5%
Glyceryl Stearate
0-5%
PEG-100 Stearate
0-5%
Sodium Polyacrylate
0-5%
Cetearyl Alcohol
0-5%
Phenoxyethanol
0-5%
Cyclopentasiloxane
0-5%
Tocopheryl Acetate
0-5%
Aluminum Starch Octenylsuccinate
0-5%
Avena sativa (Oat) Kernel Extract
0-5%
Cyclotetrasiloxane
0-5%
Ceteareth-20
0-5%
Sodium PCA
0-5%
Hordeum distichon (Barley) Extract
0-5%
Caprylyl Glycol
0-5%
Ethylhexylglycerin
0-5%
Santalum album (Sandalwood) Extract
0-5%
Phellodendron amurense Bark Extract
0-5%
Fragrance (Parfum)
0-5%
Dimethiconol
0-5%
Hexylene Glycol
0-5%
Morinda citrifolia (Noni) Seed Oil
0-5%
Disodium EDTA
0-5%
Cetyl Hydroxyethylcellulose
0-5%
Lecithin
0-5%
Sodium Benzoate
0-5%
Potassium Sorbate
0-5%
Sodium Hyaluronate
0-5%
Trisodium EDTA
0-5%
Tocopherol
0-5%
Vegetable Oil
0-5%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Seventeen
% Range
Ingredient
50-95%
Water (Aqua/Eau)
3-30%
Caprylic/Capric Triglyceride
0-15%
Glycerin
0-15%
Bis-PEG-15 Methyl Ether Dimethicone
0-15%
Behenyl Alcohol
0-15%
Dimethicone
0-15%
Pentylene Glycol
0-15%
Hydroxyethyl Acrylate/Sodium Acryloyldimethyl
Taurate Copolymer
0-15%
Polyglyceryl-3 Stearate
0-15%
Beheneth-5
0-15%
Silica
0-15%
Cetearyl Alcohol
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-10%
Morinda citrifolia (Noni) Seed Oil
0-5%
Phenoxyethanol
0-5%
PEG-40 Hydrogenated Castor Oil
0-5%
Polysorbate 60
0-5%
Caprylyl Glycol
0-5%
Titanium Dioxide
0-5%
Morinda citrifolia (Noni) Leaf Juice
0-5%
Ethylhexylglycerin
0-5%
Hexylene Glycol
0-5%
Tetrahexyldecyl Ascorbate
0-5%
Tocopheryl Acetate
0-5%
Gardenia jasminoides Meristem Cell Culture
0-5%
Olea europaea (Olive) Leaf Extract
0-5%
Disodium EDTA
0-5%
Steareth-20
0-5%
Camellia oleifera Leaf Extract
0-5%
Iron Oxides
0-5%
Retinyl Palmitate
0-5%
Chlorhexidine Digluconate
0-5%
Xanthan Gum
0-5%
N-Hydroxysuccinimide
0-5%
Vegetable Oil
0-5%
Tocopherol
0-5%
Potassium Sorbate
0-5%
Chrysin
0-5%
Palmitoyl Oligopeptide
0-5%
Palmitoyl Tetrapeptide-7
0-5%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Eighteen
% Range
Ingredient
10-75%
Soy Protein Isolate
10-75%
Sugar
3-30%
Inulin (Contains Fructooligosaccharides)
3-30%
Cocoa (processed with alkali)
3-30%
High Oleic Sunflower Oil
0-15%
Corn Syrup Solids
0-15%
Whey Protein Isolate
0-15%
Natural Flavors
0-15%
Milk Protein Concentrate
0-15%
Sodium Caseinate (a Milk Derivative)
0-15%
Maltodextrin
0-15%
Mono & Diglycerides
0-15%
Stevia
0-15%
Dipotassium Phosphate
0-15%
Salt
0-15%
Tricalcium Phosphate
0-15%
Morinda citrifolia (Noni) Fruit Fiber
0-15%
Xanthan Gum
0-15%
Pea Protein Isolate
0-15%
Soy Lecithin
0-15%
Tocopherols
Formulation Nineteen
% Range
Ingredient
10-75%
Soy Protein Isolate
10-75%
Sugar
3-30%
Inulin (Contains Fructo-oligosaccharides)
3-30%
High Oleic Sunflower Oil
3-30%
Corn Syrup Solids
0-15%
Whey Protein Isolate
0-15%
Milk Protein Concentrate
0-15%
Natural and Artificial Flavors
0-15%
Sodium Caseinate (a Milk Derivative)
0-15%
Maltodextrin
0-15%
Mono & Diglycerides
0-15%
Citric Acid
0-15%
Stevia
0-15%
Beta Carotene
0-15%
Dipotassium Phosphate
0-15%
Salt
0-15%
Tricalcium Phosphate
0-15%
Morinda citrifolia (Noni) Fruit Fiber
0-15%
Xanthan Gum
0-15%
Pea Protein Isolate
0-15%
Soy Lecithin
0-15%
Tocopherols
Formulation Twenty
% Range
Ingredient
10-75%
Soy Protein Isolate
10-75%
Sugar
3-30%
Inulin (Contains Fructo-oligosaccharides)
3-30%
High Oleic Sunflower Oil
3-30%
Corn Syrup Solids
0-15%
Whey Protein Isolate
0-15%
Milk Protein Concentrate
0-15%
Natural and Artificial Flavors
0-15%
Sodium Caseinate (a Milk Derivative)
0-15%
Maltodextrin
0-15%
Mono & Diglycerides
0-15%
Stevia
0-15%
Dipotassium Phosphate
0-15%
Salt
0-15%
Tricalcium Phosphate
0-15%
Morinda citrifolia (Noni) Fruit Fiber
0-15%
Xanthan Gum
0-15%
Pea Protein Isolate
0-15%
Soy Lecithin
0-15%
Tocopherols
Formulation Twenty-One
% Range
Ingredient
10-75%
Apple Juice
10-75%
Coconut Water
5-50%
Mango Puree
5-50%
Pineapple Juice
3-30%
Orange Juice
3-30%
Prune Juice
0-15%
Polydextrose
0-15%
Acerola Cherry Juice
0-15%
Passion Fruit Juice
0-15%
Morinda citrifolia (Noni) Fruit Puree
0-15%
Aloe barbadensis ( Aloe Vera ) Gel
0-15%
Natural Flavors
0-15%
Deglycyrrhizinated Licorice
0-15%
Taraxacum officinale (Dandelion)
Root
Formulation Twenty-Two
% Range
Ingredient
35-90%
Sugar
5-50%
Psyllium Husk Fiber
5-50%
Oat Seed Fiber (contains Beta Glucan)
0-15%
Inulin (from Chicory Root)
0-15%
Citric Acid
0-15%
Natural Flavors
0-15%
Maltodextrin
0-15%
Beet Juice (Natural Color)
0-15%
Stevia
0-15%
Turmeric (Natural Color)
0-15%
Dehydrated Lemon Juice
0-15%
Morinda citrifolia (Noni) Fruit Fiber
0-15%
Silicon Dioxide
Formulation Twenty-Three
% Range
Ingredient
35-90%
Sugar
5-50%
Psyllium Husk Fiber
5-50%
Oat Seed Fiber (Contains Beta Glucan)
0-15%
Inulin (from Chicory Root)
0-15%
Citric Acid
0-15%
Natural Flavors
0-15%
Beta Carotene (Natural Color)
0-15%
Maltodextrin
0-15%
Morinda citrifolia (Noni) Fruit Fiber
0-15%
Stevia
0-15%
Dehydrated Orange Juice from
concentrate
Formulation Twenty-Four
% Range
Ingredient
10-50%
Rolled Oats
3-30%
Soy Protein Isolate
3-30%
Rice Flour
3-30%
Salt
0-15%
Coconut
0-30%
Corn Syrup
5-35%
Brown Rice Syrup
0-15%
Glycerin
0-15%
Sea Salt
0-75%
Sugar
0-30%
Chocolate Liquor
0-30%
Cocoa Butter
0-30%
Soya Lecithin (an emulsifer)
0-30%
Vanilla Extract
0-15%
Brown Sugar
0-20%
Natural Flavors
0-15%
High Oleic Sunflower Oil
0-30%
Morinda citrifolia (Noni) Fruit Juice
0-30%
Natural Grape Juice Concentrate
0-30%
Natural Blueberry Juice Concentrate
0-15%
Molasses
5-50%
Fractionated Palm Kernel Oil
5-50%
Cocoa Processed with Alkali
5-50%
Lactose
5-50%
Palm Oil
5-50%
Soy Lecithin (an emulsifer)
5-50%
Vanilla
0-15%
Soy Protein Isolate
0-15%
Lecithin
0-15%
Whey Protein Isolate
0-15%
Whey Protein Concentrate
0-15%
Calcium Caseinate (a milk derivative)
Formulation Twenty-Five
% Range
Ingredient
0-30%
Soy Protein Isolate
0-30%
Rice Flour
0-30%
Salt
0-40%
Rolled Oats
5-50%
Brown Rice Syrup
5-50%
Corn Syrup
0-15%
Glycerin
0-15%
Sugar
5-50%
Peanuts
0-15%
Peanut Salt
0-15%
Peanut Flour
0-15%
Peanut Oil
0-30%
Glucose
3-30%
Sugar
3-30%
Modified Palm Kernel Oil
3-30%
Water
3-30%
Skim Milk Powder
3-30%
Glycerin
3-30%
Soy Lecithin
3-30%
Artificial Flavor
3-30%
Salted Butter
3-30%
Sodium Citrate
3-30%
Fractionated Palm Kernel Oil
3-30%
Cocoa Processed with Alkali
3-30%
Lactose
3-30%
Palm Oil
3-30%
Soy Lecithin (an emulsifer)
3-30%
Vanilla
0-15%
Natural and Artificial Flavor
0-30%
Morinda citrifolia (Noni) Fruit juice
0-30%
Natural Grape Juice Concentrate
0-30%
Natural Blueberry Juice Concentrate
0-30%
Natural Flavors
0-15%
Soy Protein Isolate
0-15%
Lecithin
0-15%
Whey Protein Isolate
0-15%
Whey Protein Concentrate
0-15%
Calcium Caseinate (a milk derivative)
Formulation Twenty-Six
% Range
Ingredient
5-50%
Calcium Carbonate
5-50%
Microcrystalline Cellulose
5-50%
Ascorbic Acid
3-30%
Magnesium Oxide
3-30%
Stearic Acid
3-30%
Zinc Amino Acid Chelate
0-15%
d-alpha Tocopheryl Succinate
0-15%
Selenium Chelate
0-15%
Vitamin B6 (Pyridoxine HCl)
0-15%
Vitamin B1 (Thiamin Mononitrate)
0-15%
Pantothenic Acid (d-Calcium Pantothenate)
0-15%
Maltodextrin
0-15%
Riboflavin
0-15%
Beta Carotene
0-15%
Croscarmellose Sodium
0-15%
Magnesium Stearate
0-15%
Silicon Dioxide
0-15%
Dicalcium Phosphate
0-15%
Coating (Sodium Carboxymethylcellulose,
0-15%
Dextrin, Dextrose, Medium Chain Triglycerides)
0-15%
Niacinamide
0-15%
Chromium Chelate
0-15%
Copper Gluconate
0-15%
Vitamin K1 (Phytonadione)
0-15%
Hydroxypropyl methylcellulose
0-15%
Vitamin D3 (Cholecalciferol)
0-15%
Morinda citrifolia (Noni) Fruit pulp
0-15%
Folic Acid
0-15%
Cellulose
0-15%
Biotin
0-15%
Vitamin B12 (Cyanocobalamine)
Formulation Twenty-Seven
% Range
Ingredient
5-50%
Calcium Carbonate
5-50%
Microcrystalline Cellulose
5-50%
Ascorbic Acid
3-30%
Magnesium Oxide
3-30%
Stearic Acid
3-30%
Selenium Chelate
0-15%
Zinc Amino Acid Chelate
0-15%
d-alpha Tocopheryl Succinate
0-15%
Vitamin B6 (Pyridoxine HCl)
0-15%
Ferrous Chelate
0-15%
Pantothenic Acid (d-Calcium Pantothenate)
0-15%
Vitamin B1 (Thiamin Mononitrate)
0-15%
Riboflavin
0-15%
Maltodextrin
0-15%
Beta Carotene
0-15%
Niacinamide
0-15%
Croscarmellose Sodium
0-15%
Magnesium Stearate
0-15%
Silicon Dioxide
0-15%
Dicalcium Phosphate
0-15%
Coating (Sodium Carboxymethylcellulose,
0-15%
Dextrin, Dextrose, Medium Chain Triglycerides
0-15%
Sodium Citrate)
0-15%
Vitamin K1 (Phytonadione)
0-15%
Chromium Chelate
0-15%
Copper Gluconate
0-15%
Hydroxypropyl methylcellulose
0-15%
Vitamin D3 (Cholecalciferol)
0-15%
Morinda citrifolia (Noni) Fruit Pulp
0-15%
Folic Acid
0-15%
Cellulose
0-15%
Biotin
0-15%
Vitamin B12 (Cyanocobalamin)
Formulation Twenty-Eight
% Range
Ingredient
35-90%
Noni ( Morinda citrifolia ) Fruit Puree
5-50%
Purified Water
5-50%
Methylsulfonylmethane (MSM)
3-30%
Glucosamine HCl
0-15%
Noni ( Morinda citrifolia ) Pulp
0-15%
Soy Lecithin
0-15%
dl-alpha Tocopheryl Acetate (Vitamin E)
0-15%
Flaxseed Oil
0-15%
Priopionic Acid
0-15%
Xanthan Gum
0-15%
Sunflower Oil
0-15%
Mixed Tocopherols
0-15%
Rosemary Extract
Formulation Twenty-Nine
% Range
Ingredient
35-90%
Noni ( Morinda citrifolia ) Fruit Puree
10-75%
Purified Water
0-15%
Noni ( Morinda citrifolia ) Pulp
0-15%
Soy Lecithin
0-15%
dl-alpha Tocopheryl Acetate (Vitamin E)
0-15%
Flaxseed Oil
0-15%
Priopionic Acid
0-15%
Xanthan Gum
0-15%
Sunflower Oil
0-15%
Mixed Tocopherols
0-15%
Rosemary Extract
Formulation Thirty
% Range
Ingredient
50-100%
Water (Aqua)
0-15%
Polyacrylamide
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
2-Phenoxyethanol
0-15%
C13-14 Isoparaffin
0-15%
Caprylyl Glycol
0-15%
Fragrance
0-15%
Laureth-7
0-15%
Potassium Sorbate
0-15%
Tetrasodium EDTA
0-15%
FD&C Red #33
0-15%
Ethanol
0-15%
FD&C Blue #1
0-15%
Sodium Hydroxide
0-15%
Morinda citrifolia (Noni) Leaf Extract
Formulation Thirty-One
% Range
Ingredient
35-90%
Purified Water
10-75%
Noni ( Morinda citrifolia ) Fruit Puree
0-15%
Soy Lecithin
0-15%
Natural Mesquite Smoke Flavor
0-15%
Fish Oil
0-15%
Safflower Oil
0-15%
Flaxseed Oil
0-15%
dl-alpha Tocopheryl Oil (Vitamin E)
0-15%
Microalgae Oil
0-15%
Glucosamine HCl
0-15%
Xanthan Gum
0-15%
Priopionic Acid
0-15%
Cetyl Myristoleate
0-15%
L-Threonine
0-15%
Sunflower Oil
0-15%
Mixed Tocopherols
0-15%
Rosemary Extract
Formulation Thirty-Two
% Range
Ingredient
35-90%
Purified Water
10-75%
Noni ( Morinda citrifolia ) Fruit Puree
0-15%
Natural Mesquite Smoke Flavor
0-15%
Fish Oil
0-15%
Soy Lecithin
0-15%
Safflower Oil
0-15%
dl-alpha Tocopheryl Oil (Vitamin E)
0-15%
Flaxseed Oil
0-15%
Xanthan Gum
0-15%
Microalgae Oil
0-15%
Priopionic Acid
0-15%
Cetyl Myristoleate
0-15%
Sunflower Oil
0-15%
Mixed Tocopherols
0-15%
Rosemary Extract
Formulation Thirty-Three
% Range
Ingredient
10-75%
Water
5-50%
Wheat Flour
5-50%
Noni ( Morinda Citrifolia ) Fruit Puree
5-50%
Chicken Meat
3-30%
Corn Flour
3-30%
Wheat Gluten
0-15%
Sugar
0-15%
Gelatin, tech grade
0-15%
Natural Smoke Flavor
0-15%
Glycerin
0-15%
Dextrose
0-15%
Garlic Powder
0-15%
Safflawer Seed Oil
0-15%
Salt
0-15%
Phosphoric Acid
0-15%
Soy Lecithin
0-15%
Onion Powder
0-15%
Fish Oil
0-15%
Potassium Sorbate
0-15%
Flax seed Oil
0-15%
Caramel Color
0-15%
dl-alpha Tocopheryl Acetate
0-15%
Propionic Acid
0-15%
Xanthan Gum
0-15%
Sunflower Oil
0-15%
Mixed Tocopherols
0-15%
Rosemary Extract
Formulation Thirty-Four
% Range
Ingredient
35-90%
Noni ( Morinda citrifolia ) Fruit Puree
10-75%
Purified Water
0-15%
Noni ( Morinda citrifolia ) Pulp
0-15%
dl-alpha Tocopheryl Oil (Vitamin E)
0-15%
Soy Lecithin
0-15%
Propionic Acid
0-15%
Flaxseed Oil
0-15%
Xanthan Gum
0-15%
Sunflower Oil
0-15%
Mixed Tocopherols
0-15%
Rosemary Extract
Formulation Thirty-Five
% Range
Ingredient
35-90%
Noni ( Morinda citrifolia ) Fruit Puree Organic
10-75%
Water
Formulation Thirty-Six
% Range
Ingredient
50-100%
Noni ( Morinda citrifolia ) Fruit Puree
0-15%
Noni ( Morinda citrifolia ) Pulp
0-15%
dl-alpha Tocopheryl Oil (Vitamin E)
0-15%
Microalgae Oil
0-15%
Propionic Acid
0-15%
Xanthan Gum
0-15%
Sunflower Oil
0-15%
Mixed Tocopherols
0-15%
Rosemary Extract
Formulation Thirty-Seven
% Range
Ingredient
35-90%
Noni ( Morinda citrifolia ) Fruit Puree Organic
10-75%
Water
Formulation Thirty-Eight
% Range
Ingredient
50-100%
Clarified Noni ( Morinda citrifolia ) Fruit Puree
Formulation Thirty-Nine
% Range
Ingredient
50-100%
Clarified Noni ( Morinda citrifolia ) Fruit Puree
Formulation Fourty
% Range
Ingredient
50-100%
Clarified Noni ( Morinda citrifolia ) Fruit Puree
Formulation Fourty-One
% Range
Ingredient
50-100%
Clarified Noni ( Morinda citrifolia ) Fruit Puree
Formulation Fourty-Two
% Range
Ingredient
10-75%
Plant Sterols
5-50%
Calcium Carbonate
5-50%
Vegetable Capsules
3-30%
Microcrystalline Cellulose
3-30%
Acerola Extract ( Malpighia glabra linne )
3-30%
Magnesium Oxide
0-15%
Niacinamide Yeast
0-15%
Maltodextrin
0-15%
Zinc Amino Acid Chelate
0-15%
Biotin Yeast
0-15%
Folic Acid Yeast
0-15%
Pantothenic Acid Yeast
0-15%
Noni ( Morinda citrifolia ) Leaf
0-15%
Noni ( Morinda citrifolia ) Fruit
0-15%
Selenium Chelate
0-15%
Organic Rice Flour
0-15%
Silica
0-15%
d-alpha Tocopheryl Succinate
0-15%
Kelp ( Laminaria digitata )
0-15%
Manganese Chelate
0-15%
Berry Blend (see formula or label for list)
0-15%
Quercetin
0-15%
Riboflavin Yeast
0-15%
Copper Gluconate
0-15%
Modified Food Starch
0-15%
Vitamin B6 Yeast
0-15%
Daikon Sprout ( Raphanus sativus )
0-15%
Kale Sprout ( Brassica oleracea )
0-15%
Broccoli Sprout ( Brassica oleracea )
0-15%
Cabbage Sprout ( Brassica oleracia )
0-15%
Garlic Bulb ( Allium Sativum )
0-15%
Thiamin Yeast
0-15%
Chromium Chelate
0-15%
Vitamin D2 (Ergocalciferol)
0-15%
Natural Beta Carotene
0-15%
Molybdenum Chelate
0-15%
Vitamin B12 Yeast
0-15%
Water
0-15%
Ethyl Cellulose
0-15%
dl-Alpha Tocopherol
Formulation Fourty-Three
% Range
Ingredient
35-90%
Camellia sinensis (Green Tea) Leaf
5-50%
Morinda citrifolia (Noni) Leaf Tea
5-50%
Jasminum odoratissimum (Jasmine) Flowers
Formulation Fourty-Four
% Range
Ingredient
0-100%
Morinda citrifolia (Noni) Leaf
Formulation Fourty-Five
% Range
Ingredient
35-90%
Water (Aqua)
10-75%
Morinda citrifolia (Noni) Leaf Juice
3-30%
Pentylene Glycol
0-15%
Acrylates/C10-30 Alkyl Acrylate Crosspolymer
0-15%
Butylene Glycol
0-15%
Potassium Hydroxide
0-15%
Alcohol
0-15%
Vanilla tahitensis ( Vanilla ) Fruit Extract
0-15%
Phenoxyethanol
0-15%
PEG-8 Laurate
0-15%
Laureth-4
0-15%
Sodium Dehydroacetate
0-15%
Disodium EDTA
0-15%
Morinda citrifolia (Noni) Leaf Extract
0-15%
Fragrance (Parfum)
Formulation Fourty-Six
% Range
Ingredient
35-90%
Water (Aqua)
10-75%
Morinda citrifolia (Noni) Leaf Juice
3-30%
Pentylene Glycol
0-15%
Butylene Glycol
0-15%
Ethoxydiglycol
0-15%
Phenoxyethanol
0-15%
PEG 8 Laurate
0-15%
Laureth-4
0-15%
Sodium Dehydroacetate
0-15%
Disodium EDTA
0-15%
Sodium Citrate
0-15%
Citric Acid
0-15%
Morinda citrifolia (Noni) Leaf Extract
0-15%
Fragrance
0-15%
Vanilla tahitensis ( Vanilla ) Fruit Extract
0-15%
Methylparaben
0-15%
Propylparaben
Formulation Fourty-Seven
% Range
Ingredient
50-100%
Morinda citrifolia (Noni) Seed Oil
0-15%
Vegetable Oil
0-15%
Tocopherol
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Fourty-Eight
% Range
Ingredient
10-75%
Milk Protein Isolate
10-75%
Soy Protein Isolated
10-75%
Whey Protein Isolate
5-50%
Dutch Cocoa
5-50%
Inulin
5-50%
High Oleic Sunflower Oil
0-15%
Cereal Solids/Corn Syrup Solids
0-15%
Natural and Artificial Flavors
0-15%
Egg Albumin
0-15%
Cellulose Gel
0-15%
Salt
0-15%
Lecithin (from Soy and Egg)
0-15%
Sodium Caseinate (A milk derivative)
0-15%
Mono and Diglycerides
0-15%
Dipotassium Phosphate
0-15%
Maltodextrin
0-15%
Silicon Dioxide
0-15%
Sucralose
0-15%
Morinda citrifolia (Noni) Pulp
0-15%
Mixed Tocopherols
0-15%
Magnesium Carbonate
Formulation Fourty-Nine
% Range
Ingredient
10-75%
Fructose
5-50%
Isolated Soy Protein
5-50%
Milk Protein Isolate
5-50%
Whey Protein Isolate
3-30%
Dutch Cocoa
0-15%
Inulin
0-15%
High Oleic Sunflower Oil
0-15%
Cereal Solids/Corn Syrup Solids
0-15%
Natural and Artificial Flavors
0-15%
Egg Albumin
0-15%
Cellulose Gel
0-15%
Salt
0-15%
Sodium Caseinate (A milk derivative)
0-15%
Mono-and Diglycerides
0-15%
Dipotassium Phosphate
0-15%
Malto-dextrin
0-15%
Silicon Dioxide
0-15%
Soy Lecithin
0-15%
Morinda citrifolia (Noni) Pulp
0-15%
Mixed Tocopherols
0-15%
Magnesium Carbonate
Formulation Fifty
% Range
Ingredient
10-75%
Milk Protein Isolate
10-75%
Soy Protein Isolate
10-75%
Whey Protein Isolate
5-50%
High Oleic Sunflower Oil
3-30%
Cereal Solids/Corn Syrup Solids
3-30%
Inulin
0-15%
Artificial Flavors
0-15%
Cellulose Gel
0-15%
Egg Albumin
0-15%
Sodium Caseinate (A milk derivative)
0-15%
Lecithin (from Soy and Egg)
0-15%
Mono and Diglycerides
0-15%
Dipotassium Phosphate
0-15%
Silicon Dioxide
0-15%
Malto-dextrin
0-15%
Sucralose
0-15%
Morinda citrifolia (Noni) Pulp
0-15%
Mixed Tocopherols
Formulation Fifty-One
% Range
Ingredient
10-75%
Fructose
5-50%
Milk Protein Isolate
5-50%
Soy Protein Isolate
5-50%
Whey Protein Isolate
3-30%
Inulin (contains Fructooligosaccharides)
0-15%
High Oleic Sunflower Oil
0-15%
Corn Syrup Solids
0-15%
Artificial Flavors
0-15%
Cellulose Gel
0-15%
Egg Albumin
0-15%
Maltodextrin
0-15%
Sodium Caseinate (a Milk Derivative)
0-15%
Mono and Diglycerides
0-15%
Dipotassium Phosphate
0-15%
Lecithin
0-15%
Tricalcium Phosphate
0-15%
Morinda citrifolia (Noni) Fruit Powder
0-15%
Tocopherols
Formulation Fifty-Two
% Range
Ingredient
35-90%
Corn Syrup
35-90%
Sugar
3-30%
Palm Oil
0-15%
Tahitian Noni ® Blend ( Morinda citrifolia fruit
Juice from pure noni puree from French Polynesia,
Natural Grape Juice Concentrate, Natural
Blueberry Juice Concentrate, Natural Flavors)
0-15%
Mono-and Diglycerides
0-15%
Citric Acid
0-15%
Natural Colors
0-15%
Natural Flavors
0-15%
Soy Lecithin
0-15%
Salt
Formulation Fifty-Three
% Range
Ingredient
35-90%
Corn Syrup
35-90%
Sugar
3-30%
Palm Oil
0-15%
Tahitian Noni ® Blend ( Morinda citrifolia fruit
Juice from pure noni puree from French Polynesia,
Natural Grape Juice Concentrate, Natural
Blueberry Juice Concentrate, Natural Flavors)
0-15%
Mono-and Diglycerides
0-15%
Citric Acid
0-15%
Natural Colors
0-15%
Natural Flavors
0-15%
Soy Lecithin
0-15%
Salt
Formulation Fifty-Four
% Range
Ingredient
35-90%
Morinda citrifolia (Noni) Fruit Juice
5-50%
Hypericum perforatum (St. Johns Wort) Extract
5-50%
Passiflora incarnata (Passion Flower) Extract
3-30%
Morinda citrifolia (Noni) Fruit Pulp
0-15%
Citric acid
Formulation Fifty-Five
% Range
Ingredient
50-100%
Morinda citrifolia (Noni) Fruit Juice
3-30%
Panax ginseng Root Extract
3-30%
Eleutherococcus senticosus Root Extract
0-15%
Schisandra chinensis Fruit Extract
0-15%
Grape Juice Concentrate
0-15%
Apple Juice Concentrate
0-15%
Pear Juice Concentrate
0-15%
Dextrin
0-15%
Citric acid
Formulation Fifty-Six
% Range
Ingredient
35-90%
Morinda citrifolia (Noni) Fruit Juice
5-50%
Morinda citrifolia (Noni) Fruit Pulp
3-30%
Crataegus pinnatifida (Chinese Hawthorn) Berry Extract
0-15%
Commiphora mukul (Guggul) Resin Extract
0-15%
Zingiber officinale (Ginger) Rhizome Extract
0-15%
Coenzyme Q10 (Ubiquinone)
0-15%
Citric acid
Formulation Fifty-Seven
% Range
Ingredient
35-90%
Morinda citrifolia (Noni) Fruit Juice
5-50%
Morinda citrifolia (Noni) Fruit Pulp
5-50%
Glucosamine HCL
0-15%
Curcuma longa (Curcumin) Root Extract
0-15%
Citric acid
Formulation Fifty-Eight
% Range
Ingredient
0-100%
Morinda citrifolia (Noni) Fruit Juice Concentrate
Formulation Fifty-Nine
% Range
Ingredient
35-90%
Morinda citrifolia (Noni) Fruit Juice
5-50%
Morinda citrifolia (Noni) Fruit Pulp
3-30%
Bacopa monnieri ( Bacopa ) Plant Extract
0-15%
Ginkgo biloba ( Ginkgo ) Leaf Extract
0-15%
Lycopodium serratum (Huperzine) Plant Extract
0-15%
Citric acid
Formulation Sixty
% Range
Ingredient
35-95%
Water/Aqua
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Aleurites moluccana (Kukui) Seed Oil
0-15%
Macadamia integrifolia ( Macadamia ) Seed Oil
0-15%
Cetearyl Alcohol
0-15%
Butyrospermum parkii (Shea Butter)
0-15%
Glycerin
0-15%
Glyceryl Stearate
0-15%
PEG-100 Stearate
0-15%
Theobroma cacao (Cocoa) Seed Butter
0-15%
Mangifera indica (Mango) Seed Butter
0-15%
Dimethicone
0-15%
Ceteareth-20
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Fragrance
0-15%
Carbomer
0-15%
Tocopheryl Acetate
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Aminomethyl Propanol
0-15%
Butylene Glycol
0-15%
Potassium Sorbate
0-15%
Disodium EDTA
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Adiantum pedatum (Maidenhair) Extract
0-15%
Citrus aurantifolia (Lime) Fruit Extract
0-15%
Tocopherol
0-15%
Honey Extract
0-15%
Gardenia tahitensis (Tiare) Flower
Formulation Sixty-One
% Range
Ingredient
35-95%
Water/Aqua
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Aleurites moluccana (Kukui) Seed Oil
0-15%
Macadamia integrifolia ( Macadamia ) Seed Oil
0-15%
Cetearyl Alcohol
0-15%
Butyrospermum parkii (Shea Butter)
0-15%
Glycerin
0-15%
Glyceryl Stearate
0-15%
PEG-100 Stearate
0-15%
Mangifera indica (Mango) Seed Butter
0-15%
Theobroma cacao (Cocoa) Seed Butter
0-15%
Dimethicone
0-15%
Ceteareth-20
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Fragrance (Parfum)
0-15%
Carbomer
0-15%
Tocopheryl Acetate
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Aminomethyl Propanol
0-15%
Butylene Glycol
0-15%
Potassium Sorbate
0-15%
Disodium EDTA
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Adiantum pedatum (Maidenhair) Extract
0-15%
Citrus aurantifolia (Lime) Fruit Extract
0-15%
Tocopherol
0-15%
Carica papaya ( Papaya ) Fruit Extract
0-15%
Vanilla tahitensis Fruit Extract
0-15%
Honey Extract
0-15%
Vegetable Oil
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Sixty-Two
% Range
Ingredient
35-95%
Water/Aqua
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Aleurites moluccana (Kukui) Seed Oil
0-15%
Macadamia integrifolia ( Macadamia ) Seed Oil
0-15%
Cetearyl Alcohol
0-15%
Butyrospermum parkii (Shea Butter)
0-15%
Glycerin
0-15%
Glyceryl Stearate
0-15%
PEG-100 Stearate
0-15%
Theobroma Cacao (Cocoa) Seed Butter
0-15%
Mangifera indica (Mango) Seed Butter
0-15%
Dimethicone
0-15%
Ceteareth-20
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Fragrance
0-15%
Carbomer
0-15%
Tocopheryl Acetate
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Aminomethyl Propanol
0-15%
Butylene Glycol
0-15%
Potassium Sorbate
0-15%
Disodium EDTA
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Adiantum pedatum (Maidenhair) Extract
0-15%
Citrus aurantifolia (Lime) Fruit Extract
0-15%
Tocopherol
0-15%
Mangifera indica (Mango) Fruit Extract
0-15%
Bougainvillea glabra ( Bougainvillea ) Flower
Extract
0-15%
Honey Extract
0-15%
Gardenia tahitensis (Tiare) Flower
Formulation Sixty-Three
% Range
Ingredient
35-95%
Water/Aqua
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Aleurites moluccana (Kukui) Seed Oil
0-15%
Macadamia integrifolia ( Macadamia ) Seed Oil
0-15%
Cetearyl Alcohol
0-15%
Butyrospermum parkii (Shea Butter)
0-15%
Glycerin
0-15%
Glyceryl Stearate
0-15%
PEG-100 Stearate
0-15%
Threobroma cacao (Cocoa) Seed Butter
0-15%
Mangifera indica (Mango) Seed Butter
0-15%
Dimethicone
0-15%
Ceteareth-20
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Fragrance (Parfum)
0-15%
Carbomer
0-15%
Tocopheryl Acetate
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Aminomethyl Propanol
0-15%
Butylene Glycol
0-15%
Potassium Sorbate
0-15%
Disodium EDTA
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Adiantum pedatum (Maidenhair) Extract
0-15%
Citrus aurantifolia (Lime) Fruit Extract
0-15%
Tocopherol
0-15%
Prunus persica (Peach) Fruit Extract
0-15%
Carica papaya ( Papaya ) Fruit Extract
0-15%
Vanilla tahitensis ( Vanilla ) Fruit Extract
0-15%
Honey Extract
0-15%
Vegetable Oil
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Sixty-Four
% Range
Ingredient
50-100%
Water/Aqua
0-15%
Decyl Glucoside
0-15%
Cocamidopropyl Hydroxysultaine
0-15%
Cocamidopropyl Betaine
0-15%
Cocamide MIPA
0-15%
Acrylates Copolymer
0-15%
Disodium Laureth Sulfosuccinate
0-15%
Disodium Lauryl Sulfosuccinate
0-15%
Fragrance
0-15%
Glycol Stearate
0-15%
Butylene Glycol
0-15%
Sodium Chloride
0-15%
Potassium Sorbate
0-15%
Sodium Hydroxide
0-15%
Stearamide AMP
0-15%
Disodium EDTA
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Citric Acid
0-15%
Panthenol
0-15%
Methylchloroisothiazolinone and Methylisothiazolinone
0-15%
Macadamia integrifolia ( Macadamia ) Seed Oil
0-15%
Adiantum pedatum (Tropical Fern) Extract
0-15%
Citrus aurantifolia (Lime) Fruit Extract
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Phenoxyethanol
0-15%
Pantolactone
0-15%
Honey Extract
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Tocopherol
0-15%
Glycine Soja (Soybean) Oil
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Sixty-Five
% Range
Ingredient
50-100%
Water/Aqua
0-15%
Decyl Glucoside
0-15%
Cocamidopropyl Hydroxysultaine
0-15%
Cocamidopropyl Betaine
0-15%
Cocamide MIPA
0-15%
Acrylates Copolymer
0-15%
Disodium Laureth Sulfosuccinate
0-15%
Disodium Lauryl Sulfosuccinate
0-15%
Fragrance
0-15%
Butylene Glycol
0-15%
Glycol Stearate
0-15%
Sodium Chloride
0-15%
Potassium Sorbate
0-15%
Sodium Hydroxide
0-15%
Disodium EDTA
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Citric Acid
0-15%
Panthenol
0-15%
Stearic Acid
0-15%
Aminomethyl Propanol
0-15%
Methylchloroisothiazolinone and Methylisothiazolinone
0-15%
Adiantum pedatum (Maidenhair) Extract
0-15%
Citrus aurantifolia (Lime) Fruit Extract
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Phenoxyethanol
0-15%
Carica papaya ( Papaya ) Fruit Extract
0-15%
Vanilla tahitensis ( Vanilla ) Fruit Extract
0-15%
Pantolactone
0-15%
Honey Extract
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Vegetable Oil
0-15%
Tocopherol
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Sixty-Six
% Range
Ingredient
50-100%
Water (Aqua)
0-15%
Decyl Glucoside
0-15%
Cocamidopropyl Hydroxysultaine
0-15%
Cocamidopropyl Betaine
0-15%
Cocamide MIPA
0-15%
Acrylates Copolymer
0-15%
Disodium Laureth Sulfosuccinate
0-15%
Disodium Lauryl Sulfosuccinate
0-15%
Fragrance (Parfum)
0-15%
Butylene Glycol
0-15%
Glycol Stearate
0-15%
Sodium Chloride
0-15%
Potassium Sorbate
0-15%
Sodium Hydroxide
0-15%
Disodium EDTA
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Citric Acid
0-15%
Panthenol
0-15%
Stearic Acid
0-15%
Aminomethyl Propanol
0-15%
Methylchloroisothiazolinone and Methylisothiazolinone
0-15%
Adiantum pedatum (Maidenhair) Extract
0-15%
Citrus aurantifolia (Lime) Fruit Extract
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Phenoxyethanol
0-15%
Bougainvillea glabra ( Bougainvillea ) Flower Extract
0-15%
Mangifera indica (Mango) Fruit Extract
0-15%
Pantolactone
0-15%
Honey Extract
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Vegetable Oil
0-15%
Tocopherol
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Sixty-Seven
% Range
Ingredient
50-100%
Water (Aqua)
0-15%
Decyl Glucoside
0-15%
Cocamidopropyl Hydroxysultaine
0-15%
Cocamidopropyl Betaine
0-15%
Cocamide MIPA
0-15%
Acrylates Copolymer
0-15%
Disodium Laureth Sulfosuccinate
0-15%
Disodium Lauryl Sulfosuccinate
0-15%
Fragrance
0-15%
Butylene Glycol
0-15%
Glycol Stearate
0-15%
Sodium Chloride
0-15%
Potassium Sorbate
0-15%
Sodium Hydroxide
0-15%
Disodium EDTA
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Citric Acid
0-15%
Panthenol
0-15%
Stearic Acid
0-15%
Aminomethyl Propanol
0-15%
Methylchloroisothiazolinone and Methylisothiazolinone
0-15%
Adiantum pedatum (Maidenhair) Extract
0-15%
Citrus aurantifolia (Lime) Fruit Extract
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Phenoxyethanol
0-15%
Carica papaya ( Papaya ) Fruit Extract
0-15%
Prunus persica (Peach) Fruit Extract
0-15%
Vanilla tahitensis ( Vanilla ) Fruit Extract
0-15%
Pantolactone
0-15%
Honey Extract
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Vegetable Oil
0-15%
Tocopherol
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Sixty-Eight
% Range
Ingredient
10-75%
Water (Aqua)
5-50%
Cocos nucifera (Coconut) Oil
5-50%
Elaeis guineensis (Palm) Oil
3-30%
Cyclomethicone
3-30%
Cetearyl Alcohol
3-30%
Glycerin
3-30%
Glyceryl Stearate
3-30%
PEG-100 Stearate
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Citris Aurantium dulcis (Orange) Oil
0-15%
Phenoxyethanol
0-15%
Glycine soja (Soybean) Oil
0-15%
PEG-150 Distearate
0-15%
Chlorphenesin
0-15%
Xanthan Gum
0-15%
Benzoic Acid
0-15%
Cananga odorata (Ylang Ylang) Oil
0-15%
Butylene Glycol
0-15%
Aleurites moluccana (Kukui) Seed Oil
0-15%
Mangifera indica (Mango) Seed Oil
0-15%
Macadamia ternifolia ( Macadamia ) Seed Oil
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Disodium EDTA
0-15%
Sorbic Acid
0-15%
Aminomethyl Propanol
0-15%
Jasminum officinale (Jasmine) Oil
0-15%
Calophyllum tacamahaca (Tamanu) Seed Oil
0-15%
Riboflavin
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Tocopherol
0-15%
Vegetable Oil
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Sixty-Nine
% Range
Ingredient
50-100%
Water/Aqua
0-15%
Cetearyl Alcohol
0-15%
Behentrimonium Methosulfate
0-15%
Cetyl Alcohol
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Dimethicone
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Fragrance (Parfum)
0-15%
Mangifera indica (Mango) Seed Butter
0-15%
Quaternium-91
0-15%
Cinnamidopropyltrimonium Chloride
0-15%
Cetrimonium Methosulfate
0-15%
Hydroxyethylcellulose
0-15%
Panthenol
0-15%
Butylene Glycol
0-15%
Phytantriol
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Potassium Sorbate
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Hydrolyzed Rice Protein
0-15%
Tetrasodium EDTA
0-15%
Citric Acid
0-15%
Sodium Acetate
0-15%
Starches/Sugars in situ
0-15%
DL-Lactone
0-15%
Methylisothiazolinone
0-15%
Sodium Chloride
0-15%
Aminopropanol
0-15%
Phenoxyethanol
0-15%
Cellulose
0-15%
Citrus grandis (Grapefruit) Fruit Extract
0-15%
Sodium Hydroxide
0-15%
Chlorphenesin
0-15%
Ethanedial
0-15%
Glycerin
0-15%
Sorbic Acid
0-15%
Vegetable Oil
0-15%
Tocopherol
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Seventy
% Range
Ingredient
50-100%
Water/Aqua
3-30%
Cetearyl Alcohol
0-15%
Behentrimonium Methosulfate
0-15%
Cetyl Alcohol
0-15%
Dimethicone
0-15%
Macadamia integrifolia ( Macadamia ) Seed Oil
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Mangifera indica (Mango) Seed Butter
0-15%
Quaternium 91
0-15%
Fragrance
0-15%
Cetrimonium Methosulfate
0-15%
Cinnamidoproplytrimonium Chloride
0-15%
Butylene Glycol
0-15%
Hydroxyethylcellulose
0-15%
Panthenol
0-15%
Phytantriol
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Potassium Sorbate
0-15%
Tetrasodium EDTA
0-15%
Citric Acid
0-15%
Glycerin
0-15%
Hydrolyzed Rice Protein
0-15%
Sodium Acetate
0-15%
Hedychium coronium (Awapuhi) Root Extract
0-15%
dl-Lactone
0-15%
Methylisothiazolinone
0-15%
Phenoxyethanol
0-15%
Starches/Sugars in situ
0-15%
Aminopropanol
0-15%
Sodium Chloride
0-15%
Cellulose
0-15%
Pearl Powder
0-15%
Maris Sal (Sea Salt)
0-15%
Aleurites moluccana (Kukui) Seed Extract
0-15%
Plumeria rubra ( Plumeria ) Flower Extract
0-15%
Colocasia antiquorum (Taro) Root Extract
0-15%
Sodium Hydroxide
0-15%
Tocopherol
0-15%
Ethanedial
0-15%
Chlorphenesin
0-15%
Sorbic Acid
Formulation Seventy-One
% Range
Ingredient
50-100%
Water/Aqua
3-30%
Cetearyl Alcohol
0-15%
Behentrimonium Methosulfate
0-15%
Cetyl Alcohol
0-15%
Dimethicone
0-15%
Macadamia integrifolia ( Macadamia ) Seed Oil
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Mangifera indica (Mango) Seed Butter
0-15%
Quaternium-91
0-15%
Fragrance
0-15%
Cetrimonium Methosulfate
0-15%
Panthenol
0-15%
Butylene Glycol
0-15%
Cinnamidopropyltrimonium Chloride
0-15%
Hydroxyethylcellulose
0-15%
Threobroma cacao (Cocoa) Seed Butter
0-15%
Pantethine
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Hydrolyzed Rice Protein
0-15%
Hydrolyzed Soy Protein
0-15%
Potassium Sorbate
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Phytantriol
0-15%
Tetrasodium EDTA
0-15%
Citric Acid
0-15%
Sodium Chloride
0-15%
Sodium Acetate
0-15%
Starches/Sugars in Situ
0-15%
Ficus carica (Fig) Fruit Extract
0-15%
Hedychium coronarium (Awapuhi) Root Extract
0-15%
Citrus aurantifolia (Lime) Fruit Extract
0-15%
dl-Lactone
0-15%
Phenoxyethanol
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Aminopropanol
0-15%
Methylisothiazolinone
0-15%
Chlorphenesin
0-15%
Cellulose
0-15%
Glycerin
0-15%
Sodium Hydroxide
0-15%
Ethanedial
0-15%
Tocopherol
0-15%
Sorbic Acid
0-15%
Vegetable Oil
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Seventy-Two
% Range
Ingredient
50-100%
Water/Aqua
0-15%
Decyl Glucoside
0-15%
Sodium Lauroyl Sarcosinate
0-15%
Cocamidopropyl Hydroxysultaine
0-15%
Cocamidopropyl Betaine
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Cocamide MIPA
0-15%
Sodium Chloride
0-15%
Disodium Laureth Sulfosuccinate
0-15%
Disodium Lauryl Sulfosuccinate
0-15%
Fragrance
0-15%
Butylene Glycol
0-15%
Hexylene Glycol
0-15%
Polyquaternium 10
0-15%
Panthenol
0-15%
Hydrolyzed Rice Protein
0-15%
Potassium Sorbate
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Citric Acid
0-15%
Methylchloroisothiazolinone and Methylisothiazolinone
0-15%
Tetrasodium EDTA
0-15%
Starch/Sugar
0-15%
Citrus grandis (Grapefruit) Fruit Extract
0-15%
Hedychium coronarium (White Ginger) Root Extract
0-15%
Saponaria officinalis (Soapwort) Extract
0-15%
Phenoxyethanol
0-15%
Chlorphenesin
0-15%
Glycerin
0-15%
Sodium Hydroxide
0-15%
Sorbic Acid
Formulation Seventy-Three
% Range
Ingredient
50-100%
Water (Aqua)
0-15%
Decyl Glucoside
0-15%
Sodium Lauroyl Sarcosinate
0-15%
Cocamidopropyl Hydroxysultaine
0-15%
Cocamidopropyl Betaine
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Cocamide MIPA
0-15%
Sodium Chloride
0-15%
Disodium Laureth Sulfosuccinate
0-15%
Disodium Lauryl Sulfosuccinate
0-15%
Fragrance
0-15%
Glycol Distearate
0-15%
Butylene Glycol
0-15%
Polyquaternium-10
0-15%
Hexylene Glycol
0-15%
Panthenol
0-15%
Coco-Glucoside
0-15%
Potassium Sorbate
0-15%
Cocodimonium Hydroxypropyl Hydrolyzed Rice Protein
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Glyceryl Oleate
0-15%
Glyceryl Stearate
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Citric Acid
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Glycerin
0-15%
Methylchloroisothiazolinone and Methylisothiazolinone
0-15%
Tetrasodium EDTA
0-15%
Hedychium coronarium (Awapuhi) Root Extract
0-15%
Saponaria officinalis (Soapwort) Root Extract
0-15%
Benzoic Acid
0-15%
Phenoxyethanol
0-15%
Pearl Powder
0-15%
Maris Sal
0-15%
Sodium Hydroxide
0-15%
Aleurites moluccana (Kukui) Seed Extract
0-15%
Plumeria rubra ( Plumeria ) Flower Extract
0-15%
Colocasia antiquorum (Taro) Root Extract
0-15%
Chlorphenesin
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Sorbic Acid
0-15%
Vegetable Oil
0-15%
Tocopherol
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Seventy-Four
% Range
Ingredient
50-100%
Water/Aqua
0-15%
Decyl Glucoside
0-15%
Sodium Lauroyl Sarcosinate
0-15%
Cocamidopropyl Hydroxysultaine
0-15%
Cocamidopropyl Betaine
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Cocamide MIPA
0-15%
Sodium Chloride
0-15%
Disodium Laureth Sulfosuccinate
0-15%
Disodium Lauryl Sulfosuccinate
0-15%
Fragrance
0-15%
Butylene Glycol
0-15%
Polyquaternium-10
0-15%
Panthenol
0-15%
Hexylene Glycol
0-15%
Potassium Sorbate
0-15%
Hydrolyzed Rice Protein
0-15%
Hydrolyzed Soy Protein
0-15%
Pantethine
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Citric Acid
0-15%
Phytantriol
0-15%
Methylchloroisothiazolinone and Methylisothiazolinone
0-15%
Tetrasodium EDTA
0-15%
Starches/Sugars in Situ
0-15%
Hedychium coronarium (Awapuhi) Root Extract
0-15%
Ficus carica (Fig) Fruit Extract
0-15%
Citrus aurantifolia (Lime) Fruit Extract
0-15%
Phenoxyethanol
0-15%
Aminopropanol
0-15%
dl-Lactone
0-15%
Chlorphenesin
0-15%
Glycerin
0-15%
Sodium Hydroxide
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Sorbic Acid
0-15%
Ananas sativus (Pineapple) Fruit Extract
0-15%
Carica papaya ( Papaya ) Fruit Extract
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Vegetable Oil
0-15%
Tocopherol
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Seventy-Five
% Range
Ingredient
35-90%
Water/Aqua
3-30%
Cetearyl Alcohol
3-30%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Glycerin
0-15%
Prunus amygdalus dulcis (Sweet Almond) Oil
0-15%
Elaeis guineensis (Palm) Oil
0-15%
Butyrospermum parkii (Shea Butter)
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Cetearyl Glucoside
0-15%
Phenoxyethanol
0-15%
Fragrance
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Tocopheryl Acetate
0-15%
Xanthan Gum
0-15%
Potassium Sorbate
0-15%
Retinyl Palmitate
0-15%
Tetrasodium EDTA
0-15%
Caprylyl Glycol
0-15%
Vitis vinifera (Grape) Seed Extract
0-15%
Gardenia tahitensis Flower
0-15%
Ascorbyl Palmitate
0-15%
Sodium Hydroxide
0-15%
Tocopherol
0-15%
Ash
Formulation Seventy-Six
% Range
Ingredient
35-90%
SD Alcohol-40
10-75%
Hydrofluorocarbon 152A
5-50%
Water/Aqua
3-30%
Dimethyl Ether
0-15%
Acrylates Copolymer
0-15%
Aminomethyl Propanol
0-15%
Fragrance
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Linoleamidopropyl Ethyldimonium Ethosulfate
0-15%
Triethyl Citrate
0-15%
AMP-Isostearoyl Hydrolyzed Wheat Protein
0-15%
Cyclomethicone
0-15%
PEG/PPG-17/18 Dimethicone
0-15%
Glycerin
0-15%
Cinnamidopropyltrimonium Chloride
0-15%
Aleurites moluccana (Kukui) Seed Oil
0-15%
Phytantriol
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Panthenol
0-15%
Pyrus malus (Apple) Fruit Extract
0-15%
Hydrolyzed Soy Protein
0-15%
Hydrolyzed Rice Protein
0-15%
Phenoxyethanol
0-15%
Citric Acid
0-15%
Chlorphenesin
0-15%
Tocopherol
0-15%
Sorbic Acid
Formulation Seventy-Seven
% Range
Ingredient
50-100%
Water/Aqua
0-15%
Polyimide-1
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Carbomer
0-15%
Panthenol
0-15%
Polysilicone-15
0-15%
Carthamus tinctorius (Safflower) Seed Oil
0-15%
Aminomethyl Propanol
0-15%
Potassium Sorbate
0-15%
Fragrance
0-15%
Disodium EDTA
0-15%
Aleurites moluccana (Kukui) Seed Oil
0-15%
Phytantriol
0-15%
Macadamia integrifolia ( Macadamia ) Seed Oil
0-15%
Glycerin
0-15%
Pyrus malus (Apple) Fruit Extract
0-15%
Hydrolyzed Soy Protein
0-15%
Hydrolyzed Rice Protein
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Citric Acid
0-15%
Chlorphenesin
0-15%
Sorbic Acid
0-15%
Tocopherol
0-15%
Vegetable Oil
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Seventy-Eight
% Range
Ingredient
5-50%
Milk Protein Isolate
5-50%
Inulin (Contains Fructooligosaccharides)
5-50%
Soy Protein Isolate
3-30%
Dutch Cocoa
3-30%
Citrus Fiber (From Peel & Pulp)
3-30%
Oat Fiber (From Seed)
3-30%
Whey Protein Isolate
3-30%
High Oleic Sunflower Oil
0-15%
Gum Acacia (From Sap)
0-15%
Corn Syrup Solids
0-15%
Soybean Fiber
0-15%
Natural and Artificial Flavors
0-15%
Cellulose Gum
0-15%
Guar Gum
0-15%
Egg Albumin
0-15%
Malto-Dextrin
0-15%
Sodium Caseinate (A Milk Derivative)
0-15%
Salt
0-15%
Mono-and Diglycerides
0-15%
Carrageenan
0-15%
Dipotassium Phosphate
0-15%
Silicon Dioxide
0-15%
Soy Lecithin
0-15%
Potassium Chloride
0-15%
Sucralose (Sweetener)
0-15%
Vitamin C (as Ascorbic Acid and Ascorbyl Palmitate)
0-15%
Morinda citrifolia (Noni) Fruit Fiber
0-15%
Vitamin E (as dl-alpha Tocopheryl Acetate and Mixed
Tocopherols)
0-15%
Dicalcium Phosphate
0-15%
Magnesium Oxide
0-15%
Vitamin A (as Vitamin A Palmitate and Beta-Carotene)
0-15%
Niacin (as Niacinamide)
0-15%
Zinc (as Zinc Oxide)
0-15%
Iron (as Iron Electrolytic)
0-15%
Copper (as Copper Gluconate)
0-15%
Pantothenic Acid (as d-Calcium Pantothenate)
0-15%
Vitamin D (as Cholecalciferol)
0-15%
Hydrogenated Soybean Oil
0-15%
Vitamin B6 (as Pyridoxine Hydrochloride)
0-15%
Sucrose
0-15%
Riboflavin (Vitamin B2)
0-15%
Thiamin (as Thiamine Mononitrate)
0-15%
Vitamin B12 (as Cyanocobalamin)
0-15%
Folic Acid
0-15%
Biotin
0-15%
Iodine (as Potassium Iodide)
0-15%
Sodium Ascorbate
Formulation Seventy-Nine
% Range
Ingredient
5-50%
Milk Protein Isolate
5-50%
Inulin (Contains Fructooligosaccharides)
5-50%
Soy Protein Isolate
3-30%
Oat Fiber (From Seed)
3-30%
Citrus Fiber (From Peel & Pulp)
3-30%
Whey Protein Isolate
3-30%
High Oleic Sunflower Oil
3-30%
Gum Arabic (From Sap)
0-15%
Corn Syrup Solids
0-15%
Soybean Fiber
0-15%
Natural and Artificial Flavors
0-15%
Cellulose Gum
0-15%
Guar Gum
0-15%
Egg Albumin
0-15%
Malto-Dextrin
0-15%
Sodium Caseinate (A Milk Derivative)
0-15%
Salt
0-15%
Mono-and Diglycerides
0-15%
Dipotassium Phosphate
0-15%
Carrageenan
0-15%
Silicon Dioxide
0-15%
Soy Lecithin
0-15%
Potassium Chloride
0-15%
Vitamin C (as Ascorbic Acid, Ascorbyl Palmitate, and
Sodium Ascorbate)
0-15%
Morinda citrifolia (Noni) Fruit Fiber
0-15%
Vitamin E (as dl-alpha Tocopheryl Acetate and Mixed
Tocopherols)
0-15%
Dicalcium Phosphate
0-15%
Sucralose (a Sweetener)
0-15%
Magnesium Oxide
0-15%
Vitamin A (as Vitamin A Palmitate and Beta-Carotene)
0-15%
Niacin (as Niacinamide)
0-15%
Zinc (as Zinc Oxide)
0-15%
Iron (as Iron Electrolytic)
0-15%
Copper (as Copper Gluconate)
0-15%
Dextrin
0-15%
Pantothenic Acid (as d-Calcium Pantothenate)
0-15%
Vitamin D (as Cholecalciferol)
0-15%
Vegetable Oil
0-15%
Vitamin B6 (as Pyridoxine Hydrochloride)
0-15%
Sucrose
0-15%
Riboflavin (Vitamin B2)
0-15%
Thiamin (as Thiamine Mononitrate)
0-15%
Vitamin B12 (as Cyanocobalamin)
0-15%
Folic Acid
0-15%
Biotin
0-15%
Iodine (as Potassium Iodide)
Formulation Eighty
% Range
Ingredient
35-90%
Garcinia Cambogia Fruit Extract
3-30%
Gelatin
3-30%
L-Carnitine
0-15%
Maltodextrin
0-15%
Chromium Chelate
0-15%
Magnesium Stearate
0-15%
Silicon Dioxide
0-15%
Morinda citrifolia (Noni) Fruit Fiber
Formulation Eighty-One
% Range
Ingredient
50-00%
Water (Aqua)
3-30%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Carthamus tinctorius (Safflower) Seed Oil
0-15%
Cetyl Alcohol
0-15%
Glycerin
0-15%
Glyceryl Stearate
0-15%
Progesterone
0-15%
Ethoxydiglycol
0-15%
Stearic Acid
0-15%
Helianthus annuus (Sunflower) Seed Oil
0-15%
Sodium Stearoyl Lactylate
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Triethanolamine
0-15%
Carbomer
0-15%
Polysorbate 20
0-15%
Hydrogenated Lecithin
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Tocopheryl Acetate
0-15%
Disodium EDTA
0-15%
Sorbic Acid
0-15%
Tocopherol
Formulation Eighty-Two
% Range
Ingredient
35-90%
Calcium Carbonate
5-50%
Magnesium Oxide
5-50%
Microcrystalline Cellulose
0-15%
Maltodextrin
0-15%
Calcium Citrate
0-15%
Croscarmellose Sodium
0-15%
Morinda citrifolia (Noni) Fruit Fiber
0-15%
Water
0-15%
HPMC, Maltodextrin, Fractionated Coconut Oil
0-15%
Magnesium Stearate
0-15%
Silicon Dioxide
0-15%
Vitamin D (as Cholecalciferol)
Formulation Eighty-Three
% Range
Ingredient
50-100%
Water
0-15%
TNJ Concentrate
0-15%
Iti White Guava Puree #3100
0-15%
Encore Orange Juice Concentrate
0-15%
Milne Cranberry Juice Conc. Essence Ret. 50 Brix
0-15%
NW Naturals Pineapple Ju. Conc #19666
0-15%
Milne Concord Grape Ju. Conc. 68 Brix Essnce Ret.
0-15%
Tree Top Apple Juice Conc. TTA01
0-15%
Tree Top Pear Juice Conc. TTP01
0-15%
Roche Vitamin Premix # XR13338000 no biotin/Vit E
Beta Carotene (Vitamin A)
Ascorbic Acid (Vitamin C)
Cholecalciferol (Vitamin D3)
Thiamine Mononitrate (Vitamin B1)
Riboflavin (Vitamin B2)
Niacinamide (Vitamin B3)
Pyridoxine Hydrochloride (Vitamin B6)
Folic Acid (Vitamin B9)
Cyanocobalamin (Vitamin B12)
Calcium Pantothenate (Vitamin B5)
Maltodextrin (Carrier)
Formulation Eighty-Four
% Range
Ingredient
35-90%
Fish Oil (300/200 EPH/DHA
5-50%
Morinda citrifolia (Noni) Seed Oil
5-50%
Flax Seed Oil
0-15%
Borage Oil
0-15%
Vitamin E (d-Alpha Tocopheryl Acetate)
0-15%
Evening Primrose Oil
0-15%
Black Currant Seed Oil
Formulation Eighty-Five
% Range
Ingredient
35-90%
Soy Protein Concentrate
10-75%
Soy Protein Isolate
3-30%
Dutch Cocoa
0-15%
Calcium Carbonate
0-15%
High Oleic Sunflower Oil
0-15%
Calcium Phosphate
0-15%
Corn Syrup Solids
0-15%
Maltodextrin
0-15%
Salt
0-15%
Natural and Artificial Flavors
0-15%
Soy Lecithin
0-15%
Sodium Caseinate
0-15%
Sucralose
0-15%
Mono and Diglycerides
0-15%
Dipotassium Phosphate
0-15%
Tricalcium Phosphate
0-15%
Malic Acid
0-15%
Morinda citrifolia (Noni) Fruit Fiber
0-15%
Mixed Tocopherols
Formulation Eighty-Six
% Range
Ingredient
35-90%
Soy Protein Concentrate
10-75%
Soy Protein Isolate
0-15%
Calcium Carbonate
0-15%
High Oleic Sunflower Oil
0-15%
Corn Syrup Solids
0-15%
Maltodextrin
0-15%
Salt
0-15%
Natural and Artificial Flavors
0-15%
Soy Lecithin
0-15%
Sodium Caseinate
0-15%
Sucralose
0-15%
Mono and Diglycerides
0-15%
Dipotassium Phosphate
0-15%
Tricalcium Phosphate
0-15%
Silicon dioxide
0-15%
Malic Acid
0-15%
Vitamin A (from beta-carotene
0-15%
Morinda citrifolia (Noni) Fruit Fiber
0-15%
Mixed Tocopherols
Formulation Eighty-Seven
% Range
Ingredient
10-75%
Soy Protein Concentrate
10-75%
Soy Protein Isolate
0-15%
Calcium Carbonate
0-15%
High Oleic Sunflower Oil
0-15%
Calcium Phosphate
0-15%
Corn Syrup Solids
0-15%
Maltodextrin
0-15%
Natural Flavors
0-15%
Soy Lecithin
0-15%
Salt
0-15%
Sodium Caseinate
0-15%
Mono and Diglycerides
0-15%
Dipotassium Phosphate
0-15%
Tricalcium Phosphate
0-15%
Sucralose
0-15%
Malic Acid
0-15%
Morinda citrifolia (Noni) Fruit Fiber
0-15%
Mixed Tocopherols
Formulation Eighty-Eight
% Range
Ingredient
10-75%
Maltodextrin (tableting excipient)
5-50%
Microcrystalline cellulose (tableting excipient)
5-50%
Vitamin E (as d-alpha-tocopherol Acid Succinate)
3-30%
Vegetable oil and Cellulose (coating excipient)
3-30%
Ascorbic Acid
0-15%
Coral Calcium
0-15%
Croscarmellose sodium (tableting excipient)
0-15%
Dicalcium Phosphate (carrier)
0-15%
Red clover Extract ( Trifolium pratense )
0-15%
Pyridoxine Hydrochloride
0-15%
Silicon Dioxide (excipient)
0-15%
Chasteberry Extract ( Vitex agnus - catus )
0-15%
Inositol
0-15%
P-Amino Benzoic Acid (PABA)
0-15%
Choline Bitartrate
0-15%
Magenesium oxide
0-15%
Black Cohosh Dry Extract ( Cimicifuga racemosa )
0-15%
Selenium Yeast
0-15%
Calcium D-pantothenate
0-15%
Stearic Acid (tableting excipient)
0-15%
Ferric Fumarate
0-15%
Calendula Flower Extract ( Calendula officinalis )
0-15%
Coating agent (dextrin, dextrose, lecithin, SCMC, sodium
citrate)
0-15%
Boron Amino Acid Chelate
0-15%
Zinc oxide
0-15%
Magnesium Stearate
0-15%
Copper gluconate
0-15%
Manganese Amino Acid Chelate
0-15%
Beta carotene
0-15%
Niacinamide
0-15%
Niacin
0-15%
Vanadium Amino Acid Chelate
0-15%
Coating agent (Methylcellulose and glycerin)
0-15%
Retinyl palmitate
0-15%
Cholecalciferol
0-15%
Noni Fruit pulp ( Morinda citrifola )
0-15%
Chromium Amino Acid Chelate
0-15%
Molybdenum Amino Acid Chelate
0-15%
Thiamine Mononitrate
0-15%
Riboflavin
0-15%
Cyanocobalamin
0-15%
Folic Acid
0-15%
Biotin
0-15%
Potassium Iodide
Formulation Eighty-Nine
% Range
Ingredient
10-75%
Ricinus communis (Castor) Seed Oil
5-50%
Ozokerite
5-50%
Hydrogenated Castor Oil
3-30%
Ethylhexyl Methoxycinnamate **Octinoxate
3-30%
Euphorbia cerifera (Candelilla) Wax
3-30%
Sorbitan Oleate
0-15%
Benzophenone-3 **Oxybenzone
0-15%
Flavor
0-15%
Butyrospermum parkii (Shea Butter)
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Aleurites moluccana (Kukui) Seed Oil
0-15%
Macadamia ternifolia ( Macadamia ) Seed Oil
0-15%
Sodium Saccharin
0-15%
Phenoxyethanol
0-15%
Prunus amygdalus dulcis (Sweet Almond) Oil
0-15%
Menthol
0-15%
Camphor
0-15%
Tocopheryl Acetate
0-15%
Tocopherol
0-15%
Vegetable Oil
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Ninety
% Range
Ingredient
50-100%
Ricinus communis (Castor) Seed Oil
5-50%
Ozokerite
5-50%
Hydrogenated Castor Oil
3-30%
Ethylhexyl Methoxycinnamate **Octinoxate
3-30%
Euphorbia cerifera (Candelilla) Wax
3-30%
Sorbitan Oleate
0-15%
Benzophenone-3 **Oxybenzone
0-15%
Flavor
0-15%
Butyrospermum parkii (Shea Butter)
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Aleurites moluccana (Kukui) Seed Oil
0-15%
Macadamia ternifolia ( Macadamia ) Seed Oil
0-15%
Sodium Saccharin
0-15%
Phenoxyethanol
0-15%
Prunus amygdalus dulcis (Sweet Almond) Oil
0-15%
Menthol
0-15%
Camphor
0-15%
Tocopheryl Acetate
0-15%
Tocopherol
0-15%
Vegetable Oil
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Ninety-One
% Range
Ingredient
10-75%
Ricinus communis (Castor) Seed Oil
5-50%
Ozokerite
5-50%
Hydrogenated Castor Oil
3-30%
Ethylhexyl Methoxycinnamate **Octinoxate
3-30%
Euphorbia cerifera (Candelilla) Wax
3-30%
Sorbitan Oleate
0-15%
Benzophenone-3 **Oxybenzone
0-15%
Flavor
0-15%
Butyrospermum parkii (Shea Butter)
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Aleurites moluccana (Kukui) Seed Oil
0-15%
Macadamia ternifolia ( Macadamia ) Seed Oil
0-15%
Sodium Saccharin
0-15%
Phenoxyethanol
0-15%
Prunus amygdalus dulcis (Sweet Almond) Oil
0-15%
Menthol
0-15%
Camphor
0-15%
Tocopheryl Acetate
0-15%
Tocopherol
0-15%
Vegetable Oil
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Ninety-Two
% Range
Ingredient
50-100%
Water (Aqua)
3-30%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Carthamus tinctorius (Safflower) Seed Oil
0-15%
Cetyl Alcohol
0-15%
Glycerin
0-15%
Glyceryl Stearate
0-15%
Progesterone
0-15%
Ethoxydiglycol
0-15%
Stearic Acid
0-15%
Helianthus annuus (Sunflower) Seed Oil
0-15%
Sodium Stearoyl Lactylate
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Carbomer
0-15%
Polysorbate 20
0-15%
Hydrogenated Lecithin
0-15%
Triethanolamine
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Tocopheryl Acetate
0-15%
Disodium EDTA
0-15%
Sorbic Acid
0-15%
Diethanolamine
0-15%
Vegetable Oil
0-15%
Tocopherol
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation Ninety-Three
% Range
Ingredient
10-75%
Sodium Cocoate
10-75%
Glycerin
5-50%
Deionized Water
5-50%
Sodium Castorate
3-30%
Sodium Safflowerate
3-30%
Sorbitol
3-30%
Avena sativa (Oat) Kernel Flour
0-15%
Fragrance
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Aloe barbadensis ( Aloe ) Leaf Juice
Formulation Ninety-Four
% Range
Ingredient
10-75%
Sodium Cocoate
10-75%
Aqua (Water)
10-75%
Glycerin
5-50%
Sodium Castorate
3-30%
Sodium Safflowerate
0-15%
Sorbitol
0-15%
Fragrance
0-15%
Morinda citrifolia (Noni) Puree
0-15%
Aloe barbadensis ( Aloe ) Leaf Juice
0-15%
Cocos nucifera (Coconut) Extract
0-15%
Cyamopsis tetragonoloba (Guar) Gum
0-15%
Methyl Paraben
0-15%
Sodium Benzoate
0-15%
Potassium Sorbate
0-15%
Sodium Metabisulfate
0-15%
Titanium Dioxide
0-15%
Aluminum Hydroxide
0-15%
Silica
Formulation Ninety-Five
% Range
Ingredient
10-75%
Sodium Cocoate
10-75%
Water (Aqua)
10-75%
Glycerin
5-50%
Sodium Castorate
3-30%
Sodium Safflowerate
0-15%
Sorbitol
0-15%
Fragrance (Parfum)
0-15%
Morinda citrifolia (Noni) Fruit Puree
0-15%
Aloe barbadensis ( Aloe ) Leaf Juice
0-15%
Carica papaya ( Papaya ) Fruit Extract
0-15%
Propylene Glycol
0-15%
Methylparaben
0-15%
Sodium Benzoate
0-15%
Potassium Sorbate
0-15%
Sodium Metabisulfite
0-15%
Titanium Dioxide
0-15%
Helianthus annuus (Sunflower) Seed Oil
0-15%
Lecithin
0-15%
Beta-Carotene
0-15%
Hydrogenated Vegetable Glycerides Citrate
0-15%
Ascorbic Acid
0-15%
Ascorbyl Palmitate
0-15%
Tocopherol
0-15%
Aluminum Hydroxide
0-15%
Hydrated Silica
Formulation Ninety-Six
% Range
Ingredient
10-75%
Sodium Cocoate
10-75%
Water (Aqua)
10-75%
Glycerin
5-50%
Sodium Castorate
3-30%
Sodium Safflowerate
0-15%
Sorbitol
0-15%
Fragrance (Parfum)
0-15%
Morinda citrifolia (Noni) Fruit Puree
0-15%
Aloe barbadensis ( Aloe ) Leaf Juice
0-15%
Laminaria digitata (Seaweed) Extract
0-15%
Propylene Glycol
0-15%
Methylparaben
0-15%
Sodium Benzoate
0-15%
Potassium Sorbate
0-15%
Sodium Metabisulfite
0-15%
Titanium Dioxide
0-15%
Chlorophyllin-Copper Complex
0-15%
Aluminum Hydroxide
0-15%
Hydrated Silica
Formulation Ninety-Seven
% Range
Ingredient
10-75%
Sodium Cocoate
10-75%
Water (Aqua)
10-75%
Glycerin
5-50%
Sodium Castorate
3-30%
Sodium Safflowerate
0-15%
Sorbitol
0-15%
Fragrance (Parfum)
0-15%
Morinda citrifolia (Noni) Fruit Puree
0-15%
Aloe barbadensis ( Aloe ) Leaf Juice
0-15%
Laminaria digitata (Seaweed) Extract
0-15%
Propylene Glycol
0-15%
Methylparaben
0-15%
Sodium Benzoate
0-15%
Potassium Sorbate
0-15%
Sodium Metabisulfite
0-15%
Titanium Dioxide
0-15%
Chlorophyllin-Copper Complex
0-15%
Aluminum Hydroxide
0-15%
Hydrated Silica
Formulation Ninety-Eight
% Range
Ingredient
35-90%
Water/Aqua
3-30%
*Octinoxate (Ethylhexylmethoxycinnamate)
3-30%
*Homosalate
3-30%
*Octisalate (Ethylhexyl Salicylate)
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Glyceryl Stearate SE
0-15%
*Oxybenzone (Benzophenone-3)
0-15%
C12-15 Alkyl Benzoate
0-15%
Glycerin
0-15%
*Avobenzone (Butylmethoxydibenzoylmethane)
0-15%
Cetearyl Alcohol
0-15%
Dimethicone
0-15%
Ceteareth-20
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Prunus amygdalus dulcis (Sweet Almond) Oil
0-15%
Butyrospermum parkii (Shea Butter)
0-15%
Elaeis guineensis (Palm) Oil
0-15%
Tocopheryl Acetate
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Carbomer
0-15%
Fragrance
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Potassium Sorbate
0-15%
Ascorbyl Palmitate
0-15%
Disodium EDTA
0-15%
Sodium Hydroxide
0-15%
Retinyl Palmitate
0-15%
Vitis vinifera (Grape) Seed Extract
0-15%
Tocopherol
0-15%
Gardenia tahitensis (Tiare) Flower
Formulation Ninety-Nine
% Range
Ingredient
50-100%
Water/Aqua
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Polysorbate 20
0-15%
Glycerin
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Panthenol
0-15%
Ethoxydiglycol
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Potassium Sorbate
0-15%
Fragrance
0-15%
Disodium EDTA
0-15%
Butylene Glycol
0-15%
Macrocystis pyrifera (Sea Kelp) Extract
0-15%
Avena sativa (Oat) Kernel Extract
0-15%
Morinda citrifolia (Noni) Leaf Extract
0-15%
Citric Acid
0-15%
Sodium Hyaluronate
0-15%
Ascorbic Acid
0-15%
Tocopheryl Acetate
0-15%
Retinyl Palmitate
0-15%
Tocopherol
Formulation One Hundred
% Range
Ingredient
50-100%
Water/Aqua
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Polysorbate 20
0-15%
Glycerin
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Panthenol
0-15%
Ethoxydiglycol
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Potassium Sorbate
0-15%
Fragrance
0-15%
Disodium EDTA
0-15%
Butylene Glycol
0-15%
Macrocystis pyrifera (Sea Kelp) Extract
0-15%
Avena sativa (Oat) Kernel Extract
0-15%
Morinda citrifolia (Noni) Leaf Extract
0-15%
Citric Acid
0-15%
Sodium Hyaluronate
0-15%
Ascorbic Acid
0-15%
Tocopheryl Acetate
0-15%
Retinyl Palmitate
0-15%
Tocopherol
Formulation One Hundred One
% Range
Ingredient
50-100%
Water/Aqua
3-30%
Decyl Glucoside
0-15%
Cocamidopropyl Hydroxysultaine
0-15%
Cocamidopropyl Betaine
0-15%
Cocamide MIPA
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Disodium Laureth Sulfosuccinate
0-15%
Disodium Lauryl Sulfosuccinate
0-15%
Sodium Chloride
0-15%
Fragrance
0-15%
Butylene Glycol
0-15%
Hexylene Glycol
0-15%
Potassium Sorbate
0-15%
Disodium EDTA
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Panthenol
0-15%
Methylchloroisothiazolinone and
Methylisothiazolinone
0-15%
Citric Acid
0-15%
Adiantum pedatum (Maidenhair) Extract
0-15%
Citrus aurantifolia (Lime) Fruit Extract.
0-15%
Phenoxyethanol
0-15%
Honey Extract
0-15%
Tocopheryl Acetate
0-15%
Ascorbic Acid
0-15%
Retinyl Palmitate
0-15%
Tocopherol
Formulation One Hundred Two
% Range
Ingredient
50-100%
Water/Aqua
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Polyacrylate
0-15%
Salicylic Acid
0-15%
Allyl Methacrylates crosspolymer
0-15%
Phenoxyethanol
0-15%
Polyisobutene
0-15%
Caprylyl Glycol
0-15%
Salix nigra (Willow) Bark Extract
0-15%
Modified Amorphophallus Konjac ( Konjac ) Root Extract
0-15%
Polysorbate 20
0-15%
Potassium Sorbate
0-15%
Xanthan Gum
0-15%
Ethoxydiglycol
0-15%
Zinc PCA
0-15%
Bisabolol
0-15%
Morinda citrifolia (Noni) Leaf Juice
0-15%
Disodium EDTA
0-15%
Glycerin
0-15%
Curcuma longa (Tumeric) Root Extract
0-15%
Morinda citrifolia (Noni) Leaf Extract
Formulation One Hundred Three
% Range
Ingredient
50-100%
Water (Aqua)
3-30%
Sodium Cocoyl Glutamate
3-30%
Disodium Cocoyl Glutamate
0-15%
Glycerin
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Chondrus crispus (Carrageenan)
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Citric Acid
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Butylene Glycol
0-15%
Potassium Sorbate
0-15%
Salix nigra (Willow) Bark Extract
0-15%
Disodium EDTA
0-15%
Amorphophallus konjac ( Konjac ) Root Powder
0-15%
Fragrance (Parfum)
0-15%
Glucose
0-15%
Ocimum basilicum (Basil) Leaf Extract
0-15%
Citrus grandis (Grapefruit) Fruit Extract
0-15%
Moringa pterygosperma ( Moringa ) Seed Extract
0-15%
Macrocystis pyrifera (Kelp) Extract
Formulation One Hundred Four
% Range
Ingredient
50-100%
Helianthus annuus (Sunflower) Seed Oil
3-30%
Aleurites moluccana (Kukui) Seed Oil
3-30%
Macadamia integrifolia ( Macadamia ) Seed Oil
0-15%
Laureth-4
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Phenoxyethanol
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Fragrance (Parfum)
0-15%
Calophyllum inophyllum (Tamanu) Seed Oil
0-15%
Moringa oleifera Seed Oil
0-15%
Tocopherol
0-15%
Laminaria digitata (Algae) Extract
0-15%
Macrocystis pyrifera (Kelp) Extract
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Morinda citrifolia (Noni) Fruit Juice Concentrate
0-15%
Vegetable Oil
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation One Hundred Five
% Range
Ingredient
35-90%
Water/Aqua
5-50%
Aleurites moluccana (Kukui) Seed Oil
3-30%
Macadamia integrifolia ( Macadamia ) Seed Oil
3-30%
Cetearyl Alcohol
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Dimethicone
0-15%
Cetearyl Glucoside
0-15%
Glyceryl Stearate
0-15%
PEG-100 Stearate
0-15%
Glycerin
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Glycine soja (Soybean) Seed Extract
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Glycine soja (Soybean) Sterol
0-15%
Xanthan Gum
0-15%
Panthenol
0-15%
Bisabolol
0-15%
Ethoxydiglycol
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Potassium Sorbate
0-15%
Disodium EDTA
0-15%
Butylene Glycol
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Macrocystis pyrifera (Kelp) Extract
0-15%
Ceramide NP
0-15%
Morinda citrifolia (Noni) Leaf Extract
0-15%
Avena sativa (Oat) Kernel Extract
0-15%
Beta-Glucan
0-15%
Pantolactone
0-15%
Tocopherol
0-15%
Sodium Hyaluronate
0-15%
1,2-Hexanediol
0-15%
Citric Acid
0-15%
Benzoic Acid
0-15%
Sodium Benzoate
0-15%
Vegetable Oil
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation One Hundred Six
% Range
Ingredient
50-100%
Water (Aqua)
3-30%
Aleurites moluccana (Kukui) Seed Oil
0-15%
Cetearyl Alcohol
0-15%
Macadamia integrifolia ( Macadamia ) Seed Oil
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Dimethicone
0-15%
Cetearyl Glucoside
0-15%
Glyceryl Stearate
0-15%
PEG-100 Stearate
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Glycine soja (Soybean) Seed Extract
0-15%
Phenoxyethanol
0-15%
Glycerin
0-15%
Glycine soja (Soybean) Sterols
0-15%
Morinda citrifolia (Noni) Leaf Juice
0-15%
Xanthan Gum
0-15%
Bisabolol
0-15%
Ethoxydiglycol
0-15%
Potassium Sorbate
0-15%
Butylene Glycol
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Fragrance (Parfum)
0-15%
Panthenol
0-15%
Calophyllum inophyllum (Tamanu) Seed Oil
0-15%
Ethylhexylglycerin
0-15%
Disodium EDTA
0-15%
Macrocystis pyrifera (Kelp) Extract
0-15%
Avena sativa (Oat) Kernel Extract
0-15%
Ceramide NP
0-15%
Morinda citrifolia (Noni) Leaf Extract
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Tocopherol
0-15%
Sodium Hyaluronate
0-15%
Musa sapientum (Banana) Flower Extract
0-15%
Centella asiatica (Hydrocotyl) Extract
0-15%
Vegetable Oil
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation One Hundred Seven
% Range
Ingredient
50-100%
Water (Aqua)
3-30%
Octinoxate (7.50%)** Ethylhexyl Methoxycinnamate
3-30%
Octisalate (5%)** Ethylhexyl Salicylate
0-15%
Cetearyl Alcohol
0-15%
C12-15 Alkyl Benzoate
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Avobenzone (2%)** Butyl Methoxydibenzoylmethane
0-15%
Dimethicone
0-15%
Butylene Glycol
0-15%
Cetearyl Glucoside
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Glyceryl Stearate
0-15%
PEG-100 Stearate
0-15%
Moringa oleifera Seed Oil
0-15%
Glycine soja (Soybean) Seed Extract
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Glycine soja (Soybean) Sterol
0-15%
Morinda citrifolia (Noni) Leaf Juice
0-15%
Xanthan Gum
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Ethoxydiglycol
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Fragrance
0-15%
Potassium Sorbate
0-15%
Panthenol
0-15%
Disodium EDTA
0-15%
Macrocystis pyrifera (Kelp) Extract
0-15%
Ceramide 3
0-15%
Morinda citrifolia (Noni) Leaf Extract
0-15%
Curcuma longa (Turmeric) Root Extract
0-15%
BHT
0-15%
Vanilla tahitensis ( Vanilla ) Fruit Extract
0-15%
Sodium Hyaluronate
0-15%
Centella asiatica (Hydrocotyl) Extract
0-15%
Musa sapientum (Banana) Extract
0-15%
Tocopherol
0-15%
Gardenia tahitensis (Tiare) Flower
Formulation One Hundred Eight
% Range
Ingredient
50-100%
Water (Aqua)
0-15%
Octinoxate (7.50%)** Ethylhexyl Methoxycinnamate
0-15%
Octisalate (5%)** Ethylhexyl Salicylate
0-15%
Cetearyl Alcohol
0-15%
C12-15 Alkyl Benzoate
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Avobenzone (2%)** Butyl Methoxydibenzoylmethane
0-15%
Dimethicone
0-15%
Butylene Glycol
0-15%
Cetearyl Glucoside
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Glyceryl Stearate
0-15%
PEG-100 Stearate
0-15%
Moringa oleifera Seed Oil
0-15%
Glycine soja (Soybean) Seed Extract
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Glycine soja (Soybean) Sterol
0-15%
Morinda citrifolia (Noni) Leaf Juice
0-15%
Xanthan Gum
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Ethoxydiglycol
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Fragrance
0-15%
Potassium Sorbate
0-15%
Panthenol
0-15%
Disodium EDTA
0-15%
Macrocystis pyrifera (Kelp) Extract
0-15%
Ceramide 3
0-15%
Morinda citrifolia (Noni) Leaf Extract
0-15%
Curcuma longa (Turmeric) Root Extract
0-15%
BHT
0-15%
Vanilla tahitensis ( Vanilla ) Fruit Extract
0-15%
Sodium Hyaluronate
0-15%
Centella asiatica (Hydrocotyl) Extract
0-15%
Musa sapientum (Banana) Extract
0-15%
Tocopherol
0-15%
Gardenia tahitensis (Tiare) Flower
Formulation One Hundred Nine
% Range
Ingredient
50-100%
Water (Aqua)
0-15%
Cetearyl Alcohol
0-15%
Hordeum distichon (Barley) Extract
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Squalane
0-15%
Dimethicone
0-15%
Cetearyl Glucoside
0-15%
Glycine soja (Soybean) Seed Extract
0-15%
Phenoxyethanol
0-15%
Santalum album (Sandalwood) Extract
0-15%
Phellodendron amurense Bark Extract
0-15%
Glycerin
0-15%
Glycine soja (Soybean) Sterols
0-15%
Ethoxydiglycol
0-15%
Morinda citrifolia (Noni) Leaf Juice
0-15%
Bisabolol
0-15%
Potassium Sorbate
0-15%
Butylene Glycol
0-15%
Xanthan Gum
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Panthenol
0-15%
Ethylhexylglycerin
0-15%
Disodium EDTA
0-15%
Macrocystis pyrifera (Kelp) Extract
0-15%
Ceramide NP
0-15%
Avena sativa (Oat) Kernel Extract
0-15%
Morinda citrifolia (Noni) Leaf Extract
0-15%
Sodium Hyaluronate
0-15%
Musa sapientum (Banana) Flower Extract
0-15%
Centella asiatica (Hydrocotyl) Extract
Formulation One Hundred Ten
% Range
Ingredient
35-90%
Water/Aqua
5-50%
Kaolin
3-30%
Bentonite
0-15%
Glyceryl Stearate
0-15%
Silica
0-15%
Butyrospermum parkii (Shea Butter)
0-15%
Boron Nitride
0-15%
Aleurites moluccana (Kukui) Seed Oil
0-15%
Macadamia integrifolia ( Macadamia ) Seed Oil
0-15%
Cetearyl Alcohol
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Ceteareth-20
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Carbon
0-15%
Bisabolol
0-15%
Xanthan Gum
0-15%
Potassium Sorbate
0-15%
Citric Acid
0-15%
Disodium EDTA
0-15%
Boric Oxide
0-15%
Plumeria rubra Flower Extract
0-15%
Colocasia antiquorum (Taro) Root Extract
0-15%
Aleurites moluccana (Kukui) Seed Extract
0-15%
Gardenia tahitensis Flower
0-15%
Tocopherol
Formulation One Hundred Eleven
% Range
Ingredient
50-100%
Water (Aqua)
0-15%
Macadamia integrifolia ( Macadamia ) Seed Oil
0-15%
Moringa oleifera ( Moringa ) Seed Oil
0-15%
Cetearyl Alcohol
0-15%
Aleurites moluccana (Kukui) Seed Oil
0-15%
Dimethicone
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Glyceryl Stearate
0-15%
PEG-100 Stearate
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Boron Nitride
0-15%
Phenoxyethanol
0-15%
Cetearyl Glucoside
0-15%
Caprylyl Glycol
0-15%
Glucosamine HCl
0-15%
Glycerin
0-15%
Xanthan Gum
0-15%
Morinda citrifolia (Noni) Leaf Juice
0-15%
Ethoxydiglycol
0-15%
Pisum sativum (Pea) Extract
0-15%
Potassium Sorbate
0-15%
Bambusa vulgaris (Bamboo) Extract
0-15%
Panthenol
0-15%
Disodium EDTA
0-15%
Steareth-20
0-15%
Chlorhexidine Digluconate
0-15%
Morinda citrifolia (Noni) Leaf Extract
0-15%
Boric Oxide
0-15%
Tocopherol
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
N-Hydroxysuccinimide
0-15%
Chrysin
0-15%
Palmitoyl Oligopeptide
0-15%
EDTA
0-15%
Vegetable Oil
0-15%
Palmitoyl Tetrapeptide-7
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation One Hundred Twelve
% Range
Ingredient
35-90%
Water (Aqua)
0-15%
Macadamia integrifolia ( Macadamia ) Seed Oil
0-15%
Moringa oleifera Seed Oil
0-15%
Caprylic/Capric Triglyceride
0-15%
Aleurites moluccana (Kukui) Seed Oil
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Cetearyl Alcohol
0-15%
Dimethicone
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Phenoxyethanol
0-15%
Butylene Glycol
0-15%
Glyceryl Stearate
0-15%
PEG-100 Stearate
0-15%
Caprylyl Glycol
0-15%
Cetearyl Glucoside
0-15%
Tropaeolum majus ( Nasturtium ) Flower/Leaf/Stem Extract
0-15%
Morinda citrifolia (Noni) Leaf Juice
0-15%
Xanthan Gum
0-15%
Ethoxydiglycol
0-15%
Glycerin
0-15%
Potassium Sorbate
0-15%
Fragrance (Parfum)
0-15%
Magnesium Ascorbyl Phosphate
0-15%
Arctostaphylos uva ursi (Bearberry) Leaf Extract
0-15%
Disodium EDTA
0-15%
Tocopherol
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Morinda citrifolia (Noni) Leaf Extract
0-15%
Vegetable Oil
0-15%
Diacetyl Boldine
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation One Hundred Thirteen
% Range
Ingredient
35-90%
Water (Aqua)
5-50%
Macadamia integrifolia ( Macadamia ) Seed Oil
5-50%
Aleurites moluccana (Kukui) Seed Oil
3-30%
Cetearyl Alcohol
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Cetearyl Glucoside
0-15%
Glyceryl Stearate
0-15%
PEG-100 Stearate
0-15%
Dimethicone
0-15%
Biosaccharide Gum-1
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Glycine soja (Soybean) Seed Extract
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Glycine soja (Soybean) Sterols
0-15%
Morinda citrifolia (Noni) Leaf Juice
0-15%
Xanthan Gum
0-15%
Ethoxydiglycol
0-15%
Butylene Glycol
0-15%
Pikea robusta (Red Algae) Extract
0-15%
Glucosamine HCl
0-15%
Potassium Sorbate
0-15%
Fragrance
0-15%
Panthenol
0-15%
Pisum sativum (Pea) Extract
0-15%
Hydrolyzed Ulva lactuca Extract
0-15%
Calophyllum inophyllum (Tamanu) Seed Oil
0-15%
Disodium EDTA
0-15%
Chlorella vulgaris Extract
0-15%
Bambusa vulgaris (Bamboo) Leaf/Stem Extract
0-15%
Macrocystis pyrifera (Kelp) Extract
0-15%
Ceramide NP
0-15%
Morinda citrifolia (Noni) Leaf Extract
0-15%
Gardenia tahitensis Flower
0-15%
Tocopherol
0-15%
Sodium Hyaluronate
0-15%
Musa sapientum (Banana) Flower Extract
0-15%
Centella asiatica (Hydrocotyl) Extract
0-15%
Vegetable Oil
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation One Hundred Fourteen
% Range
Ingredient
35-90%
Water (Aqua)
3-30%
Disodium Cocoyl Glutamate
3-30%
Bambusa arundinacea (Bamboo) Stem Powder
0-15%
Glyceryl Stearate
0-15%
PEG-100 Stearate
0-15%
Cetearyl Alcohol
0-15%
Sodium Cocoyl Glutamate
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Glycerin
0-15%
Aleurites moluccana (Kukui) Seed Oil
0-15%
Macadamia integrifolia ( Macadamia ) Seed Oil
0-15%
Squalane
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Chondrus crispus (Carrageenan)
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Citric Acid
0-15%
Macadamia ternifolia ( Macadamia ) Seedcake
0-15%
Cocos nucifera (Coconut) Shell Powder
0-15%
Fragrance
0-15%
Potassium Sorbate
0-15%
Disodium EDTA
0-15%
Allantoin
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Maris Sal
0-15%
Pearl Powder
0-15%
Tocopherol
0-15%
Vegetable Oil
0-15%
Rosmarinus officinalis (Rosemary) Leaf Extract
Formulation One Hundred Fifteen
% Range
Ingredient
10-75%
Macadamia integrifolia ( Macadamia ) Seed Oil
10-75%
Helianthus annuus (Sunflower) Seed Oil
5-50%
Synthetic Beeswax
3-30%
Aleurites moluccana (Kukui) Seed Oil
3-30%
Mangifera indica (Mango) Seed Butter
0-15%
Cocos nucifera (Coconut) Oil
0-15%
Ethylhexyl Palmitate
0-15%
Phenoxyethanol
0-15%
Tribehenin
0-15%
Sorbitan Isostearate
0-15%
Morinda citrifolia (Noni) Seed Oil
0-15%
Gardenia tahitensis (Tiare) Flower
0-15%
Tocopherol
0-15%
Ananas sativus (Pineapple) Fruit Extract
0-15%
Colocasia antiquorum (Taro) Root Extract
0-15%
Carica papaya ( Papaya ) Fruit Extract
0-15%
Morinda citrifolia (Noni) Fruit Juice Concentrate
0-15%
Palmitoyl Oligopeptide
Formulation One Hundred Sixteen
% Range
Ingredient
50-100%
Water/Aqua
0-15%
Morinda citrifolia (Noni) Fruit Juice
0-15%
Polysorbate 20
0-15%
Phenoxyethanol
0-15%
Caprylyl Glycol
0-15%
Carbomer
0-15%
Glucosamine HCl
0-15%
Morinda citrifolia (Noni) Leaf Juice
0-15%
Ethoxydiglycol
0-15%
Pisum sativum (Pea) Extract
0-15%
Sodium Hydroxide
0-15%
Potassium Sorbate
0-15%
Bambusa vulgaris (Bamboo) Extract
0-15%
Panthenol
0-15%
Hydrolyzed Lupine Protein
0-15%
Disodium EDTA
0-15%
Butylene Glycol
0-15%
Hibiscus rosa-sinensis Flower Extract
0-15%
Chondrus crispus (Carrageenan) Extract
0-15%
Sodium Hyaluronate
0-15%
Cocos nucifera (Coconut) Fruit Juice
0-15%
Glucose
0-15%
Morinda citrifolia (Noni) Leaf Extract
0-15%
EDTA
0-15%
Sorbic Acid
Formulation One Hundred Seventeen
% Range
Ingredients
0-15%
Morinda citrifolia (Noni) Leaf Tea Powder
0-15%
Terminalia chebula, Terminalia belerica and Embilica
officinalis (Triphala) Fruit Extract
0-15%
Tinospora cordifolia (Indian Tinospora ) Stem Extract
50-100%
Honey Powder
0-15%
Firmenich Natural Orange Flavor #860100 TD0991
0-15%
Allspice
0-15%
Cinnamon
0-15%
Silicon Dioxide
Formulation One Hundred Eighteen
% Range
Ingredient
0-15%
Vitamin A Palmitate
0-15%
Vitamin C (Ascorbic Acid)
0-15%
Calcium Ascorbate
0-15%
Vitamin D3 (Cholecalciferol)
0-15%
Vitamin E Acetate
0-15%
Vitamin E Acetate
0-15%
Vitamin B5 (d-Calcuim Pantothenate)
0-15%
Vitamin H
Calcium from Calcium Ascorbate, d-
Calcium
Pantothenate, Dibasic Calcium
Phosphate, Calcium
Chelate
0-15%
Calcium Chelate
10-75%
Dibasic Calcium Phosphate Dihydrate
0-15%
Atlantic Kelp ( Laminaria digitata ) Iodine
0-15%
Ferrous Fumarate
0-15%
Alfalfa Grass
0-15%
Apple Pectin
0-15%
Astragalus Root
0-15%
Barley Grass
0-15%
Bee Pollen Powder
0-15%
Betaine Hydrochloride
0-15%
Broccoli Powder
0-15%
Cabbage Powder
0-15%
Carrot Powder
0-15%
Choline Bitartrate
0-15%
Citrus Pectin
0-15%
Curcumin
0-15%
Echinacea Root
0-15%
Garlic Powder
0-15%
Hesperdin Complex
0-15%
Horsetail
3-30%
Inositol
0-15%
Korean Panex Ginseng Powder
0-15%
Phosphatidylcholine
0-15%
Lemon Bioflavonoids
0-15%
Ligustrum Berry
0-15%
Oat Bran Flour
0-15%
Parsley Powder
0-15%
Quercetin Dihydrate
0-15%
Raspberry Leaf Powder
0-15%
Rose Hips
0-15%
Rutin
0-15%
Schizandra Berry
0-15%
Shiitake Mushroom
0-15%
Eleuthero Root
0-15%
Spinach Powder
0-15%
Suma Powder
0-15%
Tomato Powder
0-15%
Watter Cress Powder
0-15%
Microcrystalline Cellulose
0-15%
Magnesium Stearate
0-15%
Silicon Dioxide
Formulation One Hundred Nineteen
% Range
Ingredient
0-15%
Beta Carotene
5-50%
Vitamin C (Ascorbic Acid)
5-50%
Vitamin E Acetate
0-15%
Thiamine mononitrate
0-15%
Riboflavin
0-15%
Niacin
0-15%
Niacinamide
0-15%
Pyridoxine Hydrochloride
0-15%
Pyridoxal-5-Phosphate
0-15%
Folic Acid
0-15%
Cyanocobalamin
3-30%
Magnesium Oxide
0-15%
Magnesium Glycinate Chelate
0-15%
Zinc Gluconate
0-15%
Zinc Methionine
0-15%
Zinc Glycinate
0-15%
Selenium Methionate
0-15%
Selenium Glycinate
0-15%
Copper Gluconate
0-15%
Copper
0-15%
Manganese Citrate
0-15%
Manganese Gluconate
0-15%
Manganese Glycinate Chelate
0-15%
Chromium Nicotinyl Glycinate Chelate
0-15%
Potassium Chloride
0-15%
Potassium Glycinate Chelate
0-15%
Potassium Iodine
0-15%
Ferrous Bis-Glycinate
0-15%
Molybdenum
0-15%
Bilberry
0-15%
Calcium Casienate
3-30%
Enzyme Blend
0-15%
Glutamic Acid
0-15%
Glutathione L.
0-15%
Grape Seed
0-15%
Green Tea Leaf
0-15%
Methionine L.
0-15%
Liver Spray Dried
0-15%
Papaya Leaf
0-15%
Pineapple Fruit
0-15%
Pine Bark
0-15%
Red Wine
0-15%
Silica
0-15%
Vanadium
5-50%
Dicalcium Phosphate Dihydrate
5-50%
Phosphorus from Dicalcium Phosphate Dihydrate
3-30%
Microcrystalline Cellulose
0-15%
Magnesium Stearate
0-15%
Silicon Dioxide
EXAMPLES
The following example illustrates some of the embodiments of the present invention comprising the administration of a composition comprising components of the Indian Mulberry or Morinda citrifolia L. plant. These examples are not intended to be limiting in any way, but are merely illustrative of benefits, advantages, and remedial effects of some embodiments of the Morinda citrifolia compositions of the present invention.
As illustrated by the following Example, embodiments of the present invention have been tested. Specifically, the Example illustrates the results of in-vitro studies that confirmed that concentrates of processed Morinda citrifolia products (“TNJ” is an evaporative concentrate) and processed plants selected as sources of iridoids have unexpected beneficial physiological effects. The percentage of concentration refers to the concentration strength of the particular concentrate tested; that is, the strength of concentration relative to the processed product from which the concentrate was obtained.
Example One
A human clinical trial of TAHITIAN NONI® Juice in heavy smokers revealed that ingestion of noni juice has DNA protective activity. Phytochemical analysis of TAHIITIAN NONI® Juice has revealed iridoids, specifically deacetylasperulosidic acid (DAA) and asperulosidic acid (AA) are the major phytochemcial constituents of noni fruit. DAA and AA were isolated from noni fruit puree from French Polyensia to evaluate their DNA protective potentials in vitro and make an assessment of their role in the results observed in the clinical trial.
The SOS-chromotest in E. coli PQ37 was used to determine the potential for iridoids in noni fruit from French Polynesia to prevent primary DNA damage. E coli PQ37 was incubated at 37° C. in the presence of deacetylasperulosidic acid and asperulosidic acid at a concentration of 250 ug mL −1 in a 96-well plate. Replicate samples were evaluated. The samples were also incubated with 1.25 ug mL −1 4-nitroquinoline 1-oxide (4NQO). Blank replicates were also prepared, where cells were not incubated with to iridoids or 4NQO. Additionally, a 1.25 ug mL −1 4NQO positive control was included in this assay. Following incubation with the samples, 5-bromo-4-chloro-3-indolyl-β-D-galactopyranoside was added to the wells to detect β-galactosidase enzyme activity, which is induced during SOS repair of damaged DNA. The samples were again incubated for 90 minutes and the absorbances of the samples, blank and positive control were measured at 620 nm with a microplate reader. The β-galactosidase enzyme activity induction factor of each material was calculated by dividing the absorbance of the sample at 620 nm by that of the blank, while also correcting for cell viability. Induction factors of the blank, which by definition is 1, the positive control, and the sample wells containing DAA, plus 4NQO, and AA, plus 4NQO, were compared.
The β-galactosidase enzyme activity induction factor of 1.25 ug mL −1 4NQO was 6.09, indicating a six-fold increase in DNA damage in the cells. The induction factors (mean±standard deviation) of the DAA and AA samples, each containing 1.25 ug mL −1 4NQO, were 0.98±0.02 and 1.04±0.01, respectively. The results are compared graphically in FIG. 6 . The results reveal that the DNA damaging ability of 4NQO was abolished by the addition of the iridoids.
The iridoids, DAA and AA, in noni fruit have the potential to protect DNA against 4NQO, a well known genotoxin. TAHITIAN NONI® Juice has also been shown to provide some level of DNA protection in humans against cigarette smoke, also a well known genotoxin. Further, chemical analysis has revealed that the major phytochemicals in noni fruit and TAHITIAN NONI® Juice are iridoids, specifically DAA and AA. Therefore, it can be concluded that these iridoids are responsible for, or at least have a prominant role in, the DNA protective effects of noni juice observed in the human clinical trial involving heavy smokers.
Example Two
Analytical method to determine the quantity of iridoids in noni plant, as well as other fruits and their juices were developed. Major iridoids were isolated from the Morinda citrifolia plant as follows:
Chemicals and Standards
Acetonitrile (MeCN), methanol (MeOH), and water (H 2 O) of HPLC grade were obtained from Sigma-Aldrich (St. Louis, Mo., USA). Formic acid of analytical grade was purchased from Spectrum Chemical Mfg. Corp. (New Brunswick, N.J., USA). The chemical standard deacetylasperulosidic acid (DAA, 1) and asperulosidic acid (AA, 2) were isolated from noni fruits in our laboratory. Their purities were determined by HPLC and NMR to be higher than 99%. The chemical structures of DAA and AA are listed in FIG. 1 . They were accurately weighed and then dissolved in an appropriate volume of MeCN to produce corresponding stock solutions. The working standard solution of 1 and 2 for the calibration curve was prepared by diluting the stock solution with MeOH in seven concentration increments ranging from 0.00174-1.74 and 0.0016-0.80 mg/mL, respectively. All stock and working solutions were maintained at 0° C. in a refrigerator. The calibration curves of standards were plotted after linear regression of the peak areas versus concentrations.
Materials and Sample Preparation
Tahitian noni fruit puree as used in this example is the mashed whole fruit, excluding seeds and pericarp. The fruits were originally collected from the Tahitian Islands. One gram of the puree was diluted with 5 mL of H 2 O-MeOH (1:1) and mixed thoroughly. The solution was then filtered through a nylon microfilter (0.45-μm pore size); the solution was collected into a 5 mL volumetric flask for HPLC analysis. Four batches of noni puree were analyzed in the experiments. Voucher specimens of the noni fruit puree are deposited in our lab. To test iridoid stability, a DAA solution of 0.5 mg/mL was prepared with MeOH. This solution was heated in a water-bath at 90° C. for 1 min, cooled to room temperature, and analyzed by HPLC.
Chromatographic Conditions and Instrumentation
Chromatographic separation was performed on a Waters 2690 separations module coupled with 996 PDA detectors, and equipped with an Atlantis C18 column (4.6 mm×250 mm; 5 μm, Waters Corporation, Milford, Mass., USA). The pump was connected to two mobile phases: A; MeCN, and B; 0.1% formic acid in H 2 O (v/v), and eluted at a flow rate of 0.8 mL/min. The mobile phase was programmed consecutively in linear gradients as follows: 0-5 min, 0% A; and 40 min, 30% A. The PDA detector was monitored in the range of 210-400 nm (235 nm was selected for quantitative analysis). The injection volume was 10 μl, for each of the sample solutions. The column temperature was maintained at 25° C. Data collection and integration were performed using Waters Millennium software revision 32.
Method Validation
The limits of detection (LOD) and quantitation (LOQ) were defined as the lowest concentrations of analytes in a sample that can be detected and quantified. These LOD and LOQ limits were determined on the basis of signal-to-noise ratios (S/N) of 3:1 and 10:1, respectively. The working solutions of standards 1 and 2 for LOD and LOQ were prepared by diluting them sequentially. The intra- and inter-day precision assays, as well as stability tests were performed by following the method applied to the sample analysis for 3 consecutive days. Accuracy of the method (recovery) was assessed by the recovery percentage of iridoids 1 and 2 in the spiked samples. The noni fruit puree samples were spiked with standards at 3 different concentrations (equivalent to 50%, 100% and 150% concentration of 1 and 2 in the samples). The recovery percentage was calculated using the ratio of concentration detected (actual) to those spiked (theoretical). Variation was evaluated by the relative standard deviation (RSD) of triplicate injections in the HPLC experiments.
Samples Analyzed
Several fruits and fruit juice products, such as purees, were prepared and analyzed according to the methods described above. Samples of various commercial brand name fruit juices were also analyzed. Samples of noni leaves and seeds were also analyzed. The analytical results are provided in the following tables.
TABLE 1
Iridoids analysis of fruit puree and juice concentrates
(mg/mL-blueberry, all others-mg/g)
Other
Total
Samples/
lot# or note
DAA a
AA b
iridoids
iridoids
Tahitian noni fruit
P06151-2429
1.308 ± 0.110
0.276 ± 0.003
0.0535
1.638
puree
16523
1.441 ± 0.027
0.218 ± 0.009
0.0570
1.716
16524
1.274 ± 0.014
0.256 ± 0.017
0.0535
1.584
7807
1.531 ± 0.057
0.296 ± 0.057
0.0520
1.879
blueberry juice
n.d. c
0.0612*
0.061
concentrate
grape juice
n.d. c
concentrate
acai puree
n.d. c
mongosteen whole
extracted with
n.d. c
fruit
MeOH
extracted with
n.d. c
H2O
mangosteen fruit
n.d. c
puree
pear puree
n.d. c
goji juice
n.d. c
cupuacu puree
n.d. c
a deacetylasperulosidic acid (daa);
b asperulosidic acid(aa);
c not detected;
*monotropein from blueberry.
TABLE 2
Iridoids analysis of commercial brand name fruit juice blends (mg/mL)
Other
Total
Samples/Sources (note)
DAA a
AA b
iridoids
iridoids
TNJ
TNI
0.462 ± 0.016
0.030 ± 0.001
0.0667
0.568
Acai blend juice
Monavie
n.d. c
0.0126*
0.013
n.d. c
0.00809*
0.008
Xango juice
Xango, 330
n.d. c
0.0289*
0.029
ml pouch
Xango,
n.d. c
0.0178*
0.0178
bottled
n.d. c
0.0155*
0.0155
GoChi ™ Goji
Freelife
n.d. c
0.0531**
0.0531
juice
Intl.
Le' Vive juice
Ardyness
0.0147
n.d. c
0.0183**
0.0330
intl.
Zrii juice
Zrii
n.d. c
G3
Nuskin
n.d. c
Kyani fruit juice
Kyani
n.d. c
a deacetylasperulosidic acid (daa);
b asperulosidic acid(aa);
c not detected;
*monotropein from blueberry;
**tentatively identified as iridoids based on its UV, further confirmation needed.
TABLE 3
Iridoids analysis of noni different plant parts (mg/g)
Other
Total
Samples
Notes
DAA a
AA b
iridoids
iridoids
Tahitian noni
1.441 ± 0.027
0.218 ± 0.009
0.0570
1.716
fruit puree (wet)
Tahitian noni
grounded into
3.741 ± 0.016
1.253 ± 0.0051
0.420
5.414
whole fruit (dried)
powder,
Tahitian noni leaf
extracted
0.338 ± 0.028
0.539 ± 0.0075
0.388
1.265
with
MeOH/EtOH
(1:1)
Tahitian noni root
0.0873 ± 0.008
0.326 ± 0.0309
1.714*
2.127
Tahitian noni seed
1.303 ± 0.050
0.148 ± 0.0106
n.d. c
1.451
Noni blossom
extracted
0.88
0.421
1.268
2.569
with MeOH
(1:100) 30′
sonicated
a deacetylasperulosidic acid (daa);
b asperulosidic acid(aa);
c not detected;
*tentatively identified as iridoids based on its UV, further confirmation needed.
Major phytochemical component of noni fruit and TAHITIAN NONE) Juice are iridoids, specifically deacetylasperuloside and asperulosidic acid. A small quantity of another iridoid is found in blueberry fruit juice concentrate, at approximately 3.8% of the total iridoid content of noni fruit puree. The other fruits and non-noni fruit products did not contain iridoids.
The present invention may be embodied in other specific forms without departing from its spirit of essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
Example Three
The proximate nutritional, vitamin, mineral, and amino acid contents of processed noni fruit puree were determined. The phytochemical properties were evaluated, as well as an assessment made on the safety and potential efficacy of the major phytochemicals present in the puree. Processed noni fruit puree is a potential dietary source of vitamin C, vitamin A, niacin, manganese, and selenium. Vitamin C is the major nutrient present, in terms of concentration. The major phytochemicals in the puree are iridoids, especially deacetylasperulosidic acid, which were present in higher concentrations than vitamin C. The iridoids in noni did not display any oral toxicity or genotoxicity, but did possess potential anti-genotoxic activity. These findings suggest that deacetylasperulosidic acid may play an important role in the biological activities of noni fruit juice that have been observed in vitro, in vivo, and in human clinical trials.
1. Introduction
Morinda citrifolia , commonly known as noni, is a widely distributed tropical tree. It grows on the islands of the South Pacific, Southeast Asia, Central America, Indian subcontinent, and in the Caribbean. Knowledge of the phytochemical profile of processed noni fruit puree is important in understanding potential bioactivities, as well as in understanding the compounds responsible for health effects already demonstrated in human clinical trials. Iridoids constitute the major phytochemical component of noni fruit, with a few other compounds, such as scopoletin, quercetin, and rutin have occurring in significant, although much less, quantities. Previous analyses have been limited in the amount of nutrient data provided. Further, they have not been representative of the commercially processed noni fruit puree, as processing conditions do alter the nutritional and phytochemical profiles of fruits and vegetables. Therefore, the current chemical analyses were performed to provide more complete and accurate nutritional data. Analyses of the major phytochemicals in noni fruit were also carried out to provide an important reference for quality control and identity testing of these raw materials.
As the iridoids are present in significant quantities in noni fruit puree, genotoxicity and acute toxicity tests were performed to better understand their individual safety profiles. Therefore, the anti-genotoxic activities of the iridoids were evaluated in vitro, to investigate their potential roles in this reported DNA protection.
2. Materials and Methods
2.1 Experimental Materials
Noni fruits were harvested in French Polynesia and allowed to fully ripen. The fruit was then processed into a puree by mechanical removal of the seeds and skin via micro-mesh screen in a commercial fruit pulper, followed by pasteurization (87° C. for 3 seconds) at a good manufacturing certified fruit processing facility in Mataiea, Tahiti. The pasteurized puree is filled into aseptic containers, or totes containing 880 kg of noni fruit puree, and stored under refrigeration. Samples were obtained from 10 totes, from different batches, for the chemical analyses in this study.
For the acute oral toxicity test, an iridoid enriched fruit extract was prepared. This was done by removal of seeds and skin from the fruit flesh, followed by size reduction with a 0.65 mm sieve. An aqueous extract was prepared with the remaining fruit pulp, at ambient temperature, which was then freeze-dried, resulting in a total iridoid concentration of 1690 mg/100 g extract.
Freeze-dried noni fruit powder (36 g) was extracted with 1 L of methanol by percolation to produce 10 g of methanol extract. Following addition of water, the methanol extract was partitioned with ethylacetate (150 mL three times) to remove non-polar impurities. The aqueous extract was further partitioned with n-butanol (150 mL three times) to yield 3 g n-butanol extract. The extract was subjected to flash column chromatography on silica gel, eluting with a stepwise dichloromethane:methanol (20:1→1.5:1) gradient solvent system to yield sixty-two primary fractions. Among these, the presence of two major compounds was indicated by a preliminary HPLC analysis. The iridoid containing fractions were combined and subject to further purification by using reverse phase preparative HPLC (Symmetry Prep™ C18 column, Waters Corp.), eluting with an isocratic solvent system of MeCN—H2O (35:65) at a flow rate of 3 mL/min, resulting in the isolation of DAA and AA.
2.2 Chemical Analyses
Proximate nutritional analyses of noni fruit puree were carried out to determine moisture, fat, protein, ash, and carbohydrate contents. Protein content was determined by the Kjedahl method, Association of Official Analytical Chemists (AOAC) Method 979.09 (AOAC, 2000 a). Total moisture was determined gravimetrically by loss on drying at 100° C. in a vacuum oven. Fat determination involved continuous extraction by petroleum ether in a Soxhlet apparatus, AOAC Method 960.39 (AOAC, 2000 b). Ash was determined gravimetrically following combustion in a furnace at 550° C. Carbohydrate was then calculated by difference. Total dietary fiber was determined according to AOAC Method 991.43 (AOAC, 2000 c). Fructose, glucose, and sucrose contents were determined according to AOAC method 982.14 (AOAC, 2000 d).
Minerals were determined by inductively coupled plasma (ICP) emission spectrometry (AOAC, 2000 e; AOAC, 2000 f). Vitamin A, as β-carotene, was determined by a modified AOAC official method 941.15 for an HPLC system (AOAC, 2000 g). Vitamin C was determined by titration with 2,6-dichloroindophenol, by the microfluorometric method, or by HPLC and UV detection of oxidized ascorbic acid (AOAC, 2000 h; AOAC, 20001). Niacin, thiamin, riboflavin, vitamin B6, vitamin B12, vitamin E, folic acid, biotin, and pantothenic acid were determined by AOAC and United States Pharmacopoeia methods (AOAC, 2000 j; AOAC, 2000 k; AOAC, 2000 l; AOAC, 2000 m; AOAC, 2000 n; AOAC, 2000 o; AOAC, 2000 p; United States Pharmacopeia, 2005; Scheiner & De Ritter, 1975). Vitamin E was determined by HPLC similar to a previously reported method (Omale and Omajali, 2010), but with direct organic solvent extraction and use of a 2-propanol:H 2 O (60:20, %:%) mobile phase. Vitamin K was determined according to AOAC method 992.27 (AOAC, 2000 p). Amino acids were determined with an automated amino acid analyzer, following acid hydrolysis, except for tryptophan which involved hydrolysis with sodium hydroxide (AOAC, 2000 q).
The iridoid content, inclusive of deacetylasperulosidic acid (DAA) and asperulosidic acid (AA), was determined by HPLC, according to a previously reported method (Deng et al., 2010 b). Other significant secondary metabolites, such as scopoletin, rutin, and quercetin, were also determined by HPLC (Deng et al., 2010 a).
2.4 Acute Toxicity Test of Iridoids
Twenty healthy Sprague-Dawley rats (10 males, 10 females, body weight 181-205 g) were selected for the tests. An iridoid enriched fruit extract was dissolved in water to produce a total iridoid concentration of 8.5 mg/mL. A dose of 340 mg total iridoids/kg body weight (bw) was given to each animal by gastric intubation (20 mL/kg bw twice per day). For 14 days following the administration of the iridoid solution, animals were observed daily for occurrences of death and symptoms of toxicity, including convulsions, irregular breathing, piloerection, and paralysis. As decreased weight is a typical symptom of toxicity, body weights were recorded for each animal on days 0 and 14. The acute toxicity test was carried out in accordance with EC Directive 86/609/EEC (European Communities, 1986).
2.5 Primary DNA Damage Test in E. coli PQ37
The SOS-chromotest in E. coli PQ37 was used to determine the potential for DAA and AA to induce primary DNA damage. This test was carried out according to the previously developed method (Fish et al., 1987). DAA and AA were isolated from noni fruits from Tahiti and purified to >98%. E. coli PQ37 was incubated in LB medium in a 96-well plate at 37° C. in the presence of DAA or AA for 2 hours. The DAA and AA concentrations tested were 7.81, 15.6, 31.2, 62.5, 125, 250, 500, and 1000 μg mL −1 Samples were evaluated in triplicate. Following incubation with the samples, 5-bromo-4-chloro-3-indolyl-β-D-galactopyranoside was added to the wells to detect β-galactosidase enzyme activity, which is induced during SOS repair of damaged DNA. Nitrophenyl phosphate is also added to the wells to measure alkaline phosphatase activity, an indicator of cell viability. The samples were again incubated and the absorbances of the samples, blanks and controls were measured at 410 and 620 nm with a microplate reader. Vehicle blanks and positive controls, 1.25 μg mL −1 4-nitroquinoline 1-oxide (4NQO), were included in this test. The induction factor of each material was calculated by dividing the absorbance of the sample at 620 nm by that of the blank, while also correcting for cell viability. Induction factors less than two indicate an absence of genotoxic activity.
2.6 Anti-Genotoxicity Test in E. coli PQ37
The primary DNA damage test was performed again, similar to the method described above. However, the method was modified to include incubation of E. coli PQ37 in the presence of both 1.25 μg mL −1 4NQO and 250 μg mL −1 DAA or AA. Induction factors were calculated in the same manner as described above. The percent reduction in genotoxicity was determined by dividing the difference between the induction factor of 4NQO and the blank (induction factor of 1) by the difference between the induction factor of 4NQO plus DAA or AA and the blank.
2.7 Statistical Analyses
Means and standard deviations were calculated for each set of analytical results obtained from the different batches. In both the primary DNA damage test and the anti-genotoxicity test, intergroup comparisons were made with Student's t-test.
3. Results and Discussion
The nutrient composition of processed noni fruit puree is summarized in Table 4. Proximate nutritional parameters are within the typical ranges for fruits in general. Processed noni fruit puree contains 2 g 100 g −1 dietary fiber. Noni fruit does not contain a significant quantity of protein or fat. However, all but one essential amino acid, tryptophan, as well as histidine, essential for infants, were detected in the puree (Table 5). Aspartic acid was the most predominant amino acid.
TABLE 4
Nutrient content of processed noni fruit puree.
Assay
Mean
S.D.
Protein (g/100 g)
0.55
0.11
Fat (g/100 g)
0.10
0.12
Moisture (g/100 g)
91.63
1.98
Ash (g/100 g)
0.54
0.19
Carbohydrate (g/100 g)
7.21
1.81
Fructose (g/100 g)
1.07
0.39
Glucose (g/100 g)
1.30
0.36
Sucrose (g/100 g)
<0.1
—
Kilojoules/100 g
135.56
31.73
Dietary fiber (g/100 g)
2.01
0.27
Ca (mg/100 g)
48.20
16.04
K (mg/100 g)
214.34
56.91
Na (mg/100 g)
16.99
5.98
Mg (mg/100 g)
26.10
8.33
P (mg/100 g)
20.35
6.78
Fe (mg/100 g)
0.74
0.06
Cu (mg/100 g)
0.08
0.07
Mn (mg/100 g)
0.47
0.62
Se (mg/100 g)
0.01
0.01
Zn (mg/100 g)
0.06
0.07
β-carotene (μg/g)
19.09
12.15
Niacin (mg/g)
0.03
0.01
Vitamin C (mg/g)
1.13
0.77
Thiamin (mg/g)
<0.018
—
Riboflavin (mg/g)
<0.018
—
Vitamin B6 (mg/g)
<0.018
—
Vitamin B12 (μg/g)
<0.0012
—
Vitamin E (μg/g)
10.96
6.62
Folic acid (μg/g)
<0.06
—
Biotin (μg/g)
0.02
0.00
Pantothenic acid (mg/g)
<0.018
—
Vitamin K (μg/g)
<0.10
—
S.D.—standard deviation.
TABLE 5
Amino acid profile of processed noni fruit puree.
Amino acid
Mean
S.D.
Alanine (mg/g)
0.45
0.04
Arginine (mg/g)
0.32
0.04
Aspartic acid (mg/g)
0.80
0.08
Cystine (mg/g)
0.23
0.03
Glutamic acid (mg/g)
0.64
0.05
Glycine (mg/g)
0.36
0.04
Histidine (mg/g)
<0.1
—
Isoleucine (mg/g)
0.29
0.01
Leucine (mg/g)
0.38
0.02
Lysine (mg/g)
0.25
0.04
Methionine (mg/g)
<0.1
—
Phenylalanine (mg/g)
0.21
0.05
Proline (mg/g)
0.26
0.03
Serine (mg/g)
0.27
0.02
Threonine (mg/g)
0.27
0.03
Tryptophan (mg/g)
<0.1
0.00
Tyrosine (mg/g)
0.25
0.03
Valine (mg/g)
0.36
0.03
Vitamin C is the most prominent vitamin in noni fruit puree, with a mean content of 1.13 mg −1 g. At this concentration, 100 g of puree provides 251% of the recommended daily vitamin C requirement for adults (FAO/WHO, 2001). Noni fruit puree contains appreciable quantities of β-carotene. As calculated from β-carotene concentration, the mean vitamin A content per 100 g of puree is 318.17 retinol equivalents (RE). The joint FAO/WHO recommendation for average vitamin A daily intake by adults is 270 RE for females and 300 RE for males (FAO/WHO, 1998). As such, noni fruit puree appears to have the potential to be a significant dietary source of vitamin A. The niacin content of processed noni fruit is great enough to have some nutritional impact, but will only be significant when larger quantities are consumed. At 100 g, the puree provides 18 to 21% of the recommended niacin intake for adults (FAO/WHO, 2001). Thiamin, riboflavin, vitamin B6, vitamin B12, folic acid, pantothenic acid, and vitamin K were below detection limits. Processed noni fruit puree contains, but is not a significant source of, vitamin E and biotin.
Potassium appears to be the most abundant mineral in processed noni fruit puree. It is more than four times the concentration of calcium, the next most abundant mineral, although neither is present in nutritionally significant quantities. Only two minerals are present in nutritionally significant amounts. In 100 g of noni puree, manganese and selenium contents would meet approximately 18 to 26% of the recommended daily allowance for adults (Institute of Medicine, 2000; Institute of Medicine, 2001).
The phytochemical analyses reveal that iridoids are the major secondary metabolites produced by noni fruit and are present in significant quantities following processing (Table 6). Scopoletin, rutin, and quercetin were also present after processing. The total iridoid content was 20 times greater than the combined concentrations of the other three phytochemicals. Deacetylasperulosidic acid accounted for 78% of the total iridoid content. Due to their prevalence in noni fruit, both iridoids may be used as markers for identification of products containing authentic noni ingredients. Bioactivities of iridoids from noni fruit juice and noni fruit extracts may ionclude antioxidant, anti-inflammatory, immunomodulatory, hepatoprotective, and hypolipidemic activities.
No deaths or symptoms of toxicity were observed in the acute toxicity test. Animals also gained appropriate weight (Table 7). The LD 50 of noni iridoids was determined to be >340 mg/kg bw. In the primary DNA damage test in E. coli PQ37 (Table 8), the mean induction factors for DAA and AA, at 1000 μg mL —1 , were 1.07 and 1.09, respectively. At all concentrations tested, DAA and AA did not induce any SOS repair at a frequency significantly above that of the blank. Statistically, induction factors were no different than that of the blank, and all results remained well below the two-fold criteria for genotoxicity. SOS-chromotest results have a high level of agreement (86%) with those from the reverse mutation assay (Legault et al., 1994). Therefore, the SOS-chromotest has some utility in predicting potential mutagenicity, in addition to primary DNA damage. The lack of DAA and AA toxicity in these tests are consistent with the results of toxicity tests of noni fruit juice (West et al., 2009 a; West et al., 2009 b; Westendorf et al., 2007).
TABLE 6
Phytochemical content of processed noni fruit puree.
Assay
Mean
S.D.
Deacetylasperulosidic acid (mg/100 g)
137.61
13.69
Asperulosidic acid (mg/100 g)
38.79
9.18
Scopoletin (mg/100 g)
5.68
1.58
Rutin (mg/100 g)
1.42
0.84
Quercetin (mg/100 g)
1.59
0.71
TABLE 7
Acute toxicity test of noni iridoids.
Animal
Body weight (g)
LD 50 (mg
Animal
Sex
number
Before
After
iridoids/kg bw)
S.D. rat
Male
10
191.2 ± 5.9
216.1 ± 8.3
>340.0
Female
10
192.8 ± 12.3
289.4 ± 12.3
>340.0
In the anti-genotoxicity test, 4NQO, exhibited obvious genotoxicity, inducing SOS repair more than 8-fold above that of the vehicle blank. But the induction factors of 4NQO plus DAA or AA, were the same as those of DAA or AA alone (Table 9), with no statistical difference from that of the vehicle blank. The reductions in genotoxicity from 250 μmL −1 DAA and AA were 98.96 and 99.22%, respectively. Therefore, the genotoxic activity of 4NQO was almost entirely abolished by the addition of either iridoid.
A double-blind human clinical trial revealed that ingestion of noni fruit juice reduced the amount of aromatic DNA-adduct formation in the lymphocytes of current heavy cigarette smokers. 4NQO exhibits genotoxic activity in E. coli through the formation of 4NQO-guanine and 4NQO-adenine adducts. These DNA lesions lead to the induction of the SOS repair mechanism. As such, the reduction in 4NQO genotoxicity by DAA and AA equates to a reduction in DNA adduct formation. Therefore, the results of the current anti-genotoxicity test suggest the possible involvement of these iridoids in noni juice's DNA protective effects.
4. Conclusion
Processed noni fruit puree is a potential dietary source of vitamin C, vitamin A, niacin, manganese, and selenium. Vitamin C is the major nutrient present, in terms of concentration. The major phytochemicals in the puree are iridoids, especially DAA. The iridoids in noni did not display any toxicity. On the other hand, these iridoids did display potential anti-genotoxic activity. Even though processed noni fruit puree contained an appreciable quantity of vitamin C, the average DAA content was approximately 22% greater than that of vitamin C. These findings suggest that DAA may play an important role in the biological activities of noni fruit juice that have been observed in vitro, in vivo, and in human clinical trials.
TABLE 8
Primary DNA damage assay in E. coli PQ37.
Concentration
Compound
(μg mL −1 )
Induction factor
Deacetylasperulasidic acid
1000
1.07 ± 0.14
500
1.03 ± 0.02
250
1.06 ± 0.06
125
1.00 ± 0.08
62.5
1.05 ± 0.07
31.2
1.04 ± 0.08
15.6
1.03 ± 0.16
7.81
0.93 ± 0.13
Asperulosidic acid
1000
1.09 ± 0.03
500
1.07 ± 0.04
250
1.11 ± 0.16
125
1.02 ± 0.08
62.5
1.04 ± 0.13
31.2
0.99 ± 0.06
15.6
1.04 ± 0.11
7.81
1.01 ± 0.05
4NQO
1.25
8.69 ± 3.69*
*P < 0.05, compared to vehicle blank.
TABLE 9
Anit-genotoxicity test in E. coli PQ37.
Concentration
Compound
(μg mL −1 )
Induction factor
Positive control (4NQO)
1.25
8.69 ± 3.69**
4NQO + deacetylasperulosidic acid
250*
1.08 ± 0.12
4NQO + asperulosidic acid
250*
1.06 ± 0.03
*DAA or AA concentration; 4NQO concentration is 1.25 μg mL −1 .
**P < 0.05, compared to vehicle blank.
Example Four
Noni is a medicinal plant with a long history of use as a folk remedy in many tropical areas, and is attracting more attention worldwide. A comprehensive study on the major phytochemicals in different noni plant parts, such as fruit, leaf, seed, root and flower is of great value for fully understanding their diverse medicinal benefits. Moreover, the diversity of geographic environments may contribute to the variation of noni's components.
Objective—This study quantitatively determines the major iridoid components in different parts of noni plants, and compares iridoids in noni fruits collected from different tropical areas worldwide.
Methodology—The optimal chromatographic conditions were achieved on a C 18 column with gradient elution using 0.1% formic acid aqueous formic acid and acetonitrile at 235 nm. The selective HPLC method was validated for precision, linearity, limit of detection (LOD), limit of quantitation (LOQ), and accuracy.
Results—Deacetylasperulosidic acid (DAA) was found to be the major iridoid in noni fruit. In order of predominance, DAA concentrations in different parts of the noni plant were dried noni fruit>fruit juice>seed>flower>leaf>root. The order of predominance for asperulosidic acid (AA) concentration was dried noni fruit>leaf>flower>root>fruit juice>seed. DAA and AA contents of methanolic extracts of noni fruits collected from different tropical regions were 13.8-42.9 mg/g and 0.7-8.9 mg/g, respectively, with French Polynesia containing the highest total iridoids and the Dominican Republic containing the lowest.
Conclusion—Iridoids are found to be present in leaf, root, seed, and flower of noni plants, and were identified as the major components in noni fruit. Given the great variation of iridoid contents in noni fruit grown in different tropical areas worldwide, geographical factors appear to have significant effects on fruit composition. The iridoids in noni fruit were stable at temperatures used during pasteurization and, therefore, may be useful marker compounds for identity and quality testing of commercial noni products.
Introduction
Noni ( Morinda citrifolia Linn.) is a popular medicinal plant indigenous to a wide range of tropical areas, such as southern Asia, the Caribbean, and the Pacific Islands. This study aims to quantitatively determine the major iridoids in different parts of noni (fruit, leaf, root, seed, and flower), and comparatively analyze the iridoids in different noni fruits cultivated and collected worldwide, by using a validated HPLC-PDA method.
Chemicals and Standards
HPLC grade acetonitrile (MeCN), methanol (MeOH), and water (H 2 O) were obtained from Sigma-Aldrich (St. Louis, Mo., USA). Analytical grade formic acid was purchased from Spectrum Chemical Mfg. Corp. (New Brunswick, N.J., USA). The chemical standards deacetylasperulosidic acid (DAA) and asperulosidic acid (AA) were isolated from authentic noni fruit in our laboratory. Their identification and purities were determined by HPLC, Mass spectrometry, and NMR to be higher than 99% (data not shown). The chemical structures of DAA and AA are listed in FIG. 4 . They were accurately weighed and then dissolved in an appropriate volume of MeOH to produce corresponding stock solutions. The working standard solution of DAA and AA for the calibration curve was prepared by diluting the stock solution with MeOH in seven concentration increments ranging from 0.00174-1.74 and 0.0016-0.80 mg/mL, respectively. All stock and working solutions were maintained at 0° C. in a refrigerator. The calibration curves of the standards were plotted after linear regression of the peak areas versus concentrations.
Conditions and Instrumentation
Chromatographic separation was performed on a Waters 2690 separations module coupled with 996 PDA detectors, equipped with an C18 column (4.6 mm×250 mm; 5 μm, Waters Corporation, Milford, Mass., USA). The pump was connected to two mobile phases: A; MeCN, and B; 0.1% formic acid in H 2 O (v/v), and eluted at a flow rate of 0.8 mL/min. The mobile phase was programmed consecutively in linear gradients as follows: 0-5 min, 0% A; and 40 min, 30% A. The PDA detector was monitored in the range of 210-400 nm. The injection volume was 10 μL for each of the sample solutions. The column temperature was maintained at 25° C. Data collection and integration were performed using Waters Millennium software revision 32.
Materials and Sample Preparation
Fresh noni fruit juice (sample A, FIG. 5 ) was squeezed from the noni fruit originally collected from the French Polynesia (Tahitian islands). One gram of the fresh fruit juice was diluted with 5 mL of H 2 O-MeOH (1:1), and mixed thoroughly; the solution was collected into a 5 mL volumetric flask for HPLC analysis. Dried fruit, seed, root, leaf, and flower (samples B-F, FIG. 5 ) were collected from the Tahitian islands. These were grounded into powder, and extracted with MeOH-EtOH (1:1) twice with a sonicator for 30 min each time. The extracts were combined, filtered and then dried in a rotary evaporator under vacuum at 50° C. The dried extracts were re-dissolved with MeOH for HPLC analysis.
The raw noni fruit samples ( FIG. 6 ) were collected from different areas, including the Tahitian islands, Tonga, Dominican Republic, Okinawa, Thailand, and Hawaii. The fruit samples were stored below 0° C. before use. The fruits were thawed and mashed. Two g of each mashed fruit was extracted twice with MeOH (125 mL, 30 min each) using a sonicator. The MeOH extract was dried under vacuum in a rotary evaporator. The dried MeOH extracts were re-dissolved with 10 mL of MeOH. Voucher specimens of noni samples are deposited in our lab.
Analytical Method Validation
The limits of detection (LOD) and quantitation (LOQ) were defined as the lowest concentrations of analytes in a sample that can be detected and quantified. These LOD and LOQ limits were determined on the basis of signal-to-noise ratios (S/N) of 3:1 and 10:1, respectively. The working solutions DAA and AA standards, for LOD and LOQ determinations, were prepared by serial dilution. The intra- and inter-day precision assays, as well as stability tests were performed by following the method applied to the sample analysis for 3 consecutive days. Repeatability is the degree of agreement between results, when experimental conditions are maintained as constant as possible, and is expressed as the relative standard deviation (RSD) of replicates.
In the study, intra- and inter-day precisions of the HPLC method were measured by triplicate injections of samples on 3 consecutive days. Accuracy of the method (recovery) was assessed by the recovery percentage of DAA and AA in the spiked samples. The noni fruit juices were spiked with standards at three different concentrations (equivalent to 50%, 100% and 150% concentration of DAA and AA in the samples). The recovery percentage was calculated using the ratio of concentration detected (actual) to those spiked (theoretical). Variation was evaluated by the relative standard deviation (RSD) of triplicate injections in the HPLC experiments.
Results and Discussion
Analytical Method Validation
The validation of the developed HPLC chromatographic method was conducted on the fresh noni juice to determine LOD, LOQ, linearity, intra-day and inter-day precisions, and accuracy (Tables 10-13). The selected MeCN—H 2 O gradient exhibited a good separation and symmetrical peak shapes of target analytes in the HPLC chromatograms. The LODs (S/N=3) and LOQs (S/N=10) for DAA and AA are 10.6 and 9.7 ng, and 34.8 and 32.0 ng, respectively. The linear regression equations for DAA and AA were calculated as: y=1.443×10 7 −17342.2 and y=1.537×10 7 −40804.7, respectively, where x is the concentration and y is the peak area. The results showed good linearity with correlation coefficients of 0.9994 and 0.9999 for DAA and AA, within the range of concentrations investigated. The intra- and inter-day precisions, as RSD's, of DAA and AA were less than 0.86% and 3.0%, respectively, indicating that DAA and AA were stable during investigation period. Under the established experimental conditions, percent recoveries of analytes DAA and AA were from 90.49% to 105.32%, with RSD ranging from 0.40-2.66% (Table 12). The results of the experiments are within tolerance ranges recommended in the guideline for dietary supplement issued by the Association of Analytical Communities (AOAC International, 2002). The characterization of iridoids DAA and AA in noni samples were conducted by comparing their HPLC retention times and UV maximum absorptions with these of standards (Table 10).
TABLE 10
Table 1. Chromatographic and spectroscopic
characteristics of the iridoids
UV λ max
R t
LOD
LOQ
Linearity range
Compounds
(nm)
(min)
(ng)
(ng)
(mg/mL)
DAA a
235.5
15.94
10.6
34.8
0.00174-1.74
AA b
235.5
26.08
9.7
32.0
0.0016-0.80
a Deacetylasperulosidic acid;
b asperulosidic acid.
TABLE 11
Table 2. Intra- and inter-day precisions and stability assays for
the quantitative determination of iridoids in noni by HPLC-PDA
Day 1
Day 2
Day 3
Inter-day
Amount
Amount
Amount
Amount
Samples
detected a
RSD (%)
detected a
RSD (%)
detected a
RSD (%)
detected a
RSD (%)
DAA b
1.308
0.86
1.291
0.43
1.291
0.62
1.297
0.86
AA c
0.276
1.16
0.281
3.00
0.287
1.84
0.281
2.49
a Mean ± SD, n = 3, mg/mL;
b deacetylasperulosidic acid;
c asperulosidic acid.
TABLE 12
Table 3. Accuracy assays for the quantitative
determination of iridoids in noni by HPLC-PDA
Concentration
Concentration
Recovery
Samples
spiked a
detected a,b
Percentage (%)
RSD %
DAA c
0.66
0.619 ± 0.016
93.84
2.66
1.32
1.271 ± 0.019
96.29
1.53
2.00
2.106 ± 0.009
105.32
0.40
AA d
0.146
0.132 ± 0.002
90.49
1.58
0.291
0.273 ± 0.004
93.93
1.39
0.437
0.433 ± 0.004
99.25
0.93
a Unit, mg/ml;
b mean ± SD; n = 3;
c deacetylasperulosidic acid;
d asperulosidic acid.
TABLE 13 Table 4. The concentration of major iridoids in different parts of noni Samples DAA a AA b Fruit juice (mg/mL) 1.441 ± 0.027 0.218 ± 0.009 Fruit (dried) (mg/g) 3.741 ± 0.016 1.253 ± 0.005 Leaf (mg/g) 0.338 ± 0.028 0.539 ± 0.007 Root (mg/g) 0.087 ± 0.008 0.326 ± 0.031 Seed (mg/g) 1.303 ± 0.050 0.148 ± 0.011 Flower (mg/g) 0.880 ± 0.040 0.421 ± 0.021 a Deacetylasperulosidic acid; b asperulosidic acid; mean ± SD; n = 3.
Characterization and Quantitation of DAA and AA in Noni Different Plant Parts
Iridoids have been identified in noni fruit, leaf, and root previously. In our preliminary experiments, DAA and AA appear to be the major iridoids in most parts of the noni plant. As such, these two iridoids were employed for the quantitation and comparison of iridoid contents in different noni parts. The typical HPLC chromatograms of noni fruit, leaf, root, seed, and flower are shown in FIG. 5 . The experimental results (Table 13) indicated that the DAA content in various parts of the plant are, in order of predominance, dried noni fruit>fruit juice>seed>flower>leaf>roots. For AA contents, the rank is dried noni fruit>leaf>flower>root>fruit juice>seed. Among the different plant parts, noni fruit (juice) seems a good source of iridoids. Iidoids, specifically deacetylasperulosidic acid and asperulosidic acid are the major secondary metabolites in noni fruit. As such, these may be responsible for its diverse health effects. For example, DAA and AA may have many biological activities, including anticlastogenic, antiarthritic, antinociceptive, anti-inflammatory, cardiovascular, cancer-preventive, and anti-tumor effects. Toxicity tests suggested DAA and AA are non-genotoxic in mammalian cells.
Comparison of Iridoid Contents in Noni Fruits from Different Areas
To evaluate the impact of geographical environments (soil, sunlight, temperature, precipitation, etc.) on the iridoid contents in noni fruit, analyses were performed on noni fruits cultivated and collected from different tropical regions worldwide. Ripe noni fruit samples were kept frozen during shipment. Further, MeOH extracts were analyzed to control for moisture variations. FIG. 6 shows a comparison of DAA, AA, and total iridoids (DAA+AA) in different noni fruits. The concentration ranges of DAA and AA in the MeOH extracts were 13.8-42.9 mg/g and 0.7-8.9 mg/g, respectively. Moreover, noni fruit collected from French Polynesia had the highest amount of the total iridoids, and noni fruit from the Dominican Republic contained the least. The results showed that geographical factors have significant effects on the iridoid contents in noni fruits. As such, different pharmacological activities may be expected to noni fruits collected from various areas.
The Impact of Pasteurization on DAA Content
Noni fruit juice is usually subjected to heat pasteurization during commercial processing. Pasteurization is usually employed in noni industry, i.e., heating up to 87.7° C. for several seconds. In this study, the stability of DAA was conducted. DAA was exposed to 90° C. at pH 3.3 for one minute to determine its thermal stability at acidic conditions. The results indicated that there was no difference in the DAA contents before and after heating, indicating that DAA is stable under the pasteurization conditions.
CONCLUSIONS
A selective analytical HPLC method has been developed and validated for analysis of iridoids in noni. Iridoids, specifically deacetylasperulosidic acid and asperulosidic acid, are identified as the major components in noni fruit, and also present in leaf, root, seed, and flower of the noni plant. Geographical factors seem to influence iridoid content of the fruit. Noni iridoids are stable during pasteurization. Therefore, the method reported herein may provide an accurate and rapid tool in the qualitative and quantitative analysis of noni and its commercial products.
|
Embodiments of the invention relate to fortified food and dietary supplement products which may be administered to produce desirable physiological improvement. In particular, embodiments of the invention relates to the administration of products enhanced with Morinda citrifolia and iridoids.
| 0
|
BACKGROUND OF THE INVENTION
This invention relates to switching networks and more particularly to multipath switching networks that include means for overcoming faults.
Multistage interconnection networks have long been studied for use in telephone switching and multiprocessor systems. Since the early 70's, several such networks have been proposed to meet the communication needs of multiprocessor systems in a cost-effective manner. They are typically designed for N-inputs and N-outputs, where N is a power of an integer n, such as 2, and contain log n N stages. The switches in adjacent stages are interconnected to permit the establishment of a path from any input of the network to any output of the network. These multistage networks have many properties that make them attractive for switching systems. One such property is their relatively low rate of increase in complexity and cost as the number of inputs and outputs increases. Generally their size and cost increase on the order of N log n N, as compared to crossbar switches where size and cost increase on the order of N 2 . Another such property is the ability to provide up to N simultaneous connections through path lengths on the order of log n N. Still another property is the ability to employ simple distributed algorithms that make a routing controller unnecessary. One example of such a network is found in U.S. Pat. No. 4,516,238 issued to Huang et al. on May 7, 1985.
Multistage networks with log N stages also have two other properties which are not desirable; i.e., only one path exists from any input to any output, and distinct input/output paths have common links. These properties lead to two disadvantages. First, an input/output connection may be blocked by a previously established connection even if the inputs (sources) and the outputs (destinations) of the network are distinct. Second, the failure of even a single link or switch disables several input/output connections. The former leads to poor performance in a random connections environment, and the latter leads to a lack of fault tolerance and concomitant low reliability.
The performance degradation due to blocking and the decrease in reliability due to lack of fault tolerance become increasingly serious with the size of the network, because the number of paths passing through a given link increase linearly with N. Fortunately, it turns out that the addition of a few links per stage results in a substantial increase in the number of multiple paths between every network input and network output pair, and that ameliorates the disadvantages. Such networks are called multiple path multistage networks. In setting up a connection, multiple path multistage interconnection networks allow an alternate path to be chosen where conflicts arise from a blocking situation or when faults develop in the network. This provides for both better performance and higher reliability than that which is offered by the unique path multistage networks.
To better understand the principles of the invention described below, it may be useful to have a particular multiple path multistage network in mind. To that end, the following describes the augmented shuffle exchange network described in "Augmented Shuffle-Exchange Multistage Interconnection Networks", V. P. Kumar and S. M. Reddy, Computer, Jun. 1987, pp. 30-40. FIG. 6 of the article is reproduced here as FIG. 1 to aid in explaining the network. The augmented shuffle exchange network of FIG. 1 is still a blocking network, but the probability of blocking is reduced because of the multiple paths that are included. This feature is illustrated in the description below.
FIG. 1 presents a five stage network with 16 inputs and outputs. The stage numbers are shown in the bottom of the drawing. The switches in stages 1 and 2 each have two inputs at the left of the switch, one input at the top of the switch, two outputs at the right of the switch, and one output at the bottom of the switch. The switches at stage 3 of FIG. 1 only have two inputs and two outputs, each. When the inputs at the top of the switches and the outputs at the bottom of the switches are not considered (in stages 2 and 3), the three center stages of FIG. 1 simply depict a portion of a conventional shuffle exchange network. The connections of the top inputs in the switches of stages 2 and 3 with the bottom outputs of the switches in those stages form the additional, alternate, routing paths for the network. For example, if inputs 11 and 13 of switch 10 wish to be connected to network outputs 0 and 4 respectively, switch 10 can be set to connect input 11 to output 12, switch 20 can be set to connect input 12 to output 22, switch 30 can be set to connect input 22 to output 32, and switch 40 can be set to apply input 32 to output 0 of the network. Connecting input 13 to output 15 in switch 10 would not be useful because, as shown by FIG. 1, the link connected to output 15 cannot reach output 4 of the network. Therefore, input 13 must be connected within switch 10 to the alternate routing output of the switch; to wit, output 14. Output 14 of switch 10 is connected to the top input of switch 16. From output 14, the signal of input 13 may then be routed to switch 26 through switch 16, then to switch 36, to switch 46, and finally to output 4 of the network. Thus, the alternate routing inputs and outputs of the switches in the stages 1 and 2 of FIG. 1 together the links that connect them provide for an alternate path in the network.
It may be noted that FIG. 1 also includes stage 0 and stage 4 which are somewhat different in kind from the center three stages. Specifically, stage 0 comprises two-input/one-output multiplexer switches, and stage 4 comprises one-input/two-outputs multiplexer stages. In stage 0, each switch i derives its input signals from inputs i and ##EQU1## of the network. Thus, switch i where i=0 (i.e., switch 50) derives its inputs from the network's input 0 and input 8, switch i where i=2 (i.e., switch 51) derives its inputs from the network's input 2 and input 10, etc. In stage 4, the switches are arranged in groups of four. The first and third switches in the top group connect to the network's output 0, and output 1, and the second and fourth switches connect to the network's output 2 and output 3. The next group of four switches connect to the network's outputs 4-7, etc.
The reliability and performance improvement obtained from a multipath network depend on how effectively the available alternate paths are used by the routing algorithm. One can use a back-tracking routing algorithm that exhaustively searches for an available fault-free path. However, implementation of back-tracking is relatively expensive in terms of hardware, and back-tracking can take an inordinately long time to set up connections. Non back-tracking algorithms, therefore, are much preferred. One such algorithm is described in the aforementioned Kumar et al. paper. The algorithm assumes that each switch is able to ascertain whether it is faulty in any one of its three outputs. If a faulty condition is discovered, the switch is able to communicate that information, through its inputs, to the switches to which it is connected.
The overall algorithm results from each switch performing a specified routing task. Each switch in the network has buffers at each of its three inputs. The buffers store incoming packet signals and in instances of contention, when alternate routing is not possible (such as when all three inputs have incoming pockets), the buffers store the packets so that no information is lost. Of course, the packet signals considered here are the conventional packet signals which contain a header section and a data section. The header section contains different types of information, including the source address, the destination address, parity, etc. In operation, each switch looks at the destination addresses of the packets that it receives for routing at each of the three inputs. The packets are then switched to the appropriate outputs (the two outputs on the right of the switch) based on the destination addresses of the packets in the buffers. If more than one packet is desirous of connection to a particular switch output, or if access to one of the required switch outputs is blocked by a fault in the switch, then the packet is switched to the auxiliary output of the switch (bottom output).
It may be noted that in stage 0, at the very input of the network, if access to one of the switches is blocked due to a fault, the packet at that switch is routed to another switch. It may also be noted that stage 3 switches, such as switch 36, do not have a top input and a bottom output shown. For purposes of the routing task, it may be assumed that those switches are identical to the switches in stages 1 and 2 but the bottom output tied to a faulty state.
The FIG. 1 network is described above in connection with packet switching. The same network is also described in connection with circuit switching in a PhD dissertation by V. P. Kumar, titled "On Highly Reliable High-Performance Multistage Interconnection Networks", University of Iowa, 1985. The switches described in the thesis have a modular design: there is an "input module" at each input of the switch and an "output module" at each output of the switch, for a total of six separate modules. Each input module is connected to each output module through a set of nine linking buses. Each module in the thesis switch is a state machine that implements the protocol functions in setting up a connection. The design presented employs an encoding arrangement for both the control and the data signals. The encoding employs the class of M-out-of-N codes for the control signals, for which TSC (Totally Self-Checking) checkers exist. For the data signals, the Berger code (which is also a TSC checkable code) is employed. The combinational logic portion of the modules is implemented using a single fault secure PLA (Programmable Logic Array). Each input module has a 1-to-3 demultiplexer for switching to each of the three outputs, and each output modules, in turn, has a 3-to-1 multiplexer which enables it to select from each of the three inputs. The control signals for the multiplexers and demultiplexers are generated by the control PLA. Finally, each module has an arrangement of TSC checkers that detect errors in the data lines as well as in the control paths.
The switch design described above is quite good, but it does have a number of problems. Specifically, any "line stuck-at" faults from the control PLA to the multiplexers and demultiplexers can cause corruption and/or misrouting of data. These failures can go undetected. Also, an error detected by a TSC checker in the data lines at an input module cannot be definitively pinpointed. It can be due to a fault in the preceding stage or in the current stage, and there is no way of distinguishing between these two possibilities. In short, the problems combine to make the switch not fully effective for the purpose of fault-tolerant operation.
SUMMARY OF THE INVENTION
These deficiencies are overcome and a fully fault-tolerant operation is attained in a new switch architecture that is able to detect and mask all single faults. The switch employs a controller that develops dual rail control signals. In one embodiment, the controller is made up of two controllers that receive the same inputs but generate complementary outputs. The complementary outputs form the dual rail signals that control the multiplexers which are interposed between the inputs and the outputs of the switch. The dual rail controls of the signal routing within the switch allow for effective detection of all single faults in the signal routing means. Inclusion of totally self checking circuits at the switch outputs as well as inputs enables users to readily isolate a fault and identify its source.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 presents a block diagram of an augmented shuffle exchange network employing switches that have an alternate path input and an alternate path output;
FIG. 2 depicts a general block diagram of a switch in a network such as the network of FIG. 1;
FIG. 3 shows the packet format to be used in the network;
FIGS. 4 through 4E illustrates one useful protocol to be employed in connection with the FIG. 2 switches;
FIGS. 5 and 5A together show a more detailed block diagram of the FIG. 2 switch, including the individual multiplexers, registers, TSC Checkers, and control;
FIGS. 6 and 6A present an operational sequence of the buffers within each of the switches in the FIG. 1 network; and
FIG. 7 gives the detailed circuit diagram of one bit within one multiplexer of the FIG. 4 switch embodiment.
DETAILED DESCRIPTION
FIG. 2 presents the general block diagram of a switch to be used in arrangements such as depicted in FIG. 1; e.g., switch 10 of FIG. 1. For illustrative purposes, the following description of the FIG. 1 network and the switches used in the network assumes that the FIG. 1 network operates in a pocket switching mode.
Unlike the switch design in the aforementioned thesis, which comprises six separate modules, with each including a control portion and a data portion, the FIG. 2 switch comprises a single control portion 61 and a single data portion 62. Portion 61 generates the control signals for the protocol with adjoining switches and the control signals for the multiplexing in the data portion. More specifically, control portion 61 includes a bus 63 that is connected to the alternate output port of some other switch. For example, bus 63 of switch 10 is connected to the alternate output port of switch 16 of FIG. 1. Bus 63 of switch 10 receives a MESSAGE and a MESSAGE signal (a signal in dual rail format, or complementary format, or dual rail code; this is to be distinguished from arrangements where data circuits and/or paths are duplicated and carry the same information) from switch 16 and sents a READY signal, a FAULT signal and a BACK-CHECK signal to switch 16.
Data portion 62 of switch 10 receives information from that same port of switch 16, but over bus 64. Bus 64 contains a VALID DATA signal line, a PARITY signal line, and 8 data lines. The parity sense employed is "odd". Odd parity is necessary for the TSC checkers to operate properly.
Control portion 61 also includes buses 65 and 67 which are connected to output ports of other switches in the immediately preceding stage of switches within the network of FIG. 1. In connection with switch 10, for example, bus 65 is connected to switch 50, whereas bus 67 is connected to switch 53. Data portion 62 also includes two additional buses that are connected to the two switches in the immediately preceding stage to which buses 65 and 67 are connected. These are buses 66 and 68, respectively.
The input interfaces of the control portion and the data portion have a parallel set of output interfaces. That is, control portion 61 includes buses 73, 75 and 77 that correspond to buses 63, 65, and 67. Similarly, data portion 62 includes buses 74, 76 and 78 that correspond to buses 64, 66, and 68.
In bus 63, the signals MESSAGE and MESSAGE indicate the presence of a packet. The signals READY, FAULT and BACK-CHECK are coded in 1-out-of-3 code and carry the flow control and fault notification information. In bus 64, the PARITY line carries the odd parity bit that is computed over the 8 data bit-lines (D0-D7) and the DATA VALID line.
FIG. 3 presents the format of packets that are passed through the switch of this invention. The first byte of the packet, i.e., the collection of the 8 bits on bus 64 at the first clock period, contains the address of the output port of the network to which the packet is to be switched. This address is followed by the remainder of the header and any number of data bytes.
The protocol signals used, and their timing, are illustrated in FIG. 4. The beginning of the packet is marked by the MESSAGE line rising from logic "0" to logic "1", and the end of a packet is delimited by the MESSAGE line falling back to logic "0". When the DATA VALID signal is asserted (logic "1"), it indicates the presence of legitimate signals on data lines D0 . . . D7. Conversely, when the DATA VALID signal is low, it is interpreted as an indication that the signals on the data lines are to be ignored. This situation might develop when the transmission rate of the source of the packet is slower than the transmission rate of the data buses in the switch. That is, since the switching network is synchronous, as depicted by the clock line 101 in FIG. 4, a synchronizing buffer must be included at the switching network's input. When the input data rate is slower than the rate of the switching network, "dead times" will occur when no new data is offered by the source. At such times the network input buffers will be empty and while the packet has not yet ended, there is no data to be transmitted. To inform the network of this state, the VALID DATA line goes "low". Thus, the MESSAGE lines and the DATA VALID line combine to handle the protocols for the slow source.
As the MESSAGE line on an input port of a switch is asserted and the packet address is captured in the first byte, control portion 61 determines the appropriate switch output port to which the packet should be routed. In the absence of a conflict, the control routes the received first byte to the appropriate switch output port and asserts the MESSAGE line on that switch output port (e.g. bus 75 of the source switch and bus 65 of the destination switch). When that switch output port is busy, the READY signal is sent back to the switch that submitted the packet (e.g. from bus 65 of the destination switch to bus 75 of the source switch). When the switch receives a READY signal on an output link during the transmission of a packet, it asserts its READY signal on the input link connected to that particular output link, and withholds further transmission. In other words, a switch that receives a READY signal on its bus 75 will reflect that READY signal to the input bus (63, 65 or 67) that is connected to bus 75. When the READY signal on the output link goes down, the switch drops the READY signal on its input link and resumes transmission. This is how the flow control is implemented for the fast source.
If the FAULT signal line that is fed to an output port of a switch from a subsequent switch goes high during the transmission of a packet, such as the FAULT line on bus 75, (not shown in FIG. 4) then the MESSAGE line on that output link is set to low by the switch that receives that FAULT indication (i.e. also on bus 75), and the remainder of the packet is lost. This FAULT signal stays high until it is manually reset following a repair of the faulty switch. While the FAULT line is high, the MESSAGE line cannot be raised at that switch port, and no packets can be routed to that switch port by control 61 of that switch. The purpose of setting the MESSAGE line to low value, which in effect says to the succeeding switch that the packet ended and there is no more data, is that there is no assurance as to what action, if any, is being taken by the faulty switch. If the faulty switch, in fact, continues to send data to some destination, that data would be corrupted. Sending the MESSAGE low signal terminates such transmission and has the additional benefit that the number of bytes received by that destination will not correspond to the expected number of bytes. That, in turn, would cause the destination to drop the entire packet that experienced a fault, which is a desirable result.
BACK-CHECK signal, generated in FAULT signal generator 97, is a redundant bit that, together with FAULT and READY signals, forms a 1-out-of-3 code. That is, of the three signals, exactly one takes the logic value "1", and the rest are "0", under fault-free operation. The interpretation of these signals is as follows.
______________________________________FAULT READY BACK-CHECK______________________________________1 0 0 The switch is faulty.0 1 0 The switch is ok, unable to receive data.0 0 1 The switch is ok.______________________________________
FIG. 5 provides a detailed block diagram of the switch architecture. Control portion 61 comprises control PLA 91, 1-out-of-3 code TSC checkers 96 and 98, master TSC checker 92, and FAULT signal generator circuit 97. Data portion 62 comprises input parity TSC checker 81, 82 and 83; output parity TSC checkers 84, 85, and 86; input buffers 87, 88, and 89; and multiplexers 93, 94, and 95.
PLA 91 carries out the control logic of the switch. It is implemented in two complementary PLAs (PLA+ and PLA-). The two control PLAs receive the same inputs and generate outputs which are mutually complementary. The inputs are the input MESSAGE message buses 102, 103, and 104 of buses 63, 65 and 67, respectively; the incoming READY, FAULT and BACK-CHECK buses 105, 106, and 107 of buses 75, 77, and 73, respectively, and the routing information on buses 108 208 and 308 from registers 87, 88 and 89, respectively. The outputs are sent, in dual rail form to buffers 87 (bus 109), 88 (bus 208), and 89 (bus 308), to multiplexers 93, 94 and 95, (buses 210, 211 and 212, respectively) and to faulty signal generator 97 (bus 213). Line 109, for example, enables register 87 to accept new data. Each of the control output pairs of PLA 91 is also sent to master TSC checker 92, to make sure that each pair is indeed carrying a dual rail signal. Master TSC checker 92 receives additional inputs and performs other checks, as explained below.
The 1-out-of-3 code TSC checker 96 is responsive to the READY, FAULT, and BACK-CHECK lines on buses 73, 75, and 77. More specifically, TSC checker 96 is responsive to the READY, FAULT and BACK-CHECK signals on buses 75 and 77 and TSC checker 98 is responsive to the READY, FAULT and BACK-CHECK signals on buses 77 and 73. Checkers 96 and 98 can be constructed in the manner described by Golan in "Design of totally self checking checker for 1-out-of-3 code," IEEE Transactions on Computers, Mar. 1984, pp. 998-999. The two output pairs of TSC Checker 96 are applied to master TSC checker 92.
Master checker 92 can be constructed as described, for example, in "Totally Self-Checking Circuits for Separate Codes," a PhD dissertation by M. J. Ashjaee, University of Iowa, Jul. 1976; specifically FIG. 1.8.
Controller 91 is shown in FIG. 5 to be a PLA. Of course, this is merely illustrative and any other method for developing the combinational logic necessary of controller 91 would suffice. In designing the function of the controller, one can easily separate the logic into two blocks: one that handles the protocol, such as flow control, and one that handles the actual switching (and alternate routing). The actual Boolean logic that needs to be carried out by controller 91 is strictly related to the network in which the switch of FIG. 5 is inserted. This is perfectly conventional.
In data portion 62, input bus 64 is applied to input buffer 87 and to TSC parity checker 81. Likewise, bus 66 is applied to input buffer 88 and to TSC parity checker 82, and bus 68 is applied to input buffer 89 and to TSC parity checker 83. The input TSC checkers are odd parity checkers. Their construction is conventional, as described for example by Carter and Schneider in "Design of Dynamically Checked Computers," IFIP68, Vol 2, Edinburg, Scotland, pp. 878-883, Aug. 1968. They send their outputs, in dual rail logic, to master TSC checker 92.
Input buffers 87-89 must have at least one "main-line" byte of memory and one spare byte of memory. One can have a larger number of memory bytes, and the larger number will improve performance of the switching network, as will be appreciated from the following description.
When a switch in some stage is blocked, the information that tells the system not to continue sending bytes of data (READY) is propagated back. In the mean time, data has entered the switch. If that data is not to be lost, it must be buffered. All the links that participate in the connection of an input of the network to the blocked switch are also blocked. Although the alternate routing capability of the FIG. 1 network ameliorates this problem, reducing the number of held links is beneficial. Increasing the memory size of the input buffers does exactly that. That is, when a larger buffer space is available at each input link, then each blocked switch would assert the READY signal to the preceding switch only when its buffer fills up. This quickly reduces the number of links that will be made busy by the back propagating READY signal.
The reason for the need of at least one byte of memory and of a spare byte of memory stems from the fact that there is a one-byte delay in moving the data forward, and an additional byte delay in communicating the READY condition back to the source. This is illustrated in FIG. 6.
FIG. 6 presents a sequence of signals that may occur in the switches of the FIG. 1 network. Block 100 represents the input buffer of a switch in stage 1, block 110 represents the input buffer of a switch in stage 2, and block 120 represents the input buffer of a switch in stage 3. This may be, for example, buffer 87 of FIG. 5. For simplicity, the multiplexers are not shown. Blocks 100, 110, and 120 can, of course, be constructed in an identical manner. Block 100 contains a one byte register 101 into which the incoming bytes are stored. Under control of signal C1, the output of register 101 is applied to the output of block 100 through one output, or to the input of register 102 through another output. Under control of signal C2, register 102 applies its contents to the output of block 100. The outputs of registers 101 and 102 are shown in FIG. 6 to be "collector ORed". It is assumed that registers 101 and 102 are of the type that can be placed in a neutral state. When using registers that cannot be placed in a neutral state, an additional multiplexer needs to be included to combine the outputs of registers 101 and 102, as appropriate.
At time t1, in accordance with FIG. 6, register 121 contains byte B0, register 111 contains byte B1, and register 101 contains byte B2. Registers 122, 111, and 102 are empty. If and when, at time t2, transmission is blocked from block 120 (for example, when the READY line goes high), byte B0 is transferred to register 122, byte B1 advances to register 121, byte B2 advances to register 111, and byte B3 is inserted into register 101. If transmission is still blocked, at time t3 byte B2 is transferred to register 111, byte B3 advances to register 111, and byte B4 is inserted into register 101. If, for example, transmission resumes at time t4, then the contents of register 122 is transmitted to the output of block 120. The contents of register 121 is left unchanged. Concurrently, the contents of register 101 is moved to register 102 while byte B5 is inserted into register 101. Byte B5 is inserted into register 101 and byte B4 is transferred to register 102 because the READY signal has not yet reached the source. At time t5, the READY signal prevents further insertion of bytes by the source. Register 121 accepts byte B2 from block 110, register 111 maintains byte B3, register 102 maintains byte B4, and register 101 maintains byte B5. Registers 122 and 112 are empty. At time t6, register 121 receives byte B3 from register 111, register 111 receives byte B4 from register 102, and register 101 maintains byte B5. Registers 122, 112 and 102 are empty. Finally, transmission by the source is enabled again and, at time t7, register 121 contains byte B4, register 111 contains byte B5, register 101 contains byte B6, and registers 122, 112 and 102 are empty.
The outputs of input buffers 87-89 are fed to multiplexers 93-95. More specifically, buffer 87 (the alternate input of the switch) applies its signals to multiplexers 93 and 94, while buffers 88 and 89 apply their signals to all three of the multiplexers (93, 94 and 95). Multiplexer 93 outputs its signals to bus 76 and to output TSC parity checker 84, multiplexer 94 outputs its signals to bus 78 and to output TSC parity checker 85, and multiplexer 95 outputs its signals to bus 74 and to output TSC parity checker 86.
All of the TSC parity checker outputs (81-86), the MESSAGE and MESSAGE signals, and the outputs of the control PLA are fed to master TSC checker 92. Checker 92 combines the outputs of the checkers and makes sure that the checkers themselves are operational (i.e., they develop dual rail outputs). In this manner, an error flagged by any one of the TSC Checkers ultimately results in an error indication at the master TSC checker 92. The error indication from the master TSC checker 92 is applied to FAULT generator circuit 97. Generator 97 combines this information with the READY information to form the FAULT line signals that are sent to the predecessor switches. Specifically, generator 97 can simply be one Exclusive OR gate to which the Master TSC checker outputs are connected, and the output of the Exclusive OR gate forms the FAULT line. The FAULT line of the first Exclusive OR gate can then be combined with the READY line in a second Exclusive OR gate and the output of the second Exclusive OR gate forms the BACK-CHECK line. The output READY line of generator 97 can be the same as the input READY line of generator 97.
The inclusion of the output TSC checkers facilitates a precise determination of the source of an error. If a data error is caused within the data paths in a switch, the output checkers within the switch will cause an error indication to be generated within that switch. In the absence of the output checkers, the errors would still be detected in the next switch, but these errors could be incorrectly attributed to the switch where they are detected.
FIG. 7 presents a schematic diagram of one of the multiplexers in the FIG. 5 switch. It comprises ten blocks 125 that operate in unison under control of three pairs of signals from controller 91: eight blocks for the data, one block for the parity, and one block for the DATA VALID line. Within block 125, a 1-out-of-3 selection is realized with three pass-thru branches that are connected to the input of a buffer amplifier 122. Each pass-thru branch comprises a pair of complementary MOS transistors (121 and 122) the are interconnected in parallel (sources and drains connected) and each of the transistors is controlled by complementary signals. In this manner, under normal operation, either both transistors are in on, or both transistors are off. Any single fault in the pass transistors would cause a data error that can be detected by the parity checkers. Any single error in the control signals would cause all the bits of the multiplexer output to become zero, which is also detectable by the odd output parity checkers.
|
A multi-stage, alternate routing switching network is enhanced with a switch architecture that is able to detect and mask all single faults. The switch employs a controller that develops dual rail control signals. In one embodiment, the controller is made up of two controllers that receive the same inputs but generate complementary outputs. The complementary outputs form the dual rail signals that control the multiplexers that are interposed between the inputs and the outputs of the switch. The dual rail control of the signal routing within the switch allow for effective detection of all signal faults in the signal routing means. Inclusion of totally self checking circuits at the switch outputs as well as inputs enables users to readily isolate a fault and identify its source.
| 7
|
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The invention relates generally to methods and procedures for maintaining well control during drilling operations. More specifically, the invention relates to well control methods and procedures where “riserless” drilling systems are used.
[0003] 2. Background Art
[0004] Exploration companies are continually searching for methods to make deep water drilling commercially viable and more efficient. Conventional drilling techniques are not feasible in water depths of over several thousand feet. Deep water drilling produces unique challenges for drilling aspects such as well pressure control and wellbore stability.
Deep Water Drilling
[0005] Deep water drilling techniques have, in the past, typically relied on the use of a large diameter marine riser to connect drilling equipment on a floating vessel or a drilling platform to a blowout preventer stack on a subsea wellhead disposed on the seafloor. The primary functions of the marine riser are to guide a drill string and other tools from the floating vessel to the subsea wellhead and to conduct drilling mud and earth cuttings from a subsea well back to the floating vessel. In deeper waters, conventional marine riser technology encounters severe difficulties. For example, if a deep water marine riser is filled with drilling mud, the drilling mud in the riser may account for a majority of the drilling mud in the circulation system. As water depth increases, the drilling mud volume increases. The large volume of drilling mud requires an excessively large circulation system and drilling vessel. Moreover, an extended length riser may experience high loads from ocean currents and waves. The energy from the currents and waves may be transmitted to the drilling vessel and may damage both the riser and the vessel.
[0006] In order to overcome problems associated with deep water drilling, a technique known as “riserless” drilling has been developed. Not all riserless techniques operate without a marine riser. The marine riser may still be used for the purpose of guiding the drill string to the wellbore and for protecting the drill string and other lines that run to and from the wellbore. When marine risers are used, however, they typically are filled with seawater rather than drilling mud. The seawater has a density that may be substantially less than that of the drilling mud, substantially reducing the hydrostatic pressure in the drilling system.
[0007] An example of a riserless drilling system is shown in U.S. Pat. No. 4,813,495 issued to Leach and assigned to the assignee of the present invention. A riserless drilling system 10 of the '495 patent is shown in FIG. 1 and comprises a drill string 12 including drill bit 20 and positive displacement mud motor 30 . The drill string 12 is used to drill a wellbore 13 . The system 10 also includes blowout preventer stack 40 , upper stack package 60 , mud return system 80 , and drilling platform 90 . As drilling is initiated, drilling mud is pumped down through the drill string 12 through drilling mud line 98 by a pump which forms a portion of mud processing unit 96 . The drilling mud flow operates mud motor 30 and is forced through the bit 20 . The drilling mud is forced up a wellbore annulus 13 A and is then pumped to the surface through mud return system 80 , mud return line 82 , and subsea mudlift pump 81 . This process differs from conventional drilling operations because the drilling mud is not forced upward to the surface through a marine riser annulus.
[0008] The blowout preventer stack 40 includes first and second pairs of ram preventers 42 and 44 and annular blowout preventer 46 . The blowout preventers (“BOP”s) may be used to seal the wellbore 13 and prevent drilling mud from travelling up the annulus 13 A. The ram preventers 42 and 44 include pairs of rams (not shown) that may seal around or shear the drill string 12 in order to seal the wellbore 13 . The annular preventer 46 includes an annular elastomeric member that may be activated to sealingly engage the drill string 12 and seal the wellbore 13 . The blowout preventer stack 40 also includes a choke/kill line 48 with an adjustable choke 50 . The choke/kill line 48 provides a flow path for drilling mud and formation fluids to return to the drilling platform 90 when one or more of the BOPs ( 42 , 44 , and 46 ) have been closed.
[0009] The upper end of the BOP stack 40 may be connected to the upper stack package 60 as shown in FIG. 1. The upper stack package 60 may be a separate unit that is attached to the blowout preventer stack 40 , or it may be the uppermost element of the blowout preventer stack 40 . The upper stack package 60 includes a connecting point 62 to which mud return line 82 is connected. The upper stack package 60 may also include a rotating head 70 . The rotating head 70 may be a subsea rotating diverter (“SRD”) that has an internal opening permitting passage of the drill string 12 through the SRD. The SRD forms a seal around the drill string 12 so that the drilling mud filled annulus 13 A of the wellbore 13 is hydraulically separated from the seawater. The rotating head 70 typically includes both stationary elements that attach to the upper stack package 40 and rotating elements that sealingly engage and rotate with the drill string 12 . There may be some slippage between rotating elements of the rotating head 70 and the drill string 12 , but the hydraulic seal is maintained. During drill pipe “trips” to change the bit 20 , the rotating head 70 is typically tripped into the hole on the drill string 12 before fixedly and sealingly engaging the upper stack package 60 that is connected to the BOP stack 40 .
[0010] The lower end of the BOP stack 40 may be connected to a casing string 41 that is connected to other elements (such as casing head flange 43 and template 47 ) that form part of a subsea wellhead assembly 99 . The subsea wellhead assembly 99 is typically attached to conductor casing that may be cemented in the first portion of the wellbore 13 that is drilled in the seafloor 45 . Other portions of the wellbore 13 , including additional casing strings, well liners, and open hole sections extend below the conductor casing.
[0011] The mud return system 80 includes the subsea mudlift pump 81 that is positioned in the mud return line 82 adjacent to the upper stack package 60 . The subsea mudlift pump 81 in the '495 patent is shown as a centrifugal pump that is powered by a seawater driven turbine 83 that is, in turn, driven by a seawater transmitting powerfluid line 84 . The mud return system 80 boosts the flow of drilling mud from the seafloor 45 to the drilling mud processing unit 96 located on the drilling platform 90 . Drilling mud is then cleaned of cuttings and debris and recirculated through the drill string 12 through drilling mud line 98 .
Subsea Well Control
[0012] When drilling a well, particularly an oil or gas well, there exists the danger of drilling into a formation that contains fluids at pressures that are greater than the hydrostatic fluid pressure in the wellbore. When this occurs, the higher pressure formation fluids flow into the well and increase the fluid volume and fluid pressure in the wellbore. The influx of formation fluids may displace the drilling mud and cause the drilling mud to flow up the wellbore toward the surface. The formation fluid influx and the flow of drilling and formation fluids toward the surface is known as a “kick.” If the kick is not subsequently controlled, the result may be a “blowout” in which the influx of formation fluids (which, for example, may be in the form of gas bubbles that expand near the surface because of the reduced hydrostatic pressure) blows the drill string out of the well or otherwise destroys a drilling apparatus. An important consideration in deep water drilling is controlling the influx of formation fluid from subsurface formations into the well to control kicks and prevent blowouts from occurring.
[0013] Drilling operations typically involve maintaining the hydrostatic pressure of the drilling mud column above the formation fluid pressure. This is typically done by selecting a specific drilling mud density and is typically referred to as “overbalanced” drilling. At the same time, however, the bottom hole pressure of the drilling mud column must be maintained below a formation fracture pressure. If the bottom hole pressure exceeds the formation fracture pressure, the formation may be damaged or destroyed and the well may collapse around the drill string.
[0014] A different type of drilling regime, known as “underbalanced” drilling, may be used to optimize the rate of penetration (“ROP”) and the efficiency of a drilling assembly. In underbalanced drilling, the hydrostatic pressure of the drilling mud column is typically maintained lower than the fluid pressure in the formation. Underbalanced drilling encourages the flow of formation fluids into the wellbore. As a result, underbalanced drilling operations must be closely monitored because formation fluids are more likely to enter the wellbore and induce a kick.
[0015] Once a kick is detected, the kick is typically controlled by “shutting in” the wellbore and “circulating out” the formation fluids that entered the wellbore. Referring again to FIG. 1, a well is typically shut in by closing one or more BOPs ( 42 , 44 , and/or 46 ). The fluid influx is then circulated out through the adjustable choke 50 and the choke/kill line 48 . The choke 50 is adjustable and may control the fluid pressure in the well by allowing a buildup of back pressure (caused by pumping drilling mud from the mud processing unit 96 ) so that the kick may be circulated through the drilling mud processing unit 96 in a controlled process. The drilling mud processing unit 96 has elements that may remove any formation fluids, including both liquids and gases, from the drilling mud. The drilling mud processing unit 96 then recirculates the “cleaned” drilling mud back through the drill string 12 . Typically, as the kick is circulated out, the drilling mud that is being pumped back into the wellbore 13 through drill string 12 has an increased density of a preselected value. The resulting increased hydrostatic pressure of the drilling mud column may equal or exceed the formation pressure at the site of the kick so that further kicks are prevented. This process is referred to as “killing the well.” The kick is circulated out of the wellbore and the drilling mud density is increased in substantially one complete circulation cycle (for example, by the time the last remnants of the drilling mud with the pre-kick mud density have been circulated out of the well, mud with the post-kick mud density has been circulated in as a substitute). When the wellbore is stabilized, drilling operations may be resumed or the drill string 12 may be tripped out of the wellbore 13 . This method of controlling a kick is typically referred to as the “Wait and Weight” method. The Wait and Weight Method has historically been the preferred method of circulating out a kick because it generally exerts less pressure on the wellbore 13 and the formation and requires less circulating time to remove the influx from the drilling mud.
[0016] Another method for controlling a kick is typically referred to as the “Driller's Method.” Generally, the Driller's Method is accomplished in two steps. First, the kick is circulated out of the wellbore 13 while maintaining the drilling mud at an original mud weight. This process typically takes one complete circulation of the drilling mud in the wellbore 13 . Second, drilling mud with a higher mud weight is then pumped into the wellbore 13 to overcome the higher formation pressure that produced the kick. Therefore, the Driller's Method may be referred to as a “two circulation kill” because it typically requires at least two complete circulation cycles of the drilling mud in the wellbore 13 to complete the process.
[0017] A device known as a drill string valve (“DSV”) may be used as a component of either of the previously referenced well control methods. A DSV is typically located near a bottom hole assembly and includes a spring activated mechanism that is sensitive to the pressure inside the drill string. When drill string pressure is lowered below a preselected level, the spring activates a flow cone that moves to block flow ports in a flow tube. In order for drilling mud to flow through the drill string, the flow ports must be at least partially open. Thus, the DSV permits flow through the drill string if sufficient surface pump pressure is applied to the drilling fluid column, and the DSV typically only permits flow in one direction so that it act as a check valve against mud flowing back toward the surface.
[0018] The spring pressure in the DSV may be adjusted to account for factors such as the depth of the wellbore, the hydrostatic pressure exerted by the drilling mud column, the hydrostatic pressure exerted by the seawater from a drilling mud line to the surface, and the diameter of drill pipe in the drill string. The drilling mud line may be defined as a location in a well where a transition from seawater to drilling mud occurs. For example, in the system 10 shown in FIG. 1, the drilling mud line is defined by the hydraulic seal of the rotating head 70 that separates the drilling mud of the wellbore annulus 13 A from seawater. The DSV may be used to stop drilling mud from experiencing “free-fall” when the mud circulation pumps are shut down and the well is shut-in.
[0019] Using the system of the Leach '495 patent as an example, when the pumps of the mud processing unit 96 are shut down and no DSV is present in the drill string 12 , the mud column hydrostatic pressure in the drill string 12 is greater than the sum of the hydrostatic pressure of the drilling mud in the wellbore annulus 13 A and a suction pressure generated by the subsea mudlift pump 81 . Drilling mud, therefore, free-falls in the drill string into the wellbore annulus 13 A until the hydrostatic pressure of the mud column in the drill string 12 is equalized with the sum of the hydrostatic pressure of the drilling mud in the wellbore annulus 13 A and the mudlift pump 81 suction pressure. Thus, the well continues to flow while equilibrium is established. The continued flow of drilling mud in the well after pump shut-down may typically be referred to as an “unbalanced U-tube” effect. The DSV, which should be in a closed position after the pumps are shut-down, may prevent the free-fall of drilling mud in the wellbore that may be attributable to the unbalanced U-tube.
[0020] In contrast, in conventional drilling systems where drilling mud is returned to the surface through the wellbore annulus, the drilling mud circulation system forms a “balanced U-tube” because there is no flow of drilling mud in the well after the surface pumps are shut down. The well does not flow because the hydrostatic pressure of the drilling mud in the drill string is balanced with the hydrostatic pressure of the mud in the wellbore annulus.
[0021] Well control procedures may be complicated by a leaking DSV. For example, the spring in the DSV must be adjusted correctly so that it will activate the flow cone and block the flow ports when pressure is removed from the mud column such as by shutting down the surface mud pumps. If the flow ports remain at least partially open, the well will continue to flow after all the pumps have been shut down and/or after the well has been fully shut-in. Further, the DSV may develop leaks from flow erosion, corrosion, or other factors.
[0022] Typically, there are two conditions where the DSV may be checked for leaks. The first condition is during normal drilling operations when, for example, circulation of drilling mud is stopped so that a drill pipe connection may be made (all pumps must be shut off for the DSV check). In this case, an effort is made to distinguish between a leaking DSV and a possible kick. The second condition occurs after the well has been fully shut-in on a kick (again, all pumps must be shut off for the DSV check). In this case, an effort is made to distinguish between a leaking DSV and additional flow that may have entered the well from the known kick. In both cases it is important to check the DSV for leaks because otherwise it may be difficult to determine if additional flow in the well is due to a leaking or partially open DSV or to additional flow that has entered the well from a kick.
[0023] Reliable methods are needed to quickly and efficiently control and eliminate kicks that are experienced when drilling wells. The methods must account for the special configurations of deepwater drilling systems and must function both with and without the use of a DSV. The methods must also be designed to determine the difference between a leaking DSV and a kick that may have occurred during drilling operations, and also between a leaking DSV and additional flow that may occur after a kick is shut-in. In either case, the kicks come from formations with pore pressures that exceed the fluid pressure in the wellbore. Finally, the methods should result in a hydrostatically “dead” well so that the drill string may be removed from the wellbore or so that drilling operations may resume.
SUMMARY OF THE INVENTION
[0024] One aspect of the invention is a method for a dynamic shut-in of a subsea mudlift drilling system. The method comprises detecting a kick, isolating a wellbore, and adjusting a subsea mudlift pump and a surface mud pump to provide a selected wellbore pressure. Selected well parameters are measured and used to calculate a kick intensity.
[0025] Another aspect of the invention is a method for a dynamic shut-in of a subsea mudlift drilling system comprising detecting a kick and isolating a wellbore. A first inlet pressure of a subsea mudlift pump and a first drill pipe pressure are measured. A rate of the subsea mudlift pump and a rate of a surface mud pump are adjusted to pre-kick circulation rates. A second inlet pressure of the subsea mudlift pump and a second drill pipe pressure are measured. The measurements are used to calculate a kick intensity.
[0026] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] [0027]FIG. 1 shows a schematic view of a prior art riserless drilling system.
[0028] [0028]FIG. 2 shows an example of a typical system used in an embodiment of the invention.
[0029] [0029]FIG. 3 shows a flow chart of a dynamic shut-in procedure in an embodiment of the invention.
DETAILED DESCRIPTION
[0030] [0030]FIG. 2 shows an example of a typical drilling system 101 used in an embodiment of the invention. The drilling system 101 presented in the example is provided for illustration of the methods used in the present invention and is not intended to limit the scope of the invention. The methods of the invention may function in arrangements that differ from the drilling system 101 shown in FIG. 2.
[0031] The drilling system 101 has a surface drilling mud circulation system 100 that includes a drilling mud storage tank (not shown separately) and surface mud pumps (not shown separately). The surface drilling mud circulation system 100 and other surface components of the drilling system 101 are located on a drilling platform (not shown) or a floating drilling vessel (not shown). The surface drilling mud circulation system 100 pumps drilling mud through a surface pipe 102 into a drill string 104 . The drill string 104 may include drill pipe (not shown), drill collars (not shown), a bottom hole assembly (not shown), and a drill bit 106 and extends from the surface to the bottom of a well 108 . The drill string 104 may also include a drill string valve 110 .
[0032] The drilling system 101 may include a marine riser 112 that extends from the surface to a subsea wellhead assembly 114 . The marine riser 112 forms an annular chamber 120 that is typically filled with seawater. A lower end of the marine riser 112 may be connected to a subsea accumulator chamber (“SAC”) 116 . The SAC 116 may be connected to a subsea rotating diverter 118 . The SRD 118 functions to rotatably and sealingly engage the drill string 104 and separates drilling mud in a wellbore annulus 122 from seawater in an annular chamber 120 of the marine riser 112 .
[0033] A discharge port of the SRD 118 may be connected to an inlet of a subsea mudlift pump (“MLP”) 124 . An outlet of the MLP 124 is connected to a mud return line 126 that returns drilling mud from the wellbore annulus 122 to the surface drilling mud circulation system 100 . The MLP 124 typically operates in an automatic rate control mode so that an inlet pressure of the MLP 124 is maintained at a constant level. Typically, the MLP 124 inlet pressure is maintained at a level equal to the seawater hydrostatic pressure at the depth of the MLP 124 inlet plus a differential pressure that may be, for example, 50 psi. However, the MLP 124 pumping rate may be adjusted so that back pressure may be generated in the wellbore annulus 122 . The MLP 124 may be a centrifugal pump, a triplex pump, or any other type of pump known in the art that may function to pump drilling mud from the seafloor 128 to the surface. Moreover, the MLP 124 may be powered by any means known in the art. For example, the MLP 124 may be powered by a seawater powered turbine or by seawater pumped under pressure from an auxiliary pump.
[0034] The inlet of the MLP 124 may be connected to a top of a blowout preventer stack 130 . The BOP stack 130 may be of any design known in the art and may contain several different types of BOP. As an example, the BOP stack 130 shown in FIG. 2 includes an upper annular BOP 132 , a lower annular BOP 134 , an upper casing shear ram preventer 136 , a shear ram preventer 138 , and upper, middle, and lower pipe ram preventers 140 , 142 , and 144 . The BOP stack 130 may have a different number of preventers if desired, and the number, type, size, and arrangement of the blowout preventers is not intended to limit the scope of the invention.
[0035] The BOP stack 130 also includes isolation lines such as lines 146 , 148 , 150 , 152 , and 154 that permit drilling mud to be circulated through choke/kill lines 156 and 158 after any of the BOPs have been closed. The isolation lines ( 146 , 148 , 150 , 152 , and 154 ) and choke/kill lines ( 156 and 158 ) may be selectively opened or closed. The isolation lines ( 146 , 148 , 150 , 152 , and 154 ) and the choke/kill lines ( 156 and 158 ) are important to the function of the invention because drilling mud must be able to flow in a controlled manner from the surface, through the well, and back after the BOPs are closed.
[0036] A lower end of the BOP stack 130 may be connected to a wellhead connector 160 that may be attached to a wellhead housing 162 positioned near the seafloor 128 . The wellhead housing 162 may typically be connected to conductor pipe (also referred to as conductor casing) 164 that is cemented in place in the well 108 near the seafloor 128 . Additional casing strings, such as casing string 166 , may be cemented in the well 108 below the conductor pipe 164 . Furthermore, additional casing and liners may be used in the well 108 as required.
[0037] When drilling a well 108 , kicks may be encountered when a formation fluid (or “pore”) pressure is greater than a hydrostatic pressure in the wellbore 168 . Control of the kick is critical to the safety of personnel on the drilling platform or drilling vessel. Moreover, control of the kick is critical to preserving the integrity of the environment. Therefore, a dynamic shut-in procedure, an example of which is shown in FIG. 3, has been developed that may enable the well ( 108 in FIG. 2) to be shut-in, a kick intensity to be determined, and the kick to be killed so that drilling operations may resume. The flowchart of FIG. 3 serves as an example of an embodiment of the invention. However, the dynamic shut-in procedure may be modified, and the embodiment shown in FIG. 3 is not intended to limit the scope of the invention.
[0038] The dynamic shut-in procedure begins with detection of the formation fluid influx, or kick, as shown in block 200 of FIG. 3. Potential kick indicators may include, for example, a “drilling break” where the rate of penetration (“ROP”) increases substantially, an increase in the MLP ( 124 in FIG. 2) rate, a volume gain in a riser trip tank (not shown), a volume increase in a surface mud tank (not shown) that forms a part of the surface drilling mud circulation system ( 100 in FIG. 2), and continued flow in the well ( 108 in FIG. 2) after the surface mud pumps are shut down and after the U-tube has been permitted to flow. Other kick indicators exist, however, and the choice of a kick indicator is not intended to limit the scope of the dynamic shut-in procedure. A preferred indicator, however, is an increase in the MLP ( 124 in FIG. 2) rate. The MLP ( 124 in FIG. 2) rate may be calculated, for example, with a device such as a flow-meter or by a device that counts pump strokes or pump revolutions per minute. PATENT
[0039] After a kick has been detected, the wellbore ( 168 in FIG. 2) may be isolated (as shown at block 210 ) so that the dynamic shut-in procedure may continue. The wellbore ( 168 in FIG. 2) is isolated by forming a controlled hydraulic seal between the well ( 108 in FIG. 2) and the rest of the system ( 101 in FIG. 2). A first step is to lift the drill string ( 104 in FIG. 2) and the drill bit ( 106 in FIG. 2) off of a bottom of the well ( 108 in FIG. 2). This may be achieved, for example, by raising a top drive or a kelly on the drilling platform or drilling vessel. A bypass line, such as isolation line ( 154 in FIG. 2), may be opened prior to the closing of at least one BOP (such as upper annular BOP 132 in FIG. 2). Opening the isolation line ( 154 in FIG. 2) permits drilling mud to flow through the MLP ( 124 in FIG. 2) after the upper annular BOP ( 132 in FIG. 2) sealingly engages the drill string ( 104 in FIG. 2). The closing of the upper annular BOP ( 132 in FIG. 2) is a well control measure that may prevent a kick from circulating up from the bottom of the well ( 108 in FIG. 2) to the SRD ( 118 in FIG. 2) and, subsequently, into the annulus ( 120 in FIG. 2) of the marine riser ( 112 in FIG. 2). The SAC ( 116 in FIG. 2) may typically be isolated from the well ( 108 in FIG. 2) during normal drilling operations to prevent a gas influx from entering the marine riser ( 112 in FIG. 2). However, if the SAC ( 116 in FIG. 2) is not isolated from the well ( 108 in FIG. 2), it may be isolated by closing an SRD bypass line (not shown) or by closing SAC isolation valves (not shown).
[0040] The MLP ( 124 in FIG. 2) inlet pressure and the drill pipe pressure (DPP) are measured and recorded (as shown at block 220 ) for use in later calculations of the kick intensity. The MLP ( 124 in FIG. 2) rate is then adjusted to a pre-kick circulating rate, as shown at block 230 . The adjustment is typically required because the MLP ( 124 in FIG. 2) rate may increase because of the increase in the fluid volume in the well ( 108 in FIG. 2) caused by the influx. The MLP ( 124 in FIG. 2) rate may be adjusted to increase the bottom hole pressure (BHP) to a level sufficient to stop the flow from the formation. However, the MLP ( 124 in FIG. 2) rate must be carefully monitored so that it does not fall below a rate that raises the MLP ( 124 in FIG. 2) inlet pressure above a predetermined level. For example, if lowering the MLP ( 124 in FIG. 2) rate raises the MLP ( 124 in FIG. 2) inlet pressure above a predetermined level, the wellbore ( 168 in FIG. 2) pressure may exceed the formation fracture pressure. Exceeding the formation fracture pressure may damage the wellbore ( 168 in FIG. 2) or may cause the wellbore ( 168 in FIG. 2) to collapse around the drill string ( 104 in FIG. 2).
[0041] If the MLP ( 124 in FIG. 2) fails to respond to control signals designed to adjust the MLP ( 124 in FIG. 2) rate, the surface pumps may be shut down and fluid from the well ( 108 in FIG. 2) may be diverted to an auxiliary line (not shown), such as a seawater filled boost line, in order to control the kick. Diversion of well ( 108 in FIG. 2) fluid to the auxiliary line is preferable to diverting fluid to the SAC ( 116 in FIG. 2) or to the marine riser ( 112 in FIG. 2) because of the possibility of gas entry into the riser ( 112 in FIG. 2). Moreover, as long as the wellbore ( 168 in FIG. 2) volume per foot is larger than the volume per foot of the auxiliary line, the kick may tend to “selfkill” when the fluid is diverted.
[0042] As the MLP ( 124 in FIG. 2) rate is adjusted to the pre-kick circulating rate, the surface mud pumps are substantially simultaneously adjusted to a pre-kick circulating rate (also shown at block 230 ). The adjustment of the surface mud pumps is necessary when the surface mud pump rate has also changed because of the kick. Typically, the surface mud pump rate will increase after a kick because of the loss of hydrostatic pressure in the annulus ( 122 in FIG. 2) due to the presence of “light” (e.g., less dense) fluid from the influx. After the surface mud pump rate and the MLP ( 124 in FIG. 2) rate are adjusted to pre-kick circulating rates, the DPP is monitored to determine when it is stable.
[0043] When the DPP has stabilized, the MLP ( 124 in FIG. 2) inlet pressure, the DPP, and a “mud pit gain” are measured and recorded, as shown at block 240 . The mud pit gain refers to a mud volume increase of the surface mud circulation system ( 100 in FIG. 2) storage tanks that are also known as “pits.” If a fluid influx has entered a well ( 108 in FIG. 2), the mud volume in the pits may be greater than the volume contained in the pits while circulating prior to the kick. The increase in mud volume is known as the “pit gain.” When the DPP and the MLP ( 124 in FIG. 2) inlet pressure stabilize, the well is “dynamically dead” and the dynamic shut-in procedure is complete.
[0044] The pressures recorded before and after the MLP ( 124 in FIG. 2) rate and the surface pump rate have been adjusted may be compared to determine the kick intensity (block 250 ). The increase in the DPP is typically a dynamic underbalance pressure (“DUP”). The DUP is equivalent to a conventional shut-in drill pipe pressure (“SIDP”) minus an annular friction pressure (AFP). The AFP is a pressure loss experienced because of the friction between the drilling mud and annular surfaces (outer walls of the drill string ( 104 in FIG. 2) and inner walls of the well ( 108 in FIG. 2)). The AFP is typically estimated by methods known in the art for a given drilling arrangement. For example, factors that may be considered in estimating the AFP include a drilling mud flow rate, a depth of the well ( 108 in FIG. 2), a drilling mud viscosity, a bottom hole assembly configuration, and a wellbore ( 168 in FIG. 2) configuration. However, other factors may be accounted for and the factors used in the estimation are not intended to limit the scope of the invention. Therefore, if an estimated AFP is known for the system ( 101 in FIG. 2), the conventional SIDP may be determined as:
[0045] SIDP=DUP+AFP.
[0046] The SIDP may be substantially equal to the kick intensity where the kick intensity may be defined as, for example, an excess of formation fluid (pore) pressure above a fluid pressure in the wellbore ( 168 in FIG. 2). The determination of the kick intensity is important to further well control procedures, particularly procedures used to “statically kill” the well ( 108 in FIG. 2). For example, the kick intensity must be known so that a kill mud weight may be determined so that drilling mud with the kill mud weight may be circulated into the well ( 108 in FIG. 2) to at least balance the formation pore pressure that induced the kick.
[0047] After the well has been dynamically killed, further steps may be taken in the well control procedure (as shown at block 260 ). For example, a check for leaks in the drill string valve ( 110 in FIG. 2) may be performed as disclosed in the method of co-pending U.S. application Ser. No. ______, filed on even date herewith, titled “Method for Detecting a Leak in a Drill String Valve,” and assigned to the assignee of the present invention. The well may then be statically killed by the method disclosed in co-pending U.S. application Ser. No. ______, filed on even date herewith, titled “Controlling a Well in a Subsea Mudlift Drilling System,” and assigned to the assignee of the present invention. However, regardless of further well control procedures that may be performed, the dynamic shut-in procedure establishes control of the well ( 108 in FIG. 2) and permits efficient, safe well control that may protect personnel, drilling equipment, and the environment.
[0048] Those skilled in the art will appreciate that other embodiments of the invention can be devised which do not depart from the spirit of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
|
A method for a dynamic shut-in of a subsea mudlift drilling system. The method comprises detecting a kick, isolating a wellbore, and adjusting a subsea mudlift pump and a surface mud pump to provide a selected wellbore pressure. Selected well parameters are measured and used to calculate a kick intensity.
The invention is also a method for a dynamic shut-in of a subsea mudlift drilling system including detecting a kick and isolating a wellbore. A first inlet pressure of a subsea mudlift pump and a first drill pipe pressure are measured. A rate of the subsea mudlift pump and a rate of a surface mud pump are adjusted to pre-kick circulation rates. A second inlet pressure of the subsea mudlift pump and a second drill pipe pressure are recorded. The measured values are used to calculate a kick intensity.
| 4
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation and claims priority under 35 U.S.C. §120 to U.S. application Ser. No. 10/039,904 filed Oct. 23, 2001, now U.S. Pat. No. 6,530,182 issued on Oct. 23, 2001, under 35 U.S.C. §119(e) to Provisional Patent Application Serial No. 60/242,797 filed Oct. 23, 2000; the disclosures of which are incorporated by reference herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was made in part with United States Government Support under Contract Number #DACA88-99-C0006, SBIR Topic #A98-087 awarded by the Department of the Army. Therefore, the U.S. Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
Seismic events often cause dynamic responses in structures sufficient to permanently damage or destroy the primary load-bearing members. Extensive research into the dynamic response of building structures has revealed that modest applications of ancillary damping can dramatically reduce deflections and stresses due to seismic excitation. This ancillary damping may be provided by either yielding and hysteretic energy dissipation in primary structural elements or the inclusion of devices specifically designed to absorb energy while remaining within the elastic range of the primary structure. These latter devices offer the great advantage of minimizing damage to curtain walls, interior structures, and other building systems. In some cases these auxiliary dampers are sacrificial and need replacement after extreme events, while in other cases they may sustain many extreme load cycles without significant maintenance. If effective ancillary damping mechanisms can be developed, in retrofit applications, for multi-storied steel frame buildings, then seismic upgrades of numerous buildings can be significantly expedited.
A wide variety of passive damping schemes have been marketed and implemented with varying degrees of success. These damping devices assume many forms characterized by a wide range of complexity and cost as outlined below; friction dampers, hysteretic (yielding) dampers, lead extrusion dampers, shape memory alloy devices, viscoelastic (rubber or rubber/metal hybrid) isolators, magnetostrictive or magnetorheological devices, tuned mass dampers, and tuned liquid/liquid column dampers. Aside from the tuned mass and/or liquid dampers, the basic damper configuration typically spans a building frame bay, either via a diagonal strut or a chevron brace arrangement. The key design parameters for any of the damper types include maximum force capacity and damper stroke (peak-to-peak in a load cycle). The different damper technologies exhibit hysteresis curves, bounded by these load and stroke parameters, whose shape depends upon the physical characteristics of the damper, and, in the case of viscous dampers, the velocity of the building motion. The required damper stroke is determined by the building displacement limits set either by the appropriate building code or by the builder's assessment of the acceptable damage threshold. In the US, building shear displacement angles (measured as the horizontal displacement of an upper story: the height between the upper story and the story beneath it) of 1:200 are generally considered to be limiting cases, while in Japan, shear displacement angles of 1:100 are tolerated.
One successful example of the damping devices outlined above has been the line of fluid viscous dampers by Taylor Devices, Inc. of North Tonawanda, N.Y. These fluid viscous dampers are essentially superscale versions of automotive shock absorbers, with load capacities ranging from 10 kips to 2000 kips, and strokes of up to 120 inches. While providing effective damping forces out of phase with the excitation, the fluid viscous dampers are relatively complex and costly and may not provide the desired design flexibility and longevity.
A recent development in hysteretic dampers fabricated from low strength steel and concrete by Nippon Steel has shown good performance with a minimum of complexity and cost. This damper mechanism has been used in several new-build projects in Japan. One implementation of this damper brace is a welded steel box of approximately 55 cm by 65 cm filled with concrete enclosing a low strength steel brace having a cruciform shape. Braces have been fabricated having a free length of just over 20 meters and weighing approximately 34 tons. The weight of the concrete-filled steel sleeve is very high and renders retrofit application of the damping brace difficult, if not impossible. The cost of this damping method is driven upward by the proprietary nature of the very low yield strength steel (100 Mpa/14.5 ksi) used in the strut.
The technology options for seismic energy absorbers currently available include: the Nippon Steel hysteretic strut brace and sleeve combination, yielding plate dampers, and viscous dampers such as the Taylor Devices line. While there are several other technologies that have some promise (lead extrusion, shape memory alloy, magnetorestrictive), these are not currently available on a commodity basis.
BRIEF SUMMARY OF THE INVENTION
A lightweight hysteretic damper is useful for framed buildings to reduce seismic response levels. A seismic brace incorporates a low-strength aluminum multi-armed strut that plastically deforms during a seismic event, damping a building's response because of the hysteresis in the strut material stress-strain curve. This strut is surrounded by a collar providing high bending stiffness, but no extensional stiffness, to prevent a low energy buckling failure of the brace in compression. The collar is composed of an outer sleeve of composite materials or metal construction, and spacers to provide the requisite load transfer from the strut which is free floating within the collar. Substantial improvements in weight-specific energy absorption and cost as compared to extant damper concepts are possible.
The hysteretic seismic damper employing a yielding central strut surrounded by a buckling suppression collar is utilized mounted along one or more diagonals of a building frame, and reduces structure seismic response by absorbing strain energy (providing extra damping). In order to maximize this damping energy absorption, the brace remains stable in both tension and compression load cycles to a significant level of plastic strain. When under significant compressive strain, the tangent modulus of the structural material is much lower than its initial modulus, introducing the requirement for a very rigid collar to prevent strut/brace buckling. Composite materials provide an opportunity to create such a collar at minimum weight and cost while metals employ known manufacturing methods.
In one embodiment utilizing a cruciform strut, the aluminum strut is surrounded by four hollow quarter-rounds of metal or composite construction, each of which contains both longitudinal and shear stiffness that in the aggregate is sufficient to prevent strut buckling up to its compressive yield strength. The quarter rounds are attached to one another and contained about the aluminum strut by a sleeve providing reinforcement mostly in the hoop/bias direction. For field assembly, the collar is assembled around the strut with the sleeve bonded to the spacers in the field using a room-temperature-curing adhesive. Factory assembly is an alternative although this field assembly embodiment is particularly well suited to retrofit applications.
In another embodiment, the aluminum strut is surrounded by four lightweight quarter-rounds, each of which is sufficient to transfer radial stresses to an outer sleeve. The four quarter-rounds may be attached to one another and are contained about the aluminum strut by a reinforced sleeve that contains both longitudinal and shear stiffness sufficient to prevent strut buckling up to its compressive yield strength. The sleeve is bonded to the spacers with an adhesive. This concept is optimized for initial installation applications since it can be constructed at greater lengths than the previous embodiment. Other aspects, features, and advantages of the present invention are disclosed in the detailed description that follows.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The invention will be understood from the following detailed description in conjunction with the drawings, of which:
FIG. 1 is a diagram illustrating placement of braces according to the invention;
FIG. 2 is a desirable load deflection curve;
FIG. 3A is an illustration of a brace cross section with a multi-arm strut according to the invention;
FIG. 3B is an illustration of a brace cross section with a solid strut;
FIG. 4A is an illustration of a foam spacer according to the invention;
FIG. 4B is an illustration of a hollow rigid spacer according to the invention;
FIG. 5 is a detail of construction of an implementation of a brace according to the invention;
FIG. 6 is a view of a completed brace according to the invention;
FIG. 7 is an illustration of a cross section of a brace with a clamshell outer sleeve according to the invention; and
FIG. 8 is a detail of construction of a brace with a helical split sleeve according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a structure 16 incorporating a seismic brace 10 according to the present invention. The brace spans a building frame bay 18 , via either a diagonal strut 20 or a chevron brace 22 arrangement. The key design parameters for the braces include maximum force capacity and damper stroke (peak-to-peak in a load cycle). The braces return hysteresis curves bounded by these load and stroke parameters, such as shown in FIG. 2 . Forces of 10,000 pounds or more move the brace up to 0.2 inches in this particular example. The shape of the hysteresis curves depends upon the physical characteristics of the brace. The goal of the brace is to absorb building response energy associated with a seismic event. The strut material is required to be driven substantially into the yield regime without failure at a yield stress that allows significant energy absorption in a package of tractable size. The brace material must further accommodate the expected number of load cycles without significant fatigue damage.
The specific loading and weight requirements for any particular application depend upon the frame bay proportions (H, W), the maximum allowed angle limit (typically 1:200) and the specific seismic event. The disclosed seismic brace withstands a yield load from 12-48 kips in one prototype implementation, but may easily be designed to achieve much larger load capacity.
A feasible and cost-effective hysteretic seismic brace meets these requirements by exercising in cyclic fashion a low strength aluminum strut surrounded by a buckling suppression collar. The collar is implementable utilizing combinations of metal, composite and lightweight materials. The seismic brace is composed of a central yielding strut that can be manufactured in a variety of multi-armed shapes. The central strut is surrounded by filler or spacer material contained by an outer sleeve. The filler and sleeve suppress buckling of the brace when the strut is stressed in compression. In many implementations, the central strut is made of annealed low-strength aluminum.
The basic configurations of the seismic braces according to the invention are shown in FIGS. 3A and 3B. Brace implementations using a cruciform or other multi-armed strut and a solid strut configuration are illustrated. All of the struts, whether of cruciform or cylindrical configuration, are fabricated from annealed aluminum with a yield strength between 7 to 15 ksi. Several nearly pure aluminums, 1100 and 1060 series, show yield strengths in this range. In addition, several of the 2000, 3000, 5000, and 6000 series aluminum alloys have sufficiently low yield strengths but exhibit too much age-hardening to be considered. For many implementations, 1100-O annealed aluminum is preferable.
FIG. 3A illustrates a circularly symmetric multi-armed strut 50 with a lightweight spacer 52 filling the space between the legs of the strut 50 . The strut 50 and spacer 52 are circumscribed by an outer sleeve 54 . An optional slip agent (not shown), such as a mold release agent, silicone or Teflon™ film is employed between strut 50 and spacer 52 to permit the hysteretic action of the strut to be unencumbered by the longitudinal stiffness of the spacer 52 and sleeve 54 . The desirability of such slip or release agents will be determined in each particular application case. For some applications, the natural lubricity of the constituent members may be sufficient to fulfill the stiffness-isolation function. For illustration purposes the multi-armed strut is shown as a cruciform shape, although shapes such as a tribach, star and I-section can be used. These shapes provide an axisymmetric (about the longitudinal axis) stiffness, with the tribach (three-armed) cross-section providing significant advantages in assembling end fittings.
For the multi-armed strut 50 , the basic alloy and temper may be varied to “tune” the load capacity. Annealed aluminum alloys serve as the central yielding strut 50 in this brace assembly 56 , Non-aging alloy compositions are necessary, since the service life of the seismic brace is expected to be very long (e.g. 20-50 years). In particular, 1100-O annealed aluminum is well adapted to serve as the brace strut 50 . For the multi-armed strut 50 1100-O annealed aluminum shows a material yield strength of approximately 10 ksi, and strain to failure well beyond 1%. The multi-armed strut 50 may be manufactured using extrusion or be welded from strip material.
While the 1100-O annealed aluminum exhibits the hysteretic properties needed, the resultant strut 50 must be reinforced to provide sufficient stiffening to suppress brace buckling at a reasonable weight and cost. A reinforcing outer collar (described below) is well suited to provide the stiffening. A sleeve 54 and spacer 52 together form the collar accomplishing the suppression of brace buckling.
The spacers 52 and sleeve 54 accomplish the buckling resistance as a system. When the spacer 52 serves primarily a stress transfer function, the sleeve 54 supplies the buckling suppression rigidity. When the spacer 52 performs more of the buckling suppression, the sleeve 54 may provide less of the buckling suppression rigidity, although the full function sleeves may still be used.
In a first implementation, shown in FIG. 4A, structural foam of approximately 20 lb/ft 3 density (or less) is used as the spacer 70 between the arms of the multi-armed strut 50 . The spacer 70 requires that all of the anti-buckling rigidity be supplied by the outermost sleeve 54 . An adhesive bonds the spacers 70 to the outer sleeve 54 and an optional slip agent may buffer the strut 50 and the spacer 70 preventing the application of any longitudinal restraint by the collar. The function of the foam spacers 70 is to provide a normal force restraint, effectively centering the aluminum multi-armed strut 50 within the outer sleeve 54 , and preventing any high frequency flange buckling which might be possible without deforming the sleeve 54 . This implementation is an economical configuration most amenable to factory assembly. The fully-assembled brace 56 using the foam spacer 70 is best suited to new-build applications.
A range of structural foams and pseudo concrete materials can be used in spacer 70 to provide relatively low weight at an attractive cost. The tradeoffs among these materials are related to cost, density, and performance. Compression strengths of the order a few hundred psi are sufficient for the spacer 70 , so that polymer foams of greater than 10-15 pounds per cubic foot (pcf) provide good service. In this range, there are many possible choices, ranging from homogeneous foams to syntactics. Phenolic resins and foams have the desirable characteristic of being essentially fireproof, emitting no toxins when subjected to flame.
Other choices for structural foams include polyurethane or PVC foams, epoxy based syntactic foams, or pseudo-concrete materials incorporating polymer matrices filled with inexpensive components such as fly ash, vermiculite, and pearlite. These materials are suitable for applications in which cost is a more important consideration than weight. The polymer foams are all quite expensive in the densities contemplated, but provide a 2×-3× weight advantage over the pseudo concretes (and 6×-10× as compared to regular concrete). A low initial cost fabrication method for spacer 70 is to cut the foam shapes on a shaper table, at the cost of some wasted foam. Large-scale production of the foam spacers 70 uses net-shape casting, with relatively high initial tooling cost but lower recurring cost.
The foam spacers 70 require a sleeve 54 that provides the anti-buckling function. The reinforcing sleeve 54 for the foam spacers 70 is a continuous cylinder with a suitable combination of longitudinal and off axis reinforcement. This sleeve can be fabricated from metal or composite material. Since the outer sleeve 54 is a continuous cylinder running approximately the entire length of the brace (in many cases approximately nine meters −30 ft.—or greater) that must be intimately bonded to the spacers 70 and not bonded to the multi-armed strut 50 , assembly is done in a factory-bonding fixture.
A metallic outer sleeve may be fabricated from rolled steel or aluminum sheet material of suitable alloys and provided with a fastening of the longitudinal edges of said sleeve via welding or other mechanical fastening means.
A composite outer sleeve 54 may be fabricated using a variety of methods including filament winding, roll wrapping and pultrusion. One manufacturing method for a brace using the foam spacers 70 is illustrated in FIG. 5 . The spaces in the angles of the multi-armed strut 122 are filled with the stiff polymer foam (not shown) which is bonded to an outer sleeve 120 and not the strut 122 . The sleeve 120 is most conveniently constructed of fabric 121 such as graphite fabric, filament wound or roll-wrapped using the aluminum strut 122 and foam spacers as a mandrel. After wrapping, glass fiber 124 is over wrapped around the sleeve 120 and the wrapped sleeve is impregnated with resin (the resin bonds the sleeve to the foam spacer, but not to the strut, in the process). The finished assembly is then oven-cured. The completed brace is illustrated in FIG. 6 where the strut 126 is shown prepared for mounting to structural joint adapters, and the cured sleeve 128 extends to nearly the entire length of the brace. This implementation has a cost advantage because the structural parts are simple to fabricate. This implementation is adapted to factory assembly especially in larger sizes and does not readily allow assembly at the construction site. The cost/performance tradeoffs of selecting materials and manufacturing methods for a composite sleeve are the classic ones common to most fiber-reinforced composite applications as are known in the art.
In another spacer implementation illustrated in FIG. 4B, the spacers 53 are hollow structures having sufficient bending and shear rigidity to suppress buckling of the strut 50 under the intended yielding load. The outermost sleeve 54 for the hollow spacer is only required to hold the entire assembly together, providing shear and hoop rigidity from one to the other of the hollow spacers 53 . However, the high rigidity buckling suppression sleeve described above can also be used with spacer 53 .
The hollow spacer 53 consists of walls 60 and an enclosed space 62 . The walls 60 of the spacer 53 can be made of a fiber-reinforced composite material or a metal such as steel or aluminum alloys, or a hybrid construction comprising both metallic and composite elements. The composite hollow spacers 53 are easily fabricated via pultrusion or any variety of winding process. The winding approaches are applicable especially for initial production, having relatively low non-recurring tooling cost but moderate recurring cost. Pultrusion is more applicable to large-scale production, due to its extremely low recurring cost, married to relatively high initial tooling cost. Pultruded composite spacers 53 contain a reinforcement that provides a large measure of bending rigidity to stiffen the aluminum strut 50 during the compression portion of a load cycle. Because of the reinforcement requirement, the circular arc portion 64 of the cross section is composed largely of longitudinal fibers. The right-angle portion 66 of the cross section contains a balanced fabric reinforcement to provide a combination of longitudinal, transverse, and shear stiffness.
The material and fabrication tradeoffs for the hollow reinforced composite spacers 53 are quite similar to those for the outer sleeve used with the foam spacer 70 discussed above. In one embodiment, spacer mandrels are used as the foundation for fabricating the hollow composite spacers 53 . Care must be taken to assure the mandrels will release the spacers 53 . In this fabrication process, glass fabric was first wrapped around the released mandrels and longitudinal graphite fibers were added on the outermost curved surface 64 . These graphite fibers were in turn sandwiched by another layer of glass cloth, effectively capturing the graphite reinforcement. Vinyl Ester resin was then impregnated into the dry hybrid composite wrapped around the aluminum mandrel. Once the reinforcement was completely wetted, the whole assembly was wrapped in shrink tape and cured in the oven at 250 F for 3 hours.
An advantage to the use of hollow spacers 53 is that for some sleeve implementations, the individual parts of the brace 56 can be carried to an installation site separately and assembled at the installation site using, for instance, a room-temperature-curing construction grade adhesive between spacer 53 and sleeve 54 . Field assembly renders brace 56 especially amenable to retrofit installations, where the size and weight of components represent a significant barrier to installation. While the sleeves described above in conjunction with foam spacer 70 may be used in conjunction with spacer 60 , these are not as readily amenable to on-site assembly.
FIGS. 7 and 8 illustrate two embodiments for an outer sleeve 54 that is amenable to on-site assembly. The first embodiment, a split clamshell, is shown in FIG. 7 . The individual clamshell halves 86 are extruded or pultruded with lugs 88 on the long edges. These lugs 88 are secured by a fastening mechanism such as a formed sheet metal clamp 90 that is hammered over the pair of lugs 88 from the two halves of the clamshell, a bolt pattern disposed along the clamshell flanges, or other fastening mechanism. FIG. 7 also illustrates the bonded region 92 and the unbonded regions 94 of the brace.
A second embodiment shown in FIG. 8 utilizes hollow spacers 102 that are placed within the angles of the multi-armed strut 100 coated with a suitable release agent so as to slide with respect to the strut 100 . A spirally split “barber pole”—type sleeve 104 is snapped over the strut/quadrant spacer assembly 100 / 102 . After the spiral sleeve 104 shown is installed, a second spiral sleeve piece (not shown) is installed in the interstitial areas to provide complete coverage to the brace assembly 100 / 102 . The sleeves 104 are bonded to the outer circumference of the hollow spacer assemblies 102 with a construction-grade adhesive.
The outer sleeve of the clamshell 86 or split spiral 104 type can be economically fabricated using simple tooling. These sleeves hold the quadrant pieces 102 tight against the aluminum strut 100 , and provide a stiff shear interface and hoop rigidity between these pieces across the outstanding radial edges of the aluminum strut 100 . The sleeves need not provide significant added bending rigidity. The individual piece parts comprising the brace can be carried to the installation site separately and assembled on-site with room-temperature-curing construction grade adhesive (between spacer and sleeve).
The alternate configuration of the brace shown in FIG. 3B illustrates a brace 40 with a solid center hysteretic bar strut 42 surrounded by an optional relatively uniform lightweight spacer 44 fabricated of material such as may be used in spacer 70 . The outer surface of the spacer 44 is sheathed by an outer sleeve 46 . The sleeve 46 for this brace 40 may be any sleeve applicable to spacer 70 described above. The shape of this brace and strut configuration may be varied as the building requirements dictate. An optional slip agent (not shown) may be employed between strut 42 and spacer 44 to permit the hysteretic action of the strut to be unencumbered by the stiffness of the sleeve 46 .
A strut 42 having a circular cross section is desirable from the point of view of symmetry and ease of fabrication, but it is limited in its effective energy absorption capacity. When either filled or surrounded by a sheathing material of considerable hoop/radial integrity, a transverse stress is developed by Poisson effects that increases the yield stress/load by perhaps 15% as compared to the unconstrained value. This behavior may reduce the effectiveness of the solid core strut 42 . The brace of FIG. 3B can, however, have significant value as a seismic brace for light construction, or locations where space in the curtain wall is at a severe premium. This is the simplest configuration to fabricate, and will be less expensive to build and install than any of the multi-armed embodiments described above.
For composite sleeves used with the solid strut 42 , a greater thickness of composite or other high rigidity material is required in the sleeve 46 to stabilize the buckling failure mode with the simple rod brace 40 than will be true for the multi-armed strut configurations above.
The method of attaching the brace to the building structure of interest is critical to the effectiveness of the seismic brace. When the central strut is working properly, it is by definition yielding, and the secondary modulus for most structural metals suitable for yielding struts will be quite low. This situation demands that measures be taken which prevent local buckling of the strut, especially any flanges near the end of the strut. Any end fitting must satisfy the strength and grip interface requirements and allow the sleeve to be installed or manufactured easily onto the brace without interference from plates or other fitting details. Extremely stiff support for the aluminum strut is required to within a very small distance of the outer sleeve 54 surrounding the multi-armed strut.
Finite element analysis showed that the seismic brace can provide good and stable energy absorption at relatively light weight. The buckling safety factor for the multi-armed aluminum strut was much higher than that for the solid strut. Additionally, the end fittings used to attach the braces to a structure must be designed to transfer the load into the brace.
Laboratory testing on a specific configuration of prototype braces with foam spacers 70 showed that peak load capacity of the multi-armed strut can exceed +/−12,000 pounds, while the yield load is approximately 8,000-10,000 lb. The test for hollow spacers 53 yielded results similar to that observed for foam spacers 70 , indicating that the split sleeve brace configuration is equally able to support the compression portion of the load cycle, as compared to the stiff sleeve/foam spacer embodiment. The tests on round bars, with composite stiffening sleeve showed that this embodiment does not tolerate as much yielding displacement as the multi-armed strut brace. The basic result of this prototype testing is that the seismic brace implementations provide good and stable energy absorption at relatively light weight.
The multi-armed brace with both spacer implementations was shown to possess excellent damping characteristics, and a basic robustness to the required load cycling. The described seismic braces provide good and stable energy absorption at relatively light weight. Refined end fittings to attach the braces to the structures are important to maintain the brace performance.
A stiff sleeve/foam spacer configuration with a composite sleeve showed peak compression load values essentially equaling or exceeding the peak tension values. This result indicates that the composite sleeves at least performed their main requirement of eliminating the very low strength buckling failure mode. Reviewing the load-displacement curves for the tests show further that in all cases good energy absorption was achieved in the cyclic hysteresis curves.
Having described preferred embodiments of the invention it will now become apparent to those of ordinary skill in the art that other embodiments incorporating these concepts may be used. Accordingly, it is submitted that the invention should not be limited by the described embodiments but rather should only be limited by the spirit and scope of the appended claims.
|
An energy absorbing seismic brace for both retrofit and new construction. The brace comprises a central strut of either multi-legged or homogeneous section fabricated from low strength aluminum, whose characteristics maximize the seismic energy absorption for a building installation. This central strut absorbs energy at high weight-specific levels by virtue of the hysteresis in its load-deflection relationship. In order to eliminate the possibility of buckling of the energy absorbing strut when it passes through the compression portion of a load cycle, it is surrounded by a system of spacers and an external sleeve providing very high bending rigidity at low weight. The spacers may be fabricated from low-density foams, pseudo-concrete, fibrous composites, or metals, depending upon the application. The outer sleeve may also be fabricated from a variety of materials, depending upon whether the embodiment calls for the principal bending rigidity to be provided by the spacers or sleeve.
| 4
|
[0001] This application is a continuation of International application No. PCT/FR2003/002,356, filed Jul. 25, 2003; which claims the benefit of priority of French Patent Application No. 02/09,588, filed Jul. 29, 2002, both of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] This invention relates to a series of N-[phenyl(piperidin-2-yl)methyl]benzamide derivatives, their preparation and their application in therapy.
SUMMARY OF THE INVENTION
[0004] The compounds of the invention correspond to the general formula (I)
in which
R 1 represents either a hydrogen atom, or a linear or branched (C 1 -C 7 )alkyl group optionally substituted with one or more fluorine atoms, or a (C 3 -C 7 )cycloalkyl-(C 1 -C 3 )alkyl group, or a phenyl(C 1 -C 3 )alkyl group optionally substituted with one or two methoxy groups, or a (C 2 -C 4 )alkenyl group, or a (C 2 -C 4 )alkynyl group, X represents a hydrogen atom or one or more substituents chosen from halogen atoms and trifluoromethyl, linear or branched (C 1 -C 4 )alkyl and (C 1 -C 4 )alkoxy groups, R 2 represents one or more substituents chosen from halogen atoms, from the groups of general formula OR 3 in which R 3 represents a hydrogen atom, a (C 1 -C 4 )alkyl group, a phenyl(C 1 -C 3 )alkyl group, or a group of general formula (CH 2 ) n —NR 4 R 5 in which n represents the number 2, 3 or 4 and R 4 and R 5 each represent, independently of each other, a hydrogen atom or a (C 1 -C 4 )alkyl group or form, with the nitrogen atom carrying them, a pyrrolidine, piperidine or morpholine ring, and from the amino groups of general formula NR 6 R 7 in which R 6 and R 7 each represent, independently of each other, a hydrogen atom or a (C 1 -C 4 )alkyl group, a phenyl group or a phenyl(C 1 -C 3 )alkyl group, or form, with the nitrogen atom carrying them, a pyrrolidine, piperidine or morpholine ring.
[0008] The compounds of general formula (I) may exist in the form of the threo racemate (1R,2R; 1S,2S) or in the form of enantiomers (1R,2R) or (1S,2S); they may exist in the form of free bases or of addition salts with acids.
DETAILED DESCRIPTION OF THE INVENTION
[0009] Compounds having a structure which is analogous to that of the compounds of the invention are described in U.S. Pat. No. 5,254,569 as analgesics, diuretics, anticonvulsants, anesthetics, sedatives, cerebroprotective agents, by a mechanism of action on the opiate receptors. Other compounds having an analogous structure are described in Patent Application EP 0499995 as 5-HT 3 antagonists which are useful in the treatment of psychotic disorders, neurological diseases, gastric syndromes, nausea and vomiting.
[0010] The preferred compounds of the invention are devoid of activity on the opiate or 5-HT3 receptors and exhibit a particular activity as specific inhibitors of the glycine transporters glyt1 and/or glyt2.
[0011] The compounds preferred as inhibitors of the glyt1 transporter are of the configuration (1S,2S) with R 2 representing one or more halogen atoms, while the compounds preferred as inhibitors of the glyt2 transporter are of the configuration (1R,2R) with R 2 representing one or more halogen atoms and an amino group of general formula NR 6 R 7 .
[0012] The compounds of general formula (I) in which R 1 is different from a hydrogen atom, may be prepared by a method illustrated by scheme 1 which follows.
[0013] A diamine of general formula (II), in which R 1 and X are as defined above (with R 1 different from a hydrogen atom), is coupled to an activated acid or an acid chloride of general formula (III) in which Y represents an activated OH group or a chlorine atom and R 2 is as defined above, using methods known to persons skilled in the art.
[0014] The diamine of general formula (II) may be prepared by a method illustrated by scheme 2 which follows.
[0015] The Weinreb amide of formula (IV) is reacted with the phenyllithium derivative of general formula (V), in which X is as defined above, in an ethereal solvent such as diethyl ether, between −30° C. and room temperature; a ketone of general formula (VI) is obtained which is reduced to an alcohol with the threo configuration of general formula (VII) with a reducing agent such as K-Selectride® or L-Selectride® (potassium or lithium tri-sec-butylborohydride), in an ethereal solvent such as tetrahydrofuran, between −78° C. and room temperature. The carbamate of general formula (VII) may then be reduced to a threo N-methylaminoalcohol of general formula (VIII) by the action of a mixed hydride such as lithium aluminum hydride, in an ethereal solvent such as tetrahydrofuran, between room temperature and the reflux temperature. The threo alcohol of general formula (VIII) is then converted to a threo intermediate of general formula (II) where R 1 represents a methyl group, in two steps: the alcohol functional group is first of all converted to a leaving group, for example a methanesulfonate group, by the action of methylsulfonyl chloride, in a chlorinated solvent such as dichloromethane, and in the presence of a base such as triethylamine, between 0° C. and room temperature, and then the leaving group is reacted with liquefied ammonia at −50° C., in an alcohol such as ethanol, in a closed medium such as an autoclave, between −50° C. and room temperature.
[0016] It is also possible to deprotect the carbamate of general formula (VII) by means of a strong base such as aqueous potassium hydroxide, in an alcohol such as methanol in order to obtain the threo amino alcohol of general formula (IX), and to then carry out an N-alkylation by means of a halogenated derivative of formula R 1 Z, in which R 1 is as defined above, but different from a hydrogen atom, and Z represents a halogen atom, in the presence of a base such as potassium carbonate, in a polar solvent such as N,N-dimethylformamide, between room temperature and 100° C. The alcohol of general formula (X) thus obtained is then treated as described for the alcohol of general formula (VIII).
[0017] Another variant method, illustrated by scheme 3 which follows, may be used in the case where R 1 represents a methyl group and X represents a hydrogen atom. The pyridine oxime of formula (XI) is quaternized, for example, by the action of methyl trifluoromethanesulfonate, in an ethereal solvent such as diethyl ether, at room temperature. The pyridinium salt thus obtained, of formula (XII), is then subjected to hydrogenation under a hydrogen atmosphere,
in the presence of a catalyst such as platinum oxide, in a mixture of an alcohol and an aqueous acid such as ethanol and 1 N hydrochloric acid. The diamine of general formula (II) is obtained in which R 1 represents a methyl group and X represents a hydrogen atom in the form of a mixture of the two diastereoisomers threo/erythro 9/1. It is possible to salify it, for example, with oxalic acid, and then to purify it by recrystallization of the oxalate formed from a mixture of an alcohol and an ethereal solvent such as methanol and diethyl ether, so as to obtain the pure threo diastereoisomer (1R,2R; 1S,2S).
[0018] The compounds of general formula (II) in which R 1 represents a hydrogen atom may be prepared by the method illustrated by scheme 4 which follows.
[0019] Starting with the amine of general formula (XIII), in which X is as defined above, a coupling is performed with an activated acid or an acid chloride, as described above, of general formula (III) according to methods known to persons skilled in the art, in order to obtain the compound of general formula (XIV). Finally, hydrogenation of the latter is performed, for example with hydrogen in the presence of a catalyst such as 5% platinum on carbon, in an acidic solvent such as glacial acetic acid, so as to obtain a compound of general formula (I) in which R 1 represents a hydrogen atom.
[0020] Another method consists in modifying a compound of general formula (I) in which R 1 represents either an optionally substituted phenylmethyl group and in deprotecting the nitrogen of the piperidine ring, for example, with an oxidizing agent or with a Lewis acid, such as boron tribromide, or by hydrogenolysis, or an alkenyl group, preferably allyl, and in deprotecting the nitrogen with a Pd 0 complex, in order to obtain a compound of general formula (I) in which R 1 represents a hydrogen atom.
[0021] Moreover, the chiral compounds of general formula (I) corresponding to the enantiomers (1R,2R) or (1S,2S) of the threo diastereoisomer may also be obtained by separating the racemic compounds by high-performance liquid chromatography (HPLC) on a chiral column, or by resolution of the racemic amine of general formula (II) by the use of a chiral acid, such as tartaric acid, camphorsulfonic acid, dibenzoyltartaric acid or N-acetylleucine, by fractional and preferential recrystallization of a diastereoisomeric salt, from an alcohol type solvent, or alternatively by enantioselective synthesis according to scheme 2 with the use of a chiral Weinreb amide of formula (IV).
[0022] The racemic or chiral Weinreb amide of formula (IV), as well as the ketone of general formula (VI), may be prepared according to a method similar to that described in Eur. J. Med. Chem., 35, (2000), 979-988 and J. Med. Chem., 41, (1998), 591-601. The phenyllithium compound of general formula (V) where X represents a hydrogen atom is commercially available. Its substituted derivatives may be prepared according to a method similar to that described in Tetrahedron Lett., 57, 33, (1996), 5905-5908. Also according to a method similar to that described in Patent Application EP-0366006. The amine of general formula (IX) in which X represents a hydrogen atom may be prepared in a chiral series according to a method described in U.S. Pat. No. 2,928,835. Finally, the amine of general formula (XIII) may be prepared according to a method similar to that described in Chem. Pharm. Bull., 32, 12, (1984), 4893-4906 and Synthesis , (1976), 593-595. All of the references described herein are incorporated herein by reference in their entirety.
[0023] Some acids and acid chlorides of general formula (III) are commercially available or, when they are novel, they may be obtained according to methods similar to those described in patents EP-0556672, U.S. Pat. No. 3,801,636, and in J. Chem. Soc ., (1927), 25, Chem. Pharm. Bull ., (1992), 1789-1792, Aust. J. Chem ., (1984), 1938-1950 and J.O.C ., (1980), 527. All of these references are incorporated herein by reference in their entirety.
[0024] The examples which follow illustrate the preparation of a few compounds of the invention. The elemental microanalyses, the IR and NMR spectra and the HPLC on a chiral column confirm the structures and the enantiomeric purities of the compounds obtained.
[0025] The numbers indicated in brackets in the headings of the examples correspond to those of the 1st column of the table given later.
[0026] In the names of the compounds, the dash “_” forms part of the word, and the dash “-” only serves for splitting at the end of a line; it is suppressed in the absence of splitting, and should not be replaced either by a normal dash or by a gap.
EXAMPLE 1 (COMPOUND NO. 65)
2,3-Dichloro-N-[(1S)-[(2S)-1-methylpiperidin-2-yl]phenylmethyl]benzamide Hydrochloride 1:1
1.1. 1,1-Dimethylethyl (2S)-2-benzoylpiperidine-1-carboxylate
[0027] A solution of 1,1-dimethylethyl (2S)-2-(N-methoxy-N-methylcarbamoyl)piperidine-1-carboxylate (11.8 g, 43.3 mmol) in 100 ml of anhydrous diethyl ether is introduced into a 500 ml round-bottomed flask, under a nitrogen atmosphere, the medium is cooled to −23° C., 21.6 ml (43.2 mmol) of a 1.8 M phenyllithium solution in a 70/30 mixture of cyclohexane and diethyl ether are added dropwise and the mixture is stirred at room temperature for 3 h.
[0028] After hydrolysis with a saturated aqueous sodium chloride solution, the aqueous phase is separated and it is extracted with ethyl acetate. The organic phase is dried over sodium sulfate, filtered, concentrated under reduced pressure and the residue is purified by chromatography on a silica gel column, eluting with a mixture of ethyl acetate and cyclohexane to obtain 4.55 g of a solid product.
[0029] Melting point: 123-125° C.
[0030] [α] D 25 =−25.4° (c=2.22; CH 2 Cl 2 ) ee=97.2%,
1.2. 1,1-Dimethylethyl (1S)-2-[(2S)-hydroxy(phenyl)methyl]piperidine-1-carboxylate
[0031] A solution of 1,1-dimethylethyl (2S)-2-benzoylpiperidine-1-carboxylate (4.68 g, 16.2 mmol) in 170 ml of anhydrous tetrahydrofuran is introduced into a 500 ml round-bottomed flask, under a nitrogen atmosphere, the solution is cooled to −78° C., 48.5 ml (48.5 mmol) of a 1 M solution of L-Selectride® (lithium tri-sec-butylborohydride) in tetrahydrofuran are added dropwise, and the mixture is stirred at room temperature for 5 h.
[0032] It is slowly hydrolyzed in the cold state with 34 ml of water and 34 ml of a 35% aqueous hydrogen peroxide solution, and the mixture is allowed to return to room temperature while it is being stirred for 2 h.
[0033] It is diluted with water and ethyl acetate, the aqueous phase is separated, and extracted with ethyl acetate. After washing the combined organic phases, drying over sodium sulfate, filtration and evaporation, the residue is purified by chromatography on a silica gel column, eluting with a mixture of ethyl acetate and cyclohexane to obtain 4.49 g of a pale yellow oil.
[0034] [α] D 25 =+63.75° (c=0.8; CH 2 Cl 2 ) ee=97.8%.
1.3. (1S)-[(2S)-(1-methylpiperidin-2-yl)]phenylmethanol
[0035] A solution of lithium aluminum hydride (2.96 g, 78.1 mmol) in 50 ml of anhydrous tetrahydrofuran is introduced into a 200 ml two-necked flask, under a nitrogen atmosphere, the mixture is heated under reflux, 4.49 g (15.4 mmol) of a solution of 1,1-dimethylethyl (1S)-2-[(2S)-hydroxy(phenyl)methyl]piperidine-1-carboxylate in 35 ml of tetrahydrofuran are added and the mixture is kept under reflux for 3.5 h.
[0036] It is cooled, it is slowly hydrolyzed with a 0.1 M solution of potassium sodium tartrate and the mixture is kept stirred overnight.
[0037] It is filtered and the precipitate is rinsed with tetrahydrofuran, and then the filtrate is concentrated under reduced pressure to obtain 2.95 g of a colorless oily product.
1.4. (1S)-[(2S)-(1-methylpiperidin-2-yl)]phenylmethanamine
[0038] A solution of (1S)-[(2S)-(1-methylpiperidin-2-yl)]phenylmethanol (2.95 g, 14.4 mmol) and triethylamine (2 ml, 14.4 mmol) in 70 ml of anhydrous dichloromethane is introduced into a 250 ml round-bottomed flask, under a nitrogen atmosphere, the medium is cooled to 0° C., 1.1 ml (14.4 mmol) of methanesulfonyl chloride are added, the mixture is allowed to return slowly to room temperature over 2 h and it is concentrated under reduced pressure.
[0039] Liquefied ammonia is introduced into an autoclave provided with magnetic stirring and cooled to −50° C., a solution of crude methanesulfonate prepared beforehand in solution in 30 ml of absolute ethanol is added, the autoclave is closed and the stirring is maintained for 48 h.
[0040] The mixture is transferred to a round-bottomed flask, the solvent is evaporated under reduced pressure, and the amine is isolated in the form of an oily product which is used as it is in the next step.
1.5. 2,3-Dichloro-N-[(1S)-[(2S)-1-methylpiperidin-2-yl]phenylmethyl]benzamide Hydrochloride 1:1
[0041] A solution of 2,3-dichlorobenzoic acid (0.5 g, 2.6 mmol), 1-([3-(dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride (0.5 g, 2.6 mmol) and 1-hydroxybenzotriazole (0.35 g, 2.6 mmol) in 10 ml of dichloromethane is introduced into a 50 ml round-bottomed flask and the mixture is stirred at room temperature for 30 min.
[0042] A solution of (1S)-[(2S)-(1-methylpiperidin-2-yl)]phenylmethanamine (0.53 g, 2.5 mmol) in a few ml of dichloromethane is added to the above mixture and the stirring continued for 5 h.
[0043] The mixture is treated with water and extracted several times with dichloromethane. After washing the organic phases with water and then with a 1N aqueous sodium hydroxide solution, drying over magnesium sulfate, filtration and evaporation of the solvent under reduced pressure, the residue is purified by chromatography on a silica gel column, eluting with a mixture of dichloromethane and methanol. 0.52 g of oily product is obtained which is isolated in hydrochloride form from a 0.1N hydrochloric acid solution in propan-2-ol.
[0044] 0.5 g of hydrochloride is finally isolated in the form of a white solid.
[0045] Melting point: 124-126° C.
[0046] [α] D 25 =+66.3° (c=0.58; CH 3 OH).
EXAMPLE 2 (COMPOUND NO. 55)
4-Amino-3,5-dichloro-N-[(1R)-[(2R)-1-methylpiperidin-2-yl]phenylmethyl]benzamide Hydrochloride 1:1
2.1. 2-(Benzyloxyiminophenylmethyl)-1-methylpyridinium Trifluoromethanesulfonate
[0047] 17.4 ml (120 mmol) of methyl trifluoromethanesulfonate are added dropwise at 0° C. to a suspension of 35 g (120 mmol) of phenyl(pyridin-2-yl)methanone O-benzyloxime in 200 ml of diethyl ether, and the mixture is stirred at room temperature for 3 h.
[0048] The precipitate formed is recovered by filtration and it is dried under reduced pressure to obtain 49 g of product, which product is used as it is in the next step.
2.2. threo-(1-Methylpiperidin-2-yl)phenylmethanamine Ethanedioate 2:1
[0049] A solution of 2-(benzyloxyiminophenylmethyl)-1-methylpyridinium trifluoromethanesulfonate (14.8 g, 31.89 mmol) and 0.74 g of platinum oxide in 50 ml of ethanol and 50 ml of 1 N hydrochloric acid is placed in a Parr flask, and hydrogenation is performed for 5 h.
[0050] The ethanol is evaporated under reduced pressure, the residue is extracted with dichloromethane, the aqueous phase is separated, a solution of ammonia is added thereto and it is extracted with dichloromethane. After washing the combined organic phases, drying over sodium sulfate, filtration and evaporation of the solvent under reduced pressure, 6.7 g of an oily product comprising 10% of erythro diastereoisomer are obtained.
[0051] The ethanedioate is prepared by dissolving the above isolated 6.7 g of base in methanol, and by the action of two equivalents of ethanedioic acid dissolved in the minimum amount of methanol.
[0052] The salt obtained is purified by recrystallization from a mixture of methanol and diethyl ether to isolate 4.7 g of pure ethanedioate of the threo diastereoisomer.
[0053] Melting point: 156-159° C.
2.3. (1R)-[(2R)-(1-methylpiperidin-2-yl)]phenylmethanamine
[0054] A solution of threo-(1-methylpiperidin-2-yl)phenylmethanamine (80 g, 390 mmol) in 300 ml of methanol, and a solution of N-acetyl-D-leucine (68 g, 390 mmol) in 450 ml of methanol are introduced into a 4 l round-bottom flask. The solution is concentrated under reduced pressure and the residue is recrystallized from 1100 ml of propan-2-ol to obtain 72 g of salts of (1R)-[(2R)-(1-methylpiperidin-2-yl)]phenylmethanamine.
[0055] The recrystallization is repeated three more times to obtain 15 g of additional salt of (1R)-[(2R)-(1-methylpiperidin-2-yl)]phenylmethanamine.
[0056] Melting point: 171.5° C.
[0057] [α] D 25 =−11° (c=1; CH 3 OH) ee>99%.
2.4. 4-Amino-3,5-dichloro-N-[(1R)-[(2R)-1-methylpiperidin-2-yl]phenylmethyl]-3,5-dichlorobenzamide Hydrochloride 1:1
[0058] Employing the procedure described in step 1.6 of Example 1 above, and starting with 2.18 g (11.65 mmol) of 4-amino-3,5-dichlorobenzoic acid, 2.23 g (10.6 mmol) of 1-[3-(dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride, 1.41 g (10.6 mmol) of 1-hydroxybenzotriazole and 2.16 g (10.6 mmol) of (1R)-[(2R)-methylpiperidin-2-yl]phenylmethanamine, 3.92 g of the title compound are obtained in base form.
[0059] The hydrochloride thereof is prepared using a 0.1 N hydrochloric acid solution in propan-2-ol to obtain 3.94 g of the hydrochloride in the form of a white solid.
[0060] Melting point: 250-260° C.
[0061] [α] D 25 =+24.5° (c=0.9; CH 3 OH).
EXAMPLE 3 (COMPOUND NO. 59)
3,5-Dichloro-N-[(1-methylpiperidin-2-yl)phenylmethyl]-4-(pyrrolidin-1-yl)benzamide Hydrochloride 1:1
3.1. 3,5-Dichloro-4-fluorobenzoic Acid
[0062] A solution of 3,5-dichloro-4-fluoro[(trifluoromethyl)benzene] (5 g, 21.46 mmol) in 10 ml of concentrated sulfuric acid is introduced into an autoclave and the solution is heated at 120° C. overnight.
[0063] After cooling, the mixture is taken up in water, the precipitate formed is recovered by filtration and it is dried under reduced pressure.
[0064] The title acid is quantitatively obtained, which acid is used as it is in the next step.
3.2. 3,5-Dichloro-4-(pyrrolidin-1-yl)benzoic Acid
[0065] 1 g (4.8 mmol) of 3,5-dichloro-4-fluorobenzoic acid, 1.56 g (4.8 mmol) of cesium carbonate and 1 ml (12 mmol) of pyrrolidine in solution in 5 ml of dimethyl sulfoxide are introduced into a 100 ml round-bottom flask and the mixture is heated at 125° C. overnight.
[0066] After cooling, it is hydrolyzed with concentrated hydrochloric acid, the precipitate formed is recovered by filtration and it is dried under reduced pressure to obtain 0.65 g of title acid.
3.3. 3,5-Dichloro-N-[(1-methylpiperidin-2-yl)phenylmethyl]-4-(pyrrolidin-1-yl)benzamide Hydrochloride 1:1
[0067] Using the procedure described in step 1.6 of Example 1 above, and starting with 0.5 g (2 mmol) of 3,5-dichloro-4-(pyrrolidin-1-yl)benzoic acid, 0.35 g (1.82 mmol) of 1-[3-(dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride, 0.25 g (1.82 mmol) of 1-hydroxybenzotriazole and 0.37 g (1.82 mmol) of threo-(1-methylpiperidin-2-yl)]phenylmethanamine, 0.1 g of product is obtained in base form.
[0068] The hydrochloride thereof is prepared from a 0.1 N hydrochloric acid solution in propan-2-ol.
[0069] 0.85 g of hydrochloride is finally isolated in the form of a white solid.
[0070] Melting point: 157-159° C.
EXAMPLE 4 (COMPOUND NO. 76)
2,3-Dichloro-N-[(S)-phenyl[(2S)-piperidin-2-yl]methyl]benzamide
4.1. (S)-Phenyl[(2S)-piperidin-2-yl]methanol
[0071] A solution of 2.0 g (6.9 mmol) of 1,1-dimethylethyl (1S)-2-[(2S)-hydroxy(phenyl)methyl)-piperidine-1-carboxylate (obtained according to the procedure described in step 1.2 of Example 1) in 40 ml of methanol is placed in a 250 ml round-bottom flask, an aqueous potassium hydroxide solution prepared from 2 g of potassium hydroxide pellets and 20 ml of water is added, and the mixture is heated under reflux for 2 h.
[0072] It is cooled, the solvent is evaporated off under reduced pressure, water is added and the mixture is extracted several times with dichloromethane. After washing the combined organic phases, drying on magnesium sulfate, filtration and evaporation of the solvent under reduced pressure, 1 g of a white solid is obtained.
[0073] Melting point: 148-150° C.
[0074] [α] D 25 =+38.4° (c=0.98; CHCl 3 ).
4.2. (S)-[(2S)-1-Allylpiperidin-2-yl](phenyl)methanol
[0075] 2.6 g (13.58 mmol) of (S)-phenyl[(2S)-piperidin-2-yl]methanol and 100 ml of acetonitrile are introduced into a 500 ml round-bottom flask provided with magnetic stirring and purged with argon. 2.8 g of potassium carbonate and 1.4 ml (1.2 eq.) of allyl bromide are then added to the suspension obtained, and the stirring is maintained at 25° C. for 6 h.
[0076] 100 ml of water and 100 ml of ethyl acetate are added, the aqueous phase is separated, it is extracted three times with 50 ml of ethyl acetate, the combined organic phases are washed with 100 ml of water and then 100 ml of a saturated aqueous sodium chloride solution, dried over sodium sulfate, filtered and the solvent is evaporated off under reduced pressure.
[0077] 3 g of a yellow oil are obtained, which oil is purified by chromatography on a silica gel column (120 g, elution gradient from 2% to 10% of methanol in dichloromethane over 30 min).
[0078] 2.7 g of product are isolated in the form of a yellow oil.
4.3. (S)-[(2S)-1-Allylpiperidin-2-yl](phenyl)-methanamine
[0079] 2.7 g (11.67 mmol) of (S)-[(2S)-1-allylpiperidin-2-yl](phenyl)methanol and 1.62 ml of triethylamine in 80 ml of anhydrous dichloromethane are introduced into a 250 ml round-bottom flask, under a nitrogen atmosphere, the medium is cooled to 0° C., 0.9 ml of methylsulfonyl chloride is added, the mixture is allowed to return slowly to room temperature over 2 h and it is concentrated under reduced pressure.
[0080] Liquefied ammonia is introduced into an autoclave provided with magnetic stirring and cooled to −50° C., a solution of crude methanesulfonate previously prepared in solution in 30 ml of absolute ethanol is added, the autoclave is closed and the stirring is maintained for 48 h.
[0081] The mixture is poured into a round-bottom flask, it is concentrated under reduced pressure and 1.5 g of amine are isolated in the form of an oily product which is used as it is in the next step.
4.4. N-[(S)-[(2S)-1-Allylpiperidin-2-yl](phenyl)-methyl]-2,3-dichlorobenzamide
[0082] 5 ml of dichloromethane, 0.13 g (0.68 mmol) of 2,3-dichlorobenzoic acid, 0.13 g (0.68 mmol) of 1-[3-(dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride and 0.085 g of dimethylaminopyridine are successively introduced into a 10 ml round-bottom flask, and the mixture is stirred at room temperature for 30 min.
[0083] 0.18 g of (S)-[(2S)-1-allylpiperidin-2-yl](phenyl)methanamine in solution in a few ml of dichloromethane is added and the stirring is continued for 24 h. 5 ml of water are added, the mixture is filtered on a Whatman® cartridge (PTFE) and purified directly on a cartridge of 10 g of silica, eluting with a 98/2 to 90/10 mixture of dichloromethane and methanol.
[0084] 0.18 g of base is isolated in the form of a colorless oil.
4.5. 2,3-Dichloro-N-[(S)-phenyl[(2S)-piperidin-2-yl]methyl]benzamide
[0085] 0.21 g (3 eq.) of 1,3-dimethylbarbituric acid in solution in 3 ml of anhydrous dichloromethane is introduced into a 10 ml round-bottom flask provided with mechanical stirring, under an argon atmosphere, 0.005 g (0.01 eq.) of tetrakis(triphenylphosphine)-palladium (0) is added and the mixture is heated at 30° C.
[0086] A solution of 0.18 g (0.3 mmol) of N-[(S)-[(2S)-1-allylpiperidin-2-yl](phenyl)methyl]-2,3-dichlorobenzamide in 1 ml of dichloromethane is added and the mixture is kept stirring for 24 h.
[0087] 3 ml of a saturated aqueous sodium hydrogen sulfate solution are added, the mixture is filtered on a Whatman® cartridge (PTFE) and purified directly on a cartridge of 10 g of silica, eluting with dichloromethane containing 0.4% of a 33% ammonia solution.
[0088] 0.1 g of base is isolated, which base is salified with a 0.1 N hydrochloric acid solution in propan-2-ol.
[0089] 0.076 g of hydrochloride is obtained which is purified in a reversed phase on an XTerra® MS C18 column (pH 10).
[0090] 0.037 g of base is finally isolated in the form of white crystals.
[0091] Melting point: 156-158° C.
[0092] The table that follows lists the chemical structures and the physical properties of a few compounds of the invention.
[0093] In the “R 2 ” column of this table, “piperid” denotes a piperidin-1-yl group, “pyrrolid” denotes a pyrrolidin-1-yl group and “morphol” denotes a morpholin-4-yl group.
[0094] In the “Salt” column, “-” denotes a compound in base state and “HCl” denotes a hydrochloride; the acid:base molar ratio is indicated opposite.
[0095] The optical rotations of the optically pure compounds are as follows
No. Stereochemistry [α] D 20 (°, CH 3 OH) 41 threo (1S, 2S) −73.3 c = 0.225 55 threo (1R, 2R) +24.5 c = 0.9 64 threo (1S, 2S) +13.2 c = 0.84 65 threo (1S, 2S) +66.3 c = 0.58 71 threo (1S, 2S) +73.9 c = 0.89 72 threo (1R, 2R) −97.0 c = 1 74 threo (1R, 2R) −104.4 c = 1
[0096]
No.
Stereochemistry
R 1
X
R 2
Salt
M.p. (° C.)
1
threo (1R,2R;1S,2S)
CH 3
H
3-OCH 3 , 4-Cl
—
159-161
2
threo (1R,2R;1S,2S)
CH 3
H
3-I, 4-Cl
—
102-104
3
threo (1R,2R;1S,2S)
CH 3
H
4-Cl
—
149.5-150.5
4
threo (1R,2R;1S,2S)
CH 3
H
3,5-Cl 2
HCl
1:1
152-154
5
threo (1R,2R;1S,2S)
CH 3
H
4-N(CH 3 ) 2
—
128-130
6
threo (1R,2R;1S,2S)
CH 3
H
3,4-Cl 2
—
50-52
7
threo (1R,2R;1S,2S)
CH 3
H
3,4-(OCH 3 ) 2
HCl
1:1
68-70
8
threo (1R,2R;1S,2S)
CH 3
H
3,4-F 2
HCl
1:1
62-64
9
threo (1R,2R;1S,2S)
CH 3
H
3-F
HCl
1:1
36-38
10
threo (1R,2R;1S,2S)
CH 3
H
3-Br
HCl
1:1
116-118
11
threo (1R,2R;1S,2S)
CH 3
H
3,5-Cl 2 , 4-OH
—
266-268
12
threo (1R,2R;1S,2S)
CH 3
H
3-N(CH 3 ) 2
HCl
1:1
87-88
13
threo (1R,2R;1S,2S)
CH 3
H
3,5-Cl 2 , 4-NH 2
—
170-171
14
threo (1R,2R;1S,2S)
CH 3
H
3-Br, 4-OCH 3
HCl
1:1
136-137
15
threo (1R,2R;1S,2S)
CH 3
H
2,4,6-Cl 3
—
97-104
16
threo (1R,2R;1S,2S)
CH 3
H
2,3-Cl 2
—
107-114
17
threo (1R,2R;1S,2S)
CH 3
H
2-Cl
—
126-130
18
threo (1R,2R;1S,2S)
CH 3
H
2,4-Cl 2
—
138-142
19
threo (1R,2R;1S,2S)
CH 3
H
2-Cl, 4-Br
—
143-145
20
threo (1R,2R;1S,2S)
CH 3
H
2,5-Cl 2
—
133-134
21
threo (1R,2R;1S,2S)
CH 3
H
2,6-Cl 2
—
138-143
22
threo (1R,2R;1S,2S)
CH 3
H
2,3,5-Cl 3
—
156-159
23
threo (1R,2R;1S,2S)
CH 3
H
2-NH 2 , 3,5-Cl 2
HCl
1:1
186-188
24
threo (1R,2R;1S,2S)
CH 3
H
2-Cl, 5-NH 2
HCl
1:1
266-268
25
threo (1R,2R;1S,2S)
CH 3
H
3-Cl, 4-NH 2
HCl
1:1
164-166
26
threo (1R,2R;1S,2S)
CH 3
H
3-NH 2 , 4-Cl
HCl
1:1
230-232
27
threo (1R,2R;1S,2S)
CH 3
H
2-Cl, 4-NH 2
HCl
1:1
254-256
28
threo (1R,2R;1S,2S)
CH 3
H
2-NH 2 , 4-Cl
HCl
1:1
236-238
29
threo (1R,2R;1S,2S)
CH 3
H
2-Cl, 3-NH 2
HCl
1:1
195-200
30
threo (1R,2R;1S,2S)
CH 3
H
6-NH 2 , 2,5-Cl 2
HCl
1:1
267-268
31
threo (1R,2R;1S,2S)
CH 3
H
3,5-Cl 2 , 4-O(CH 2 ) 2 piperid
HCl
2:1
44-46
32
threo (1R,2R;1S,2S)
CH 3
H
3,5-Cl 2 , 4-O(CH 2 ) 3 N(CH 3 ) 2
HCl
2:1
39-41
33
threo (1R,2R;1S,2S)
CH 3
H
3,5-Cl 2 , 4-O(CH 2 ) 2 N(CH 3 ) 2
HCl
2:1
130-132
34
threo (1R,2R;1S,2S)
CH 3
H
3,5-Cl 2 , 4-O(CH 2 ) 2 pyrrolid
HCl
2:1
78-80
35
threo (1R,2R;1S,2S)
CH 3
H
3,5-Cl 2 , 4-O(CH 2 ) 2 morphol
HCl
2:1
166-168
36
threo (1R,2R;1S,2S)
CH 3
H
2-Cl, 6-F
HCl
1:1
266-268
37
threo (1R,2R;1S,2S)
CH 3
H
3,5-Cl 2 , 4-N(CH 3 ) 2
HCl
1:1
157-159
38
threo (1R,2R;1S,2S)
CH 3
H
2-Cl, 5-I
HCl
1:1
281-285
39
threo (1R,2R;1S,2S)
CH 3
H
3,5-Cl 2 , 4-NHCH 2 CH 3
HCl
1:1
175-180
40
threo (1R,2R;1S,2S)
CH 3
H
3-Cl, 4-I
HCl
1:1
98-99
41
threo (1S,2S)
CH 3
H
3,5-Cl 2 , 4-NH 2
—
176-177
42
threo (1R,2R;1S,2S)
CH 3
H
2-I, 4-Cl
—
213-214
43
threo (1R,2R;1S,2S)
CH 3
H
3-Cl, 4-OH
HCl
1:1
194-195
44
threo (1R,2R;1S,2S)
CH 3
H
3-Cl, 4-piperid
HCl
1:1
270-272
45
threo (1R,2R;1S,2S)
CH 3
H
2-OCH 3 , 3,5-Cl 2
—
97-98
46
threo (1R,2R;1S,2S)
CH 3
H
2-Cl, 3,4-(OCH 3 ) 2
—
229-230
47
threo (1R,2R;1S,2S)
CH 3
H
2-Br, 4-F
—
124-125
48
threo (1R,2R;1S,2S)
CH 3
H
3-Cl, 4-pyrrolid
HCl
1:1
154-156
49
threo (1R,2R;1S,2S)
CH 3
H
2-Br, 5-Cl
—
156-157
50
threo (1R,2R;1S,2S)
CH 3
H
2-Br
—
202-203
51
threo (1R,2R;1S,2S)
CH 3
H
2-Br, 4,5-(OCH 3 ) 2
—
218-219
52
threo (1R,2R;1S,2S)
CH 3
H
2-Cl, 3,6-F 2
—
52-53
53
threo (1R,2R;1S,2S)
CH 3
H
3-Cl, 4-morphol
HCl
1:1
158-162
54
threo (1R,2R;1S,2S)
CH 3
H
3,5-Cl, 4-piperid
HCl
1:1
154-163
55
threo (1R,2R)
CH 3
H
3,5-Cl 2 , 4-NH 2
HCl
1:1
250-260
56
threo (1R,2R;1S,2S)
CH 3
H
2-I, 3-Cl
HCl
1:1
253-255
57
threo (1R,2R;1S,2S)
CH 3
H
2-Cl, 3-I
HCl
1:1
297-298
58
threo (1R,2R;1S,2S)
CH 3
H
3,5-Cl 2 , 4-NHC 6 R 5
HCl
1:1
236-240
59
threo (1R,2R;1S,2S)
CH 3
H
3,5-Cl 2 , 4-pyrrolid
HCl
1:1
157-159
60
threo (1R,2R;1S,2S)
CH 3
H
2-Cl, 6-F
HCl
1:1
271-272
61
threo (1R,2R;1S,2S)
CH 3
H
2-Cl, 4,5-(OCH 3 ) 2
—
242-243
62
threo (1R,2R;1S,2S)
CH 3
H
2-Cl, 4-F
HCl
1:1
365-366
63
threo (1R,2R;1S,2S)
CH 3
H
2-Br, 5-OCH 3
—
213-214
64
threo (1S,2S)
CH 3
H
3,5-Cl 2 , 4-N(CH 3 ) 2
HCl
1:1
158-168
65
threo (1S,2S)
CH 3
H
2,3-Cl 2
HCl
1:1
124-126
66
threo (1R,2R;1S,2S)
CH 3
H
3,5-(OCH 3 ) 2 , 4-OCH 2 C 6 H 5
HCl
1:1
274-275
67
threo (1R,2R;1S,2S)
CH 3
H
3,5-Cl 2 , 4-OCH 2 C 6 H 5
HCl
1:1
165-175
68
threo (1R,2R;1S,2S)
CH 3
H
3,5-Cl 2 , 4-NHCH 2 C 6 H 5
HCl
1:1
165-175
69
threo (1R,2R;1S,2S)
CH 3
H
2-Cl, 3-F
HCl
1:1
115-116
70
threo (1R,2R;1S,2S)
CH 3
H
2-Cl, 5-F
HCl
1:1
212-215
71
threo (1S,2S)
CH 3
H
2-Cl, 4-F
HCl
1:1
123-125
72
threo (1R,2R)
CH 3
H
2,5-Cl 2 , 6-NH 2
HCl
1:1
66-67
73
threo (1R,2R;1S,2S)
CH 3
H
2-Cl, 5-OCH 3 , 6-NH 2
HCl
1:1
258-259
74
threo (1R,2R)
CH 3
H
2-Cl, 5-OCH 3 , 6-NH 2
HCl
1:1
138-139
75
threo (1R,2R;1S,2S)
CH 3
H
2,3-Cl 2 , 6-NH 2
HCl
1:1
230-236
76
threo (1S,2S)
H
H
2,3-Cl 2
—
—
156-158
[0097] The compounds of the invention were subjected to a series of pharmacological trials which demonstrated their utility as substances having therapeutic activity.
[0000] Study of the Transport of Glycine in SK-N-MC Cells Expressing the Native Human Transporter Glyt1.
[0098] The capture of [ 14 C]glycine is studied in SK-N-MC cells (human neuroepithelial cells) expressing the native human transporter glyt1 by measuring the radioactivity incorporated in the presence or in the absence of the test compound. The cells are cultured in a monolayer for 48 h in plates pretreated with fibronectin at 0.02%. On the day of the experiment, the culture medium is removed and the cells are washed with a Krebs-HEPES ([4-(2-hydroxyethyl)piperiazine-1-ethanesulphonic acid) buffer at pH 7.4. After a preincubation of 10 min at 37° C. in the presence either of buffer (control batch), or of test compound at various concentrations, or of 10 mM glycine (determination of the nonspecific capture), 10 μM [ 14 C]glycine (specific activity 112 mCi/mmol) are then added. The incubation is continued for 10 min at 37° C., and the reaction is stopped by 2 washes with a Krebs-HEPES buffer at pH 7.4. The radioactivity incorporated by the cells is then estimated after adding 100 μl of liquid scintillant and stirring for 1 h. The counting is performed on a Microbeta Tri-lux™ counter. The efficacy of the compound is determined by the IC 50 , the concentration of the compound which reduces by 50% the specific capture of glycine, defined by the difference in radioactivity incorporated by the control batch and the batch which received the glycine at 10 mM.
[0099] The compounds of the invention, in this test, have an IC 50 of the order of 0.001 to 10 μM.
[0000] Study Ex Vivo of the Inhibitory Activity of a Compound on the Capture of [ 14 C]glycine in Mouse Cortical Homogenate
[0100] Increasing doses of the compound to be studied are administered by the oral route (preparation by trituration of the test molecule in a mortar in a solution of Tween/Methocel™ at 0.5% in distilled water) or by the intraperitoneal route (dissolution of the test molecule in physiological saline or preparation by trituration in a mortar in a solution of Tween/Methocel™ at 0.5% in water, according to the solubility of the molecule) to 20 to 25 g Iffa Crédo OF1 male mice on the day of the experiment. The control group is treated with the vehicle. The doses in mg/kg, the route of administration and the treatment time are determined according to the molecule to be studied.
[0101] After the animals have been humanely killed by decapitation at a given time after the administration, the cortex of each animal is rapidly removed on ice, weighed and stored at 4° C. or frozen at −80° C. (in both cases, the samples are stored for a maximum of 1 day). Each sample is homogenized in a Krebs-HEPES buffer at pH 7.4 at a rate of 10 ml/g of tissue. 20 μl of each homogenate are incubated for 10 min at room temperature in the presence of 10 mM L-alanine and buffer. The nonspecific capture is determined by adding 10 mM glycine to the control group. The reaction is stopped by filtration under vacuum and the retained radioactivity is estimated by solid scintillation by counting on a Microbeta Tri-lux™ counter.
[0102] An inhibitor of the capture of [ 14 C]glycine will reduce the quantity of radioligand incorporated into each homogenate. The activity of the compound is evaluated by its ED 50 , the dose which inhibits by 50% the capture of [ 14 C]glycine compared with the control group.
[0103] The most potent compounds of the invention, in this test, have an ED 50 of 0.1 to 5 mg/kg by the intraperitoneal route or by the oral route.
[0000] Study of the Transport of Glycine in Mouse Spinal Cord Homogenate
[0104] The capture of [ 14 C]glycine by the transporter glyt2 is studied in mouse spinal cord homogenate by measuring the radioactivity incorporated in the presence or in the absence of the compound to be studied.
[0105] After the animals have been humanely killed (Iffa Crédo OF1 male mice weighing 20 to 25 g on the day of the experiment), the spinal cord of each animal is rapidly removed, weighed and stored on ice. The samples are homogenized in a Krebs-HEPES ([4-(2-hydroxyethyl)piperazine-1-ethanesulphonic acid) buffer, pH 7.4, at a rate of 25 ml/g of tissue.
[0106] 50 μl of homogenate are preincubated for 10 min at 25° C. in the presence of Krebs-HEPES buffer, pH 7.4 and of compound to be studied at various concentrations, or of 10 mM glycine in order to determine the nonspecific capture. The [ 14 C]glycine (specific activity=112 mCi/mmol) is then added for 10 min at 25° C. at the final concentration of 10 μM. The reaction is stopped by filtration under vacuum and the radioactivity is estimated by solid scintillation by counting on a Microbeta Tri-lux™counter. The efficacy of the compound is determined by the concentration IC 50 capable of reducing by 50% the specific capture of glycine, defined by the difference in radioactivity incorporated by the control batch and the batch which received the 10 mM glycine.
[0107] The compounds of the invention in this test have an IC 50 of the order of 0.001 to 10 μM.
[0000] Study Ex Vivo of the Inhibitory Activity of a Compound on the Capture of [ 14 C]glycine in Mouse Spinal Homogenate
[0108] Increasing doses of the compound to be studied are administered by the oral route (preparation by trituration of the test compound in a mortar, in a solution of Tween/Methocel™ at 0.5% in distilled water) or intraperitoneal route (test compound dissolved in physiological saline, or triturated in a mortar, in a solution of Tween/Methocel™ at 0.5% in distilled water) to 20 to 25 g Iffa Crédo OF1 male mice on the day of the experiment. The control group is treated with the vehicle. The doses in mg/kg, the route of administration, the treatment time and the humane killing time are determined according to the compound to be studied.
[0109] After humanely killing the animals by decapitation at a given time after the administration, the spinal cords are rapidly removed, weighed and introduced into glass scintillation bottles, stored on crushed ice or frozen at −80° C. (in both cases, the samples are stored for a maximum of 1 day). Each sample is homogenized in a Krebs-HEPES buffer at pH 7.4, at a rate of 25 ml/g of tissue. 50 μl of each homogenate are incubated for 10 min at room temperature in the presence of buffer.
[0110] The nonspecific capture is determined by adding 10 mM glycine to the control group.
[0111] The reaction is stopped by filtration under vacuum and the radioactivity is estimated by solid scintillation by counting on a Microbeta Tri-lux™ counter.
[0112] An inhibitor of the capture of [ 14 C]glycine will reduce the quantity of radioligand incorporated in each homogenate. The activity of the compound is evaluated by its ED 50 , the effective dose which inhibits by 50% the capture of [ 14 C]glycine compared with the control group.
[0113] The best compounds of the invention have, in this test, an ED 50 of 1 to 20 mg/kg, by the intraperitoneal route or by the oral route.
[0114] The results of the trials carried out on the compounds of the invention having the configuration (1S,2S) and their threo racemates having the configuration (1R,2R; 1S,2S) in the general formula (I) of which R 2 represents one or more halogen atoms show that they are inhibitors of the glycine transporter glyt1 which are present in the brain, this being in vitro and ex vivo.
[0115] These results suggest that the compounds of the invention can be used for the treatment of behavioral disorders associated with dementia, psychoses, in particular schizophrenia (deficient form and productive form) and acute or chronic extrapyramidal symptoms induced by neuroleptics, for the treatment of various forms of anxiety, panic attacks, phobias, obsessive-compulsive disorders, for the treatment of various forms of depression, including psychotic depression, for the treatment of disorders due to alcohol abuse or to withdrawal from alcohol, sexual behavior disorders, food intake disorders, and for the treatment of migraine.
[0116] The results of the trials carried out on the compounds of the invention having the configuration (1R,2R) and their racemates having the configuration (1R,2R; 1S,2S) in the general formula (I) of which R 2 represents both a halogen atom and an amino group NR 6 R 7 show that they are inhibitors of the glycine transporter glyt2, predominantly present in the spinal cord, this being in vitro and ex vivo.
[0117] These results suggest that the compounds of the invention may be used for the treatment of painful muscular contractures in rheumatology and in acute spinal pathology, for the treatment of spastic contractures of medullary or cerebral origin, for the symptomatic treatment of acute and subacute pain of mild to moderate intensity, for the treatment of intense and/or chronic pain, of neurogenic pain and rebellious algia, for the treatment of Parkinson's disease and of Parkinsonian symptoms of neurodegenerative origin or induced by neuroleptics, for the treatment of primary and secondary generalized epilepsy, partial epilepsy with a simple or complex symptomatology, mixed forms and other epileptic syndromes as a supplement to another antiepileptic treatment, or in monotherapy, for the treatment of sleep apnea, and for neuroprotection.
[0118] Accordingly, the subject of the present invention is also pharmaceutical compositions containing an effective dose of at least one compound according to the invention, in the form of a pharmaceutically acceptable base or salt or solvate, and in the form of a mixture, where appropriate, with suitable excipients.
[0119] The said excipients are chosen according to the pharmaceutical dosage form and the desired mode of administration.
[0120] The pharmaceutical compositions according to the invention may thus be intended for oral, sublingual, subcutaneous, intramuscular, intravenous, topical, intratracheal, intranasal, transdermal, rectal or intraocular administration.
[0121] The unit forms for administration may be, for example, tablets, gelatin capsules, granules, powders, oral or injectable solutions or suspensions, patches or suppositories. For topical administration, it is possible to envisage ointments, lotions and collyria.
[0122] The said unit forms contain doses in order to allow a daily administration of 0.01 to 20 mg of active ingredient per kg of body weight, according to the galenic form.
[0123] To prepare tablets, there are added to the active ingredient, micronized or otherwise, a pharmaceutical vehicle which may be composed of diluents, such as for example lactose, microcrystalline cellulose, starch, and formulation adjuvants such as binders, (polyvinylpyrrolidone, hydroxypropylmethylcellulose, and the like), flow-enhancing agents such as silica, lubricants such as magnesium stearate, stearic acid, glyceryl tribehenate, sodium stearylfumarate. Wetting agents or surfactants, such as sodium lauryl sulfate, may also be added.
[0124] The techniques for production may be direct compression, dry granulation, wet granulation or hot-melt.
[0125] The tablets may be uncoated, coated, for example with sucrose, or coated with various polymers or other appropriate materials. They may be designed to allow rapid, delayed or prolonged release of the active ingredient by virtue of polymer matrices or specific polymers used in the coating.
[0126] To prepare gelatin capsules, the active ingredient is mixed with dry (simple mixture, dry or wet granulation, or hot-melt), liquid or semisolid pharmaceutical vehicles.
[0127] The gelatin capsules may be hard or soft, film-coated or otherwise, so as to have rapid, prolonged or delayed activity (for example for an enteric form).
[0128] A composition in syrup or elixir form or for administration in the form of drops may contain the active ingredient together with a sweetener, preferably calorie-free, methylparaben or propylparaben as antiseptic, a flavor modifier and a coloring agent.
[0129] The water-dispersible powder and granules may contain the active ingredient in the form of a mixture with dispersing agents or wetting agents, or dispersants such as polyvinylpyrrolidone, and with sweeteners and flavor corrigents.
[0130] For rectal administration, suppositories are used which are prepared with binders which melt at rectal temperature, for example cocoa butter or polyethylene glycols.
[0131] For parenteral administration, there are used aqueous suspensions, isotonic saline solutions or sterile solutions for injection containing pharmacologically compatible dispersing agents and/or wetting agents, for example propylene glycol or butylene glycol.
[0132] The active ingredient may also be formulated in the form of microcapsules, optionally with one or more carriers or additives, or alternatively with a polymer matrix or with a cyclodextrin (patches, prolonged release forms).
[0133] The topical compositions according to the invention comprise a medium compatible with the skin. They may be provided in particular in the form of aqueous, alcoholic or aqueous-alcoholic solutions, gels, water-in-oil or oil-in-water emulsions having the appearance of a cream or of a gel, microemulsions, aerosols, or alternatively in the form of vesicular dispersions containing ionic and/or nonionic lipids. These galenic forms are prepared according to the customary methods in the fields considered.
[0134] Finally, the pharmaceutical compositions according to the invention may contain, apart from a compound of general formula (I), other active ingredients which may be useful in the treatment of the disorders and diseases indicated above.
[0135] 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.
|
This invention discloses and claims a compound of general formula (I)
in which R 1 represents either a hydrogen atom, or an optionally substituted alkyl group, or a cycloalkylalkyl group, or an optionally substituted phenylalkyl group, or an alkenyl group, X represents a hydrogen atom or one or more substituents chosen from halogen atoms and trifluoromethyl, alkyl and alkoxy groups, R 2 represents one or more substituents chosen from halogen atoms, optionally substituted alkoxy and optionally substituted amino. The compounds of this invention exhibit therapeutic utility.
| 2
|
DESCRIPTION
1. Technical Field
The present invention generally relates to a waste material collection tub and method of use and more particularly to such tubs which are usually located behind a restaurant or other commercial site for temporarily storing waste material therein until periodically picked up and their contents dumped into a waste material transport vehicle for removal of the waste material from the site.
2. Background Art
Conventional waste material collection tubs and their use are typically disclosed and described in U.S. Pat. No. 4,450,828 issued on May 29, 1984, to Donald R. Onken, et al. This patent shows a waste material collection tub primarily for collecting and temporarily storing used deep-frying grease with the tub being of generally rectangular configuration and having a pair of upwardly disposed outwardly extended tub lifting lugs and a pair of lower laterally offset tub dumping lugs. The lugs are rigidly non-removably mounted on the tubs either by welding or by providing some type of bolting flanges on the tubs. Such rigid mountings have been found to be highly disadvantageous due to the inability to nest several tubs together when it is desirable to transport them from one collection site to another. Even with the bolted on types of lugs, the bolts and nuts are subject to the harsh outside environment which causes them to rust and corrode and which usually become frozen in place making it virtually impossible to remove. When this occurs, removal can only be accomplished by a manually manipulated hammer and chisel or an acetylene torch which not only destroys the lugs but also frequently results in serious damage to the sides of the tubs. In addition, the permanently mounted tub dumping lugs are also subject to damage from backing vehicles, which if not completely removed from the tubs, are frequently bent to such an extent that they no longer can be aligned with the dumping lug receiving mechanism on the transport vehicle.
A further disadvantage with the abovedescribed conventional tubs is that in order to dependably hold the relatively high loads encountered with various types of waste material, the side walls thereof are usually corrugated or are provided with large channular sections for added rigidity. Such channular wall configurations are not only difficult and expensive to manufacture, but afford undesirable grooves or pockets within the tubs which collect compacted waste material that cannot be easily dislodged from the tub during the dumping operation. This usually requires manual cleaning of the tubs to remove such impacted material.
It is therefore recognized that an improved waste material collection tub is desirable which can provide easily selectively mountable and removable tub dumping lugs or pins and relatively smooth interior side walls to better assure complete emptying of the tubs into the transport vehicle. Accordingly, the present invention is directed to overcoming the problems as set forth above.
DISCLOSURE OF THE INVENTION
In accordance with one aspect of the present invention there is provided a waste material collection tub which utilizes a plurality of tapered side walls having substantially flat planar inner and outer surfaces with a pair of tub lifting pins individually outwardly extended in opposed relation from said outer surfaces of the side walls which are centrally located adjacent to the top edge of the tub with the tub further including a pair of opposed outwardly extended tub dumping pins individually selectively removably mounted on said pair of opposite side walls in downwardly spaced laterally offset relation to said lift pins.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevational view of a material collecting tub embodying the principles of the present invention showing a dumping pin mounting structure on the side wall thereof with the dumping pin removed.
FIG. 2 is a somewhat enlarged elevational view of the dumping pin mounting structure of FIG. 1 showing the dumping pin in an installed position.
FIG. 3 is a vertical cross section through the pin and pin mounting structure taken along the line III--III of FIG. 2.
FIG. 4 is a further enlarged vertical cross section through the pin mounting structure taken along the line IV--IV of FIG. 1.
FIG. 5 is a three-dimensional view of the tub dumping pin of the preceding Figures removed from the tub.
FIG. 6 is a top plan view of the waste material collection tub of the preceding Figures.
BEST MODE FOR CARRYING OUT THE INVENTION
Referring more particularly to the drawings and as best shown in FIGS. 1 and 6, a material collection tub embodying the principles of the present invention is generally indicated by the reference numeral 10. The tub has a plurality of side walls 11 constructed of a relatively heavy sheet metal material which are joined together at corners 12 as by welding or the like in a substantially rectangular configuration and in circumscribing relation to a waste material collection compartment 14. The side walls present substantially flat inner and outer surfaces 15 and 16, respectively. The tub further includes a bottom wall 17, again rigidly connected to the side walls 11 by welding or the like. Each side wall 11 tapers downwardly from an upper edge 18 to an opposite lower edge 19. An enlarged overhanging upper reinforced flange 20 is disposed in circumscribing relation around the plurality of side walls 11 which mounts a pair of outwardly extended lifting pins 22. The pins are individually disposed in an opposed relation from opposite ones of a pair of side walls in a substantially central location adjacent to the upper edge 18 thereof. The lift pins are also rigidly secured to the side walls and to the upper flange by welding which provides a sufficiently rigid structure to permit lifting of the entire collection tub when full of waste material by lifting chains or the like from a material collection and transport vehicle, not shown.
The pair of opposed side walls 11 which mount the lifting pins 22 further include an elongated reinforcing strap 25 which enables the inner surface of the side walls to be completely free of any bracing. The strap is welded to the outer surface of the side walls in substantially flat overlying relation and in upwardly closely spaced substantially parallel relation to the bottom wall 17 of the tub. The strap has a downwardly opening notch 27 providing oppositely spaced substantially parallel side edges 28 terminating in an upper arcuately closed upper end 29. A pair of spacer bars 32 are individually welded in overlying relation to the reinforcing strap 25 in laterally outwardly spaced parallel relation with associated side edges 28 on either side of the notch 27.
A substantially flat rectangular-shaped guide plate 35 is mounted in overlying bridging relation between the spacer bars 32 and is secured thereto by welding or the like. The guide plate has a pin guiding slot 37 which is the same size and configuration as the notch 27 in the reinforcing strap 25. The slot provides a pair of spaced vertically extended side edges 38 terminating in an upper arcuately closed end 39 precisely aligned with the upper closed end 29 of the strap. With the guide plate disposed on the spacer bars 32, a downwardly opening pin mounting pocket 42 is thus formed between the guide plate 35 and the reinforcing strap 25.
As best shown in FIGS. 2 and 3, a pair of elongated cylindrical sleeves 45 are individually welded to the lower edge of each of the spacer bars 32 in aligned coaxial relation with each other. Each sleeve has a cylindrical bore 46 therein which is adapted to receive an elongated locking rod 48 which has a L-shaped handle end 49 and an opposite distal end 51. The locking rod 48 is slideably extendable through the bores 46 in the sleeves 45 in dependable locking relation to the pocket 42. A cotter pin 53 is extendable through a suitable hole in the distal end 51 to retain the rod in the described locking position.
A tub dumping pin 55 is adapted to be releasably mounted on the side wall 11 of the tub by the above described mounting structure in outwardly extending relation therefrom at a position downwardly spaced and laterally offset from the tub lifting pins 22. As best shown in FIGS. 3 and 5, each tub dumping pin 55 includes an elongated cylindrical body providing an outer end 57 and an opposite inner end 58. A substantially square flat pin mounting plate 60 is provided having a circular bore 62 therethrough which is adapted to receive the inner end 58 of the dumping pin 55. The pin and mounting plate are securely welded together with the inner end of the pin extending through the plate a short distance to provide a guiding projection 64 for the pin during installation on the tub. The mounting plate 60 is of a size to be upwardly slideably received within the pocket 42 of the pin mounting structure between the side edges 38 of the spacer bars 32.
Industrial Applicability
In use, the material collection tub 10 of the present invention is disposed behind a restaurant or other commercial site without the tub dumping pins 55. The dumping pins 55 and the locking rods 48 are carried on the transport vehicle which during a collection visit is parked closely adjacent to the material collection tub 10. The dumping pins are then installed on the tub by sliding the pin mounting plate 60 upwardly within the pocket 42 during which time the pin is accurately guided by the guide slot 37 in the guide plate 35. During such movement the projection 64 of the pin through the mounting plate is also guided upwardly through the notch 27 in the reinforcing strap 25 on the tub. The dumping pin 55 and mounting plate 60 are temporarily held in the installed position of FIG. 2 and the locking rod 48 extended in sliding relation through the bores 46 and the sleeves 45 and the cotter pin 53 installed with the rod positioned in supporting relation beneath the mounting plate 60.
The lift pins 22 are then engaged by the appropriate lifting chains, not shown, or other lifting mechanism on the transport vehicle and the tub lifted into the vehicle for positioning the dumping pins with the dumping mechanism thereon to cause tipping of the tub and the emptying of its contents into the material collecting receptacle on the vehicle, not shown. It is significant that most of the weight of the tubs is transferred from the dumping pins through the reinforcing straps and into the side walls of the tub. Such weight transfer occurs as the inner end 58 and projection 64, respectively, engage the closed upper ends 29 and 39 of the guide slots 27 and 37 on either side of the pin mounting plate 60. It is also significant that during such dumping operation, the tapered substantially flat uncluttered inner side wall surfaces 15 of the tubs ensure complete cleaning and emptying of waste material therefrom. This is made possible by the reinforcing straps 25 being located on the outer surfaces 16 of the side walls 11 to provide added rigidity to the walls. The straps also provide the dual function of providing a mounting base for the dumping pin mounting structure which permits the dumping pins 55 to be conveniently removed between uses and stored on the transport vehicle for use at the next collection tub site. After dumping, the tub 10 is returned to its original collecting position on the ground and the dumping pins 55 easily and conveniently removed by reversing the above-described installation procedure.
In view of the foregoing it is readily apparent that the material collection tub 10 of the present invention provides a vastly superior system by which the tub dumping pins 55 can be installed and readily removed after use so as not to be exposed to the harsh environment between dumping operations and which provide relatively clean tapered side walls for the tub that can be easily nested with other tubs for transport when desirable to move the tubs to different collection sites.
|
The present invention relates to a waste material collection tub which is provided with a pair of selectively removable tub dumping pins which are precisely located in relation to the tub lifting pins for use with appropriate material transport vehicles to ensure a longer life for such tubs and to maintain them in good working condition throughout such period. The prior art tubs only provide rigid non-removable dumping pins which are exposed to the severe environment, or subject to damage by being struck by other vehicles in the high traffic areas adjacent to commercial sites and cannot be nested together with other similar tubs during transport from site to site. The present invention overcomes these problems by providing a tub with exterior reinforcing straps enabling the interior surfaces of the side walls of the tub to be completely uncluttered and also to provide a convenient mounting structure so that the dumping pins can be quickly and conveniently mounted on the tubs only during the dumping operation and thereafter conveniently removed and stored for safe keeping until the next dumping operation.
| 8
|
BACKGROUND OF THE INVENTION
This application is filed under 35 U.S.C. 371 of International Application No. PCT/FR97/00715 filed Apr. 21, 1997.
The present invention relates to a cast wall with continuous reinforcement, to a method of making such a cast wall in the ground, and to shuttering for making such a cast wall.
Cast walls are structures made in the ground by digging a trench and filling the trench with a binder, generally concrete, which sets on site.
The trench can be dug under a slurry which is subsequently replaced by the binder.
To obtain good continuity of the cast wall, the binder must be cast on a single occasion over the full depth of the trench.
To this end, the cast wall is made in the form of successive contiguous panels.
Each panel is obtained by casting the binder into a length of trench that has been dug in line with a solidified panel that has already been made.
The panels are connected together in pairs by their side edges being mutually engaged with a shape that is defined by the shuttering, the engagement also being referred to as an end joint, extending transversely to the trench over the full depth thereof and being put into place prior to casting the binder.
In general, a cast wall is reinforced by reinforcement that is put into place in each length of the trench prior to casting the binder.
Nevertheless, in such a cast wall, the reinforcement is missing at the connections between panels, and as a result such connections constitute zones of weakness in the cast wall, such that the transmission of forces, in particular transverse bending, but also longitudinal compression and traction, does not take place properly from one panel to another, which can give rise to problems in the event of the ground moving, particularly in areas of high seismic activity.
Patent Document FR-A-2 517 717 describes a solution to that problem. It consists in fixing vertical elements of sheet piling to the ends of the panel reinforcement, which elements arc provided with locks that co-operate with one another to provide continuity of the reinforcement from one panel to another.
Nevertheless, that solution does not provide adequate transmission of forces applied to the reinforcement under the effect of external stresses.
In addition, engaging the locks in one another can become difficult when the reinforcing members are not properly aligned.
Finally, the means which are provided for protecting the locks while the casting material is being cast into the trenches are not really satisfactory.
A first object of the invention is to provide a cast wall constituted by a plurality of juxtaposed panels making it possible in particular to obtain a good distribution of the forces applied to the reinforcing members of the various panels, and which is implemented in improved manner.
To this end, the invention provides a cast wall constituted by a succession of panels touching via their end edges and made by casting a binder into contiguous lengths of trench dug in the ground in line with one another, each panel having reinforcement, said wall further including link means between the reinforcement of two contiguous panels, the wall being characterized in that the link means are separate from said reinforcement and comprise an anchor clement having a first end fitted with at least one vertical first locking clement and a second end engaged in one of said panels, and a link clement having a first end fitted with at least one second locking element suitable for co-operating with the first locking clement, and a second end engaged in the other of said panels.
Another object of the invention is to provide a method of making a cast wall, in particular of the above-defined type, and which does not have the drawbacks of the prior art.
To achieve this object, the invention provides a method of making a cast wall in the ground, in particular a wall as defined above, in which method a first length of trench is prepared in which end shuttering is placed and a binder is cast to obtain a first wall panel, and then, at the shuttering end, a second length of trench is prepared contiguous to the first and in line therewith, the shuttering is removed, and a binder is cast into the second length of trench to obtain a second wall panel adjacent to the first, which method is characterized by the fact that, prior to casting the binder in the first length of trench, reinforcement is placed therein together with a link element including locking ends that are positioned in the immediate vicinity of the shuttering, and during casting, said locking ends are prevented from being embedded in the binder so that they project from the first wall panel into the second length of trench after the shuttering has been removed, and prior to casting the binder in the second length of trench, reinforcement is put into place therein together with an anchor element which is secured to the locking ends of the link element, and in that the shuttering is secured to the link element prior to being put into place in the length of trench, the link and anchor elements not being directly secured to the reinforcement, but being engaged therein.
A third object of the invention is to provide shuttering for making a cast wall in a trench, in particular a wall of the type defined above, which shuttering does not have the drawbacks of the prior art.
To achieve this object, the invention provides shuttering for making a cast wall of the above-defined type, which shuttering is designed to be put into place against an end wall of a length of trench dug in the ground to obtain a wall panel by casting a binder into said length of trench, said shuttering including a face for bearing against the end wall of the length of trench, and opposite said bearing face, a casting face looking into the length of trench, the shuttering being characterized by the fact that it includes on its casting face, at least one recess suitable for receiving the locking element of a link element placed in the length of trench, each recess being closed by a vertical wall element provided with a vertical slot suitable for passing a sheet piling element fitted with the locking element and providing sealing between said sheet piling element and the wall of said recess.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics of the invention appear more clearly on reading the following description of various embodiments of the invention given as non-limiting examples. The description refers to the accompanying drawings, in which:
FIGS. 1 to 6 show the principle of the invention by showing the various steps in which two contiguous panels of the cast wall are made;
FIGS. 7 and 8 are a plan view and an elevation view of preferred embodiments of reinforcement for a panel and of an anchor element;
FIG. 9 shows the connection between the reinforcement of two is panels of the cast wall;
FIG. 10 is a vertical section through a preferred embodiment of the shuttering when there is only one lock;
FIG. 11 is a detail view of FIG. 10; and
FIGS. 12 and 13 are section views seen vertically of variant embodiments of the shuttering.
With reference initially to FIGS. 1 to 6, the principle of making a cast wall in accordance with the invention is described.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, there can be seen a length of trench 20 being dug in the ground under a slurry using appropriate apparatus, e.g. a digger bucket.
A metal reinforcement element 22 (described in greater detail below) is put into place in the length of trench, together with a link element 24 secured to a shuttering element 26 that is designed to limit the length of the panel that is to be made. The link element 24 (also described in detail below) is engaged in the reinforcement 22 but is not welded thereto. The term "engaged" is used to mean that a portion of the link element penetrates inside the cage constituted by the reinforcement. The link element 24 is terminated by two locks 28 and 30 which are disposed in two housings 32 and 34 of the shuttering element 26. These housings are closed by means which are described below. The purpose of these means is to prevent the locks being covered by the material constituting the binder (concrete or grout), during casting. In addition, these means temporarily hold together the link element 24 and the shuttering element 26.
In the following step shown in FIG. 3, the concrete or the grout is cast into the trench 20 to make a panel 36. The panel is reinforced by the reinforcement 22. In addition, it provides mechanical connection between the reinforcement 22 and the link element 24 which are both embedded in the concrete. Nevertheless, because of the housings 32 and 34, the locks 30 and 33 remain free. Also, in conventional manner, the shuttering element 26 is generally U-shaped in horizontal section so that, after the end shuttering 38 of the panel has been removed, the panel 36 is of a shape that is suitable for receiving the following panel. The locks 28 and 30 project into the panel-receiving shape 38.
Prior to removing the shuttering, a second length of trench 40 is dug in which the second panel of cast wall is to be made.
In the length of trench 40, there are put into place simultaneously a piece of metal reinforcement 42 and an anchor element 44, with the anchor element 44 being engaged in the reinforcement 42 but not being welded thereto. While the anchor element 44 is being put into place, its locks 46 and 48 are engaged in the locks 28 and 30 of the link element 24 of the panel 36 that has already been made. This mutual engagement of the locks is greatly facilitated by the fact that since the anchor element 44 is not fixed to the reinforcement 42, the anchor element can be moved horizontally relative to the reinforcement about a vertical midplane of the reinforcement.
Once this operation has been completed, concrete or grout is cast into the length of trench 40 to make a second panel 50 of the cast wall.
It will be understood that because of the hooking between the link elements 24 and the anchor elements 44, continuity of mechanical strength is provided between the metal reinforcement elements of the two panels. Although there is no direct mechanical connection, e.g. by welding, between the reinforcement 22 and 42 and the assembly constituted by the link element 26 and the anchor clement 44, the engagement of said reinforcement elements as embedded in the concrete ensures mechanical continuity.
With reference now to FIGS. 7 and 8, a preferred embodiment of the reinforcement 22 and 42, and of the link or anchor elements 24 and 44 is now described.
The reinforcement 22 is constituted in conventional manner by a cage made up of horizontal concrete reinforcing bars 52 and of vertical concrete reinforcing bars 54 that are welded together.
In a preferred embodiment, the link element 24 (or the anchor element 44) is constituted by U-shaped round bars referenced 56. The bars 56 (56a, 56b, 56c) are disposed in horizontal planes that are regularly spaced apart. For example, for reinforcement that is 12 meters high, the bars 56 are spaced about at 66 cm. The free ends 58 and 60 of the branches of the bars 56 are welded to respective sheet piling elements 62 and 64 which are terminated by locks 28 and 30 (or 46 and 48). Optionally flat horizontal bars 66 can be welded at regular intervals between the sheet piling elements 62 and 64.
It will be understood that the link elements or anchor elements are essentially constituted by horizontal U-shaped round bars secured to one another by the sheet piling. The U-shaped bars are engaged in the bars forming the reinforcement, but they are not secured thereto.
It would not go beyond the ambit of the invention if the link elements or anchor elements were made in some other way. Nevertheless, it is important for them to be essentially constituted by concrete bars that are horizontal in order to facilitate horizontal transmission of forces that are liable to be applied to the panels, and thus to their reinforcement.
Also naturally, the locking elements for locking the anchor elements and the link elements could be constituted by members other than sheet piling type locks. It suffices for them to be male and female locking members suitable for co-operating with one another when a piece of reinforcement is put into place in a length of trench.
FIG. 9 is a plan view of the locking between a link element 24 and an anchor element 44, with the concrete omitted to facilitate understanding.
In FIG. 7, there can also be seen the shuttering element 26 with its two housings 32 and 34 in which the locks 28 and 30 are "enclosed". The preferred embodiment of the shuttering element 26 is described below with reference to FIGS. 10 and 11.
In FIG. 10, there can be seen a shuttering element 26' for a link element 24' that has only one lock 28.
The shuttering 26' proper is provided on its molding face 70 with two metal parts 72 and 74 which define a housing or recess 76 between them having an opening 78. The dimensions of the housing 76 are sufficient to receive the lock 28 disposed at the end of the vertical sheet piling element 80. The opening 78 is closed by two rigid wall portions 82 and 84 which leave between them a slot 86 of width slightly greater than the width of the sheet piling 80, with the wall portions 82 and 84 being fixed to the parts 72 and 74. The slot 86 is closed by flexible sealing lips 88 and 90 fixed on the walls 82 and 84. These lips 88 and 90 bear by resilient deformation on the faces of the sheet piling 80, thus providing sealing against the binder.
The rigid walls 82 and 84 position the link element 24 horizontally and secure the shuttering 26 temporarily on the clement 24.
To further improve sealing, two vertical flexible hoses 91 and 92 can be mounted inside the housing 76 in contact with the lock, the wall portions 82 and 84, and the inside wall of the housing. This provides a double sealing system.
These hoses can also be used to establish a flow of water for "cleaning" the locks, after the grout or concrete has been cast, supposing a small quantity thereof has managed to penetrate into the housing.
FIGS. 12 and 13 show variant embodiments of the means serving for sealing the housing(s) formed in the shuttering element.
In the embodiment of FIG. 12, the locks 28 and 30 are protected in the housings 32 and 34 by rubber covers 100 and 102.
In the embodiment of FIG. 13, the locks 28 and 30 are protected by split tubes 104 and 106 which are threaded over the locks. Even if a coating of binder does form around the tubes 104 and 106 after the shuttering 26 has been removed, these coatings are easily destroyed by the locks of the next element of sheet piling being put into place.
|
The invention relates to a cast wall constituted by a succession of panels touching via their end edges and made by casting a binder in contiguous lengths of trench dug in the ground in line with one another, each panel including reinforcement, said wall further including link means between the reinforcements in two contiguous panels. The link means (24, 44) are separate from the reinforcement (22, 42) and comprise an anchor element (24) having a first end fitted with at least one vertical first locking element (28, 30) and a second end engaged in one of said panels (22), and a link element (44) having a first end provided with at least a second locking element (46, 48) suitable for co-operating with the first locking element, and a second end engaged in the other one of said panels (42).
| 4
|
BACKGROUND OF THE INVENTION
The invention concerns an rpm governor for fuel injected internal combustion engines--especially diesel engines--which has an rpm-dependent, automatic regulating member that is connected with the feed control member of the fuel injection pump by means of an intermediate lever, and which operates on the control lever of an rpm-controlled starting device only during non-operation of the governor at rpm's lower than the idling rpm. This lever is coupled to a stop, and is located in the governor housing. In the normal operational range of the governor, the stop which limits the volume to the operational maximum can be moved out of the way of a counter-stop connected to the feed control member, and the feed control member is capable of being shifted into a position, in which the fuel injection pump supplies a quantity of fuel (start quantity) which exceeds the operational maximum. The fuel injection pump is connected to a return spring which holds the control lever in its original position, not touching the regulating member, when it is not in operation.
An rpm governor is already known (Austrian Pat. No. 185,613), whose starting device controls an automatically increased starting quantity, by means of a control lever acted upon by regulating member and coupled to a stop, during non-operation of the engine and at rpm's lower than the lowest idling rpm. The increased starting quantity is cut off after the first reving of the engine and the limitation to the maximum operational quantity becomes effective. This rpm governor is employed with special effectiveness in fast starting diesel engines, but has the disadvantage that this increased starting quantity is released and controlled during every start, i.e., even when the engine is warm. Rapid starting diesel engines need, however, the increased starting quantity only in starting when the engine is below a predetermined operational temperature, so that by the use of the automatic starting device in a warm engine, too much fuel is injected, and the exhaust gases unnecessarily exceed the values for the allowable exhaust density (smog limits).
It is further known with injection pumps with rpm governors, but without automatic starting devices (FIGS. 1-3 of British Pat. No. 529,671), to limit the position of the feed control member of the fuel injection pump in the direction of greater supply quantities by stops controlled by a thermostat. These stops depend only on the temperature. The known governor contains no means for an automatic, rpm-controlled increased starting quantity release and subsequent decrease, so that the increased starting quantity is maintained too long, until the operational temperature is attained. In rapid starting diesel engines, this leads to excessive exhaust fumes.
In a special exemplary embodiment of the previously mentioned rpm governor (FIG. 4 of British Pat. No. 529,671), the stop is activated by a magnet located in the starting circuit which can be shut off by a temperature-dependent bimetallic switch. Apart from the forces that disadvantageously load the armature of the magnet, this starting device is expensive and can be unnecessarily activated by a bypass of the thermostat switch or of the starter even during operation of the motor vehicle. In this manner it may be true that a corresponding rise in performance is attained, but it also entails as an unavoidable consequence damage or destruction of the engine or of the assembly attached to the engine. In addition, during an adjustment of the maximum quantity in the governor, the position of the magnet must also be adjusted, which leads to an expensive construction.
OBJECT AND SUMMARY OF THE INVENTION
The rpm regulator according to the present invention with a combination of temperature and rpm controls, avoids the disadvantages of the known rpm governor and makes it possible in an advantageous and simple manner for an rpm governor of this type to automatically shut off the increased starting quantity of fuel when the engine is warm, even before the first reving of the engine, so that the engine can then, at most, be started at its maximum operational quantity.
A further advantage is security against tampering, because the starting process and the starting quantity decrease cannot be influenced by the driver, and above all, the starting quantity cannot be injected when the engine is in operation.
A still further advantage of this invention is the provision of an inexpensive and compact construction being accomplished by assembling the thermostat into the rpm governor either directly on the stop element, or on the control lever, for in this manner, the parts that are provided with thermostats can be pre-adjusted outside the governor as to their temperature behavior.
A starting device that is secure against tampering and overload, and is easily adjustable without influencing the other regulating functions in the governor can be achieved in an especially advantageous manner by means of the characteristics narrated hereinafter.
Because the operational temperature of the engine, that is, the corresponding temperature range can be exceeded by a large degree, in both extremes of temperature, the danger exists, that the thermostat and structural parts of the govenor can become overloaded.
The invention will be better understood as well as further objects and advantages thereof become more apparent from the ensuing detailed description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a generally cross-sectional view of the first embodiment of this invention;
FIG. 2 is a cross-sectional view along the line II--II in FIG. 1;
FIGS. 3 and 4 are each generally side elevational views of the second and third embodiments of this invention; and
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the first embodiment of this invention that is shown in FIGS. 1 and 2, the only partially shown injection pump, labeled as 10, is assembled with the governor 11 according to the invention and is flush with its housing 12. A flyweight regulator 14 of a known construction is attached to the drive shaft 13 of the injection pump 10. The centrifugal flyweight regulator 14 has flyweights 15, which move in a known manner under the effects of centrifugal force against the force of regulating springs 16, so that this regulating movement is transferred through angle lever 17 to an adapter sleeve 18 which serves as the regulating member. Coupled with the adapter sleeve 18 by means of a slide ring 19 and its pivot pin 21 is an intermediate lever 22, which is formed as a slotted lever and which connects the adapter sleeve 18 with a regulating rod 24 of the injection pump 10 which serves as the feed control member by means of a side bar 23. In this manner the regulating motions of the regulating member 18 are transferred to the regulating rod 24.
The intermediate lever 22 has a known guide bar bracket 25 with a pin 26 that is arranged to slide in the guide bar bracket 25 as the point of support. This pin 26 is part of a steering lever 27, which for its part is connected by a lever pivot 28 so as to rotate together with an adjusting lever 29 which serves as the adjusting member.
A control lever 32 is also movably mounted on the lever pivot 28 as part of a starting device 31. The control lever 32 has two coupled part levers 33 and 34, from which the first part lever 33 is formed as a double-armed lever, whose first lever arm 33a in the shown normal position of the control lever 32 lies against a travel stop 35 located on the second part lever 34, while the second part lever 34, formed as only a one armed lever, is pressed against a raised portion 36 of the governor housing 12 in the area of the stop 35 by the force of a return spring 37. This raised portion 36 determines the original position of the control lever 32 as shown in the drawing. The return force Pr of the return spring 37 is slightly increased by the force of a compression spring 38, which is arranged between the governor housing 12 and the second lever arm 33b of the first indexing arm 33, and whose function it is to hold the first part lever 33 in position against the travel stop 35 on the second part lever 34. One end of the return spring 37 is coupled with the second part lever 34 of the control lever 32. The other end is supported on a protrusion 39 of the governor housing 12. Both part levers 33 and 34 are mediately held in their illustrated normal positions by a thermostat 41, formed as a spiral, wound, bimetallic spring, when the engine is cold, that is, below a predetermined operating temperature. In this position, the first part lever 33 is held against the stop 35 of the second part lever 34. The bimetallic, thermostatic spring 41 is assembled with the control lever 32 and is thereby a part of the same. One end 41a of the bimetallic spring 41 is attached to a stationary support 42, which consists of a forked protrusion of a support plate 43 (see also FIG. 2). The support plate 43 is adjustable over a limited range to set the tension force Pv of the bimetallic spring 41, and is mounted on a post 44 of a receptacle 45, which is formed as a lever-shaped sheet extending from the second part lever 34 of the control lever 32, and includes both the post 44 and a positioning screw 46 for the support plate 43. While one end 41a of the bimetallic spring 41 is held by the stationary support 42, the other end 41b is secured so as to resist rotation on the perforated four-sided carrier 47 supported on the post 44. A pressure lever 48 is connected to the four-sided carrier 47 and arranged to resist rotation. The pressure lever 48 is formed as a disc in the area near the carrier 47, in order to provide an additional side guide for the bimetallic spring 41. When the engine is cold the lever arm 48a, which is integral with the disc-shaped part, presses with a tension force Pv1 of the bimetallic spring 41 against a resistive support surface 49 on the first lever arm 33a of the first part lever 33 and presses the first part lever 33 against the travel stop 35 with such force that when the regulating member 18 which acts on the lever arm 33b of the first part lever 33 while overcoming the force of the return force Pr of the return spring 37, will also cause both part levers 33 and 34 as well as the control lever 32 to perform a rotating motion around the axis of the lever pivot 28. During this rotating motion, a stop member 52 which is rotatably supported on a supporting piece 54 in the governor housing 12 is swung clockwise out of the way of a counter stop 55 mediately connected to the regulating rod 24 by a pin 53 which engages a guide slit 51 of the stop member 52, and which is located on the extreme end of the second indexing arm 34. The counter stop 55 in the present embodiment is carried by the side bar 23 and determines, in the position shown, the maximum load position (V) of the regulating rod 24 by its position of engagement with the stop dog 56, affixed to stop member 52. Consequently, in this maximum load position the injection pump 10 supplies the quantity of fuel that is required therefor. This maximum load position V can be adjusted by turning an adjusting screw 57 that contacts the supporting piece 54, and when the dog 56 of the stop member 52 is swung out of the way of the counter stop 55, the regulating rod 24 can be pushed into the position shown as (S) to supply an increased starting volume of fuel. When the engine is warm, that is above a predetermined temperature, the tensional force Pv of the bimetallic spring 41 lowers to a value Pv2, which is smaller than the reduced return force Pr of the return spring 37 that acts on the resistive support 49. Thus, when the engine is not operating and when the first part lever 33 which influences the lever arm 33b that is associated with the first part lever 33, the first part lever 33 performs a rotational motion while the pressure lever 48 is deflected. The second part lever 34 of the control lever 32 is held firmly against the raised portion 36 of the governor housing 12 by the return force Pr of the return spring 37, so that the control lever 32 does not perform a rotational motion, and so that the stop member 52 remains in its maximum load position V blocking the regulating rod 24, as shown. In this manner when the engine is warm the governor will be in its maximum load position V, thereby blocking the maximum supply quantity despite the influence of the regulating member 18 on the control lever 32.
The regulating member 18 contains a deflecting spring 59 and a pressure bolt 58 that cooperates with the second lever arm 33b of the first part lever 33, so that the regulating member 18 also serves as a force accumulator, protects the governor's inner parts against overloads, and forms the necessary deflecting member when the governor is used as a variable speed governor.
In the further exemplary embodiments of this invention according to FIGS. 3 through 5, the elements that correspond to the elements of the first exemplary embodiment of this invention are given the same reference numerals, while those that are functionally similar but include differently formed elements are given the same reference numerals, but are provided with further appropriate indicia.
The second exemplary embodiment of this invention according to FIG. 3 has in contrast to the starting device 31 of the first exemplary embodiment, a differently constructed starting device 31', which, however, operates similarly to the increasing or decreasing starting position S of the regulating rod 24. In this construction, control lever 32' rotatably mounted with a first part lever 33' on the lever pivot 28 in the governor housing 12, lies against the raised portion 36 of the governor housing 12, as shown in the drawing, and carries with it a second part lever 34' that is supported on a pivotal joint 61. When the engine is cold, the part lever 34' is held in its normal position against a first travel stop 35' by a spiral, wound bimetallic spring 41' that serves as the thermostat. In this position the regulating member 18 activates the control lever 32', whose pin 53' can rotate the stop member 52' out of the way of the counter stop 55. This occurs while overcoming the return force of a spring 62, which serves as a holding means for the stop member 52', as well as the return force of the return spring 37' that is mounted between the governor housing 12 and the first part lever 33' at the level of the regulating member 18.
The bimetallic spring 41' is connected on one end 41a' with a pivotal point 63 of the first part lever 33' and the other end, 41b', whose position is dependent on the temperature, is inserted in a slit 64 of the second part lever 34'. When the engine is warm, i.e., above a predetermined operating temperature, the bimetallic spring 41' moves the second part lever 34' into a position in which the pin 53' takes the position shown by the broken line and the second part lever 34' comes to rest against a second travel stop 65 that is connected with the first part lever 33'.
The spring 62, which serves as a holding means for the stop 52', is attached on one end to a correspondingly formed holding piece 54' and on the other terminal end is secured in the stop member 52'. The return force of the spring means 62 thereby holds the stop member 52', which has a stop dog 66, against a corresponding resistive support 67 on the holding piece 54', as shown, until a clockwise rotational motion of the control lever 32', caused by the regulating member 18, rotates the stop member 52' also clockwise, against the force of the spring 62.
In the partially dotted line position of the second part lever 34', the pin 53' does not arrive at a position of the control lever 32' because of the lost motion coupling with the stop member 52', so that the stop member 52' remains in the dotted line position blocking the maximum load position V of the regulating rod 24 even when the engine is not operating and when the regulating member 18 is acting on the control lever 32'.
In the third exemplary embodiment of this invention according to FIG. 4 the counter stop 55 of the regulating rod 24 is held by the stop member 52, as in the example in FIG. 3, in a position so as to block the maximum load setting V, when the flyweight regulator 14 and the regulating member 18 are in their corresponding positions. This continues as long as the control lever 32" of a starting device 31" remains in the position as shown and abuts the raised portion 36 of the governor housing 12. The control lever 32" is a known, one-piece, double-armed lever which is coupled by its pin 53" in the guide slit 51 of the stop member 52.
When the engine is warm, that is, above a predetermined operating temperature, a contact rod 71 associated with a thermostat 41", which is formed of an extensible material, presses against a dependent extremity or lever arm 32a" that is carried by the control lever 32", and which cooperates with the regulating member 18. The control lever 32" is thus blocked in the position shown and the contact rod 71 serves thereby also as a holding means for the stop member 52.
When the engine is cold the contact rod 71 remains in a shortened position shown by the dotted line and is no longer in contact with the lever arm 32a". In this operational condition a return spring 37" holds the control lever 32" in the position shown until, when the engine is cold or the rpm's are below the lowest idling rpm, the regulating member 18 has moved far enough to the left to allow it to act upon the lever arm 32a" and to rotate the control lever 32" clockwise against the force of the return spring 37". In this manner the stop member 52 is rotated out of the way of the counter stop 55 so that the regulating rod 24 can arrive in the starting position S, which is possible in the shown maximum load setting of the adjusting lever 29.
In order to prevent tampering with the thermostat 41", it is conceivable to locate it inside the governor housing 12, which is modified to receive the same, or it could be replaced by a bimetallic spring, which is supported on one end on the governor housing and on the other end on the control lever 32" (not shown).
In the following the method of operation of the governor according to the invention is described on the basis of the exemplary embodiments in FIGS. 1 through 4 with special attention given the first example described in FIGS. 1 and 2, whereby especially the method of operation of the starting device 31 will be explained.
In FIGS. 1 and 2 the adjusting lever 29 is in its maximum load setting and the flyweights 15 of the centrifugal flyweight regulator 14 are in a position which they take at an rpm above the idling rpm. In this position of the flyweights, the pressure bolt 58 of the regulating member 18 does not contact the control lever 32, and the control lever 32 remains in its original position in which it holds the stop 52 in the position limiting the travel of the counter stop 55. If the engine is shut off, and the drive shaft 13 comes to a stop, then the flyweights 15 move in a known manner in towards the axis of the drive shaft 13. The regulating member 18 is thus pushed to the left--as seen from the view in FIG. 1--over the angle lever 17 and the pressure bolt 58 presses on the lever arm 33b of the first part lever 33 and rotates it clockwise while the play take-up spring 38 is compressed.
When the engine is cold and the tension Pv1 of the bimetallic spring 41 is accordingly higher as compared to the return force Pr of the return spring 37 the pressure lever 48 is pressed against the resisting support 49 on the first part lever 33 so hard, that the part lever 33 is firmly pressed against the travel stop 35 on the second part lever 34, thus both part levers 33 and 34 are joined so as to practically be a united control lever 32, and this control lever 32 is rotated clockwise by the regulating member 18. The control lever 32 takes the stop 52 with it by means of the bolt 53, then rotates the stop clockwise, and the stop dog 56 of the stop 52 is taken out of contact with the counter stop 55 of the regulating rod 24. Because the pin 26 of the steering lever 27, which serves as the point of rotation for the intermediate lever 22, remains in the position shown, while the support pin 21 has moved to the left, the intermediate lever 22 also moves clockwise, moving the regulating rod 24 by means of the side bar 23, in the direction of greater fuel supply quantity into the starting position S. If the engine is running fast, the flyweights move accordingly out away from the axis of the drive shaft 13, and the regulating member 18 is pulled to the right. The intermediate lever 22 thus rotates counter-clockwise and pulls the regulating rod 24 back in the direction of smaller supply quantity. In this process, the control lever 32 also moves counter-clockwise, the pressure bolt 58 of the regulating member 18 is released from its position against the control lever 32 and the lever arm 33b of the first part lever 33 moves back into the position shown. The second part lever 34 follows the first part lever 33, because of the described rigid coupling, and the stop 52 moves back into the position shown. When the regulating rod 24 next moves in the direction of greater injection quantity (+), the counter stop 55 can only move as far as the shown maximum load setting, limited by the stop 52.
If the same starting procedure occurs when the engine is warm, then the tension force Pv2, as already described above, of the bimetallic spring 41 is decreased so much, that when the first part lever 33 is rotated clockwise by the control movement from the regulating member 18, the pressure lever 48 moves away, while the second part lever 34 remains against the raised portion 36 of the governor housing 12 because of the correspondingly greater return force Pr of the return spring 37. In this manner the stop 52 also remains in the position shown, blocking the maximum load setting V and the engine receives no starting quantity greater than the maximum operational quantity. By this means, the bothersome smoke cloud that appears when a warm engine is started, is avoided.
In the second exemplary embodiment of this invention, according to FIG. 3, when the engine is warm, the changed position of the pin 53' prevents the feed of an increased starting quantity of fuel.
In the third exemplary embodiment of this invention, according to FIG. 4, the feed of an increased starting quantity of fuel is prevented by the contact rod 71 of the thermostat 41", which acts on the lever arm 32a" of the control lever 32", because both the control lever 32" and the stop 52, which is firmly coupled with the control lever 32", remain in their shown positions, blocking the maximum load setting. In this manner the pressure bolt 58 can only be moved by the flyweights 15 until it abuts the lever arm 32a', which brings no material disadvantages.
If the contact rod 71 is in its position shown as a broken line, then when the engine is not operational the control lever 32" can be rotated counter-clockwise, rotating the stop 52 by means of the pin 53", and moving the stop 52 out of the way of the counter stop 55, so that the regulating rod 24 can reach the starting position S.
The foregoing relates to preferred exemplary embodiments of the invention, it being understood that other embodiments and variants thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims.
|
An rpm governor for diesel engines, with which an increased starting quantity of fuel, controlled by the rpm, is released automatically when the engine is started, but which is only released during a start when the engine is cold, and which is limited to the operational maximum when the engine is warm. The governor includes a starting device with a control lever which can be moved by the regulating member of the governor, which lever is connected to a stop which either limits the quantity to the operational maximum of releases the increased starting quantity, and to a thermostat, which causes the stop to be held in its position limiting the quantity to the operational maximum despite the control lever being activated by the regulating member.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of co-pending Chilean Patent Application No. CL 3295-2014, filed 2 Dec. 2014, which is hereby incorporated herein.
TECHNICAL FIELD
[0002] The invention is related to the field of components for earthmoving equipment, specifically a large rolled and folded lip for excavator bucket, and to a method for manufacturing it.
DESCRIPTION OF THE PRIOR ART
[0003] Today's bucket lips for rope shovel machines and front excavators or special backhoes, for capacities above 25 m 3 , are manufactured cast, resulting in that said lips' material typically has a hardness of about 240 HB and low weldability that makes repairs difficult, factors affecting the durability and ease of repair tasks.
[0004] In the state of the art, there are patent documents related to lips for backhoes; we can mention, for example, document CA2319619A1, showing a lip whose ends are curved, the lip has two rolled steel plates and an additional plate welded to said lip, there is mention of a method to obtain a folded curved lip like the one proposed by the invention.
[0005] Another application related to lips for backhoes is US2005241195, which also discloses a lip with curved edges, there is also no mention of a method to obtain a rolled lip by folding.
[0006] Finally, we can mention the Chilean application 3127-2011, which discloses a rolled lip; in this case, the lip is straight so the folding process is not used.
SUMMARY OF THE INVENTION
[0007] The invention consists of a rolled lip that has a higher weldability and is more resistant because it is made of rolled stainless steel and is used for excavator buckets, the lip obtained is of high hardness and improved weldability, it is folded and used in buckets with capacities above 25 m3., said lip is made of rolled steel plates of up to 3,000 mm wide and 12,000 mm long and up to 250 mm thick and wherein said steel has flow characteristics between 600 and 900 MPa, the lip's holes and noses are drilled using roughing, machining, drilling, grinding and oxy-cutting tools. The width, height and shape of the noses are provided by templates or gauges.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows a rolled steel plate with folding lines which has not been folded.
[0009] FIG. 2 a shows the folding to curve the plate which is unfolded.
[0010] FIG. 2 b shows the folding to curve the plate after a first folding.
[0011] FIG. 2 c shows the folding to curve the plate after a second folding.
[0012] FIG. 3 shows a plate that is folded and ready for the drilling step.
[0013] FIG. 4 shows a die.
[0014] FIG. 5 a shows a first template to provide the width and shape of the nose.
[0015] FIG. 5 b shows a second template to give the thickness and shape of the nose.
[0016] FIG. 6 a shows how the first template is used to provide the width and shape of the nose.
[0017] FIG. 6 b shows how the second template is used to provide the thickness and shape of the nose.
[0018] FIG. 7 shows a schematic view of the finally shaped plate, obtaining the folded lip with its noses and other holes.
[0019] FIG. 8 shows a type of lip that may be obtained with this invention.
[0020] FIG. 9 shows another type of lip that may be obtained with this invention.
[0021] FIG. 10 shows another type of lip that may be obtained with this invention.
[0022] FIG. 11 shows an example of wear-resistant steel plates installed on the lip.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The proposed invention discloses a method to obtain a large rolled and folded lip, that is, a lip for buckets, rope shovels and front excavators or backhoes over 25 m3. The lip in question is obtained from a rolled steel plate ( 1 ) of a predetermined thickness with the approximate width and height dimensions of the lip to be obtained. The proposed invention may use rolled steel plates ( 1 ) up to 3,000 mm wide and 12,000 mm long with thicknesses up to 250 mm and a flow stress of 600-900 MPa and weighing between 7-14 tons. To obtain a finished lip, some steps must be followed: first, folding lines ( 2 ) are marked on both sides of the plate ( 1 ) as shown in FIG. 1 , these lines ( 2 ) are used to apply a folding pressure on them by a punch ( 13 ) and a die ( 4 ) located on a press. To best illustrate, FIGS. 2 a , 2 b and 2 c show the steps of folding a rolled steel plate ( 1 ) at one end. FIG. 2 a shows the first folding where the pressure of the punch ( 13 ) is applied on one of the lines ( 2 ) on the plate in which no folding has yet been made, for this, the plate is supported below by the two edges ( 5 ) of the die ( 4 ) which are separated by a distance A which depends on the design and dimensions of the die ( 4 ) for each lip to be folded, by applying a pressure of the punch ( 13 ) until a certain predetermined depth, the plate is curved in the section where it was between the two edges ( 5 ) of the die ( 4 ), as shown in FIG. 2 b , then the plate ( 1 ) moves to the left of the figure, as shown in the same FIG. 2 b , until placing the punch on a new folding line and the edges ( 5 ) of the die ( 4 ) on another location, having placed the punch on this second folding line, pressure is applied resulting in a new folding, as shown in FIG. 2 c . For the purposes of illustration, in this case, only two foldings of this process are shown, a process which is carried out at all steps as necessary to achieve the desired curvature.
[0024] Depending on the dimensions and material of the plate ( 1 ) the number of lines ( 2 ) may vary, and consequently the number of foldings necessary to achieve the desired curvature, which can be at the ends, as shown in FIG. 2 c , or on the entire plate, having different folding radii along the plate. It is also necessary to consider that, according to these dimensions and material of the lip, other factors may vary too, such as the depth of folding with the punch and especially the dimensions of the die, in its length (L), width (W) and height (H), depending on the case, it is estimated that the weight of the die is 2-3 times the weight of the lip. Once one side of the plate ( 1 ) has been finished, where the curvature has been achieved by necessary folding, the plate ( 1 ) is rotated 180° and the folding process is started using the folding lines of the other end of the plate ( 1 ) to finally achieve a curved plate at its ends ( 3 ), as shown in FIG. 3 .
[0025] Once the process of folding the plate ( 1 ) is finished, this is placed as shown in the same FIG. 3 , so as to be able to drill, on one if its edges, the noses ( 6 ) where the lip's adapters and/or teeth, as may be the case, will be subsequently located, also in this step, holes ( 8 ) may be made on the plate, in case of being necessary for final use. The process of drilling and perforating the plate is carried out using tools such as roughing, machining, drilling, grinding and oxy-cutting tools.
[0026] In a first step, oxy-cutting is applied to obtain a recessed edge ( 7 ) projecting toward the edges of the plate ( 1 ) and between the noses ( 6 ), a profile is thus obtained where an approximate shape of the noses ( 6 ) and the recessed edge ( 7 ) is achieved, finally, a final shape of the lip's flow edge is obtained by the drilling process.
[0027] The drilling process is basically a process of machining and/or processing with manual tools where, besides the roughing, machining, drilling, grinding and oxy-cutting tools, templates ( 9 , 11 ) are used, as shown in FIGS. 5 a and 5 b , which serve as gauges for shaping the nose ( 6 ) with respect to its width, height and thickness, and making the holes ( 8 ).
[0028] As shown in FIG. 5 a , there is a first template or gauge ( 9 ) for drilling, which is used to provide the width, height and shape of the nose, placing the first template or gauge ( 9 ) in said nose, as shown in FIG. 6 a , FIG. 6 a also shows a nose that has not been drilled and machined ( 15 ), and a nose that is in the process of being drilled and machined ( 16 ), in this case, work is made using manual tools, placing said that template or gauge ( 9 ) on the nose until the cavity ( 10 ) of the template or gauge ( 9 ) fits the shape of the nose ( 6 ). Once a nose ( 6 ) is finished, the process continues to work on the next nose ( 6 ) until it fits again the shape of the cavity of the template or gauge ( 9 ); the process is repeated until finishing all noses ( 6 ) required by the design.
[0029] As shown in FIG. 5 b , there is a second template or gauge ( 11 ) used to provide the shape and thickness of the nose ( 6 ), in this case, work is also made using manual tools, placing the second template or gauge ( 11 ) on the tooth until the cavity ( 12 ) of the template or gauge ( 11 ) fits the shape of the nose ( 6 ). Once a nose is finished, the process continues to work on the next nose ( 6 ) until it fits the shape of the cavity of the template or gauge ( 11 ); the process is repeated until finishing all noses ( 6 ) required by the design. Noses may be different from each other, in which case there is more than one set of templates.
[0030] Then, all the necessary holes ( 8 ) are made on the plate, providing adequate finish, also using the roughing, machining, drilling, welding or grinding tools.
[0031] Finally, a wear-resistant hardened steel layer is installed, which can extend the life of the component. This steel layer on standard cast lips is part of the base material, thus, with the same or a lower weight and with the same thickness of the steel, the lip obtains a surface more resistant to abrasion than cast.
[0032] FIG. 8 shows a type of lip in which curving of the plate ( 1 ) is possible, in this case, drilling of the noses ( 6 ) is also carried out, as described above, and once the process of folding and drilling is finished, the side edges ( 14 ) are welded to the plate ( 1 ).
[0033] FIGS. 9 and 10 show other types of lips that may be made by means of the method described.
[0034] FIG. 11 shows a lip with the hardened steel layer installed.
|
A rolled lip for rope shovel machine buckets and for excavator buckets of high hardness and improved weldability is provided. The rolled lip is folded and used in buckets with capacities above 25 m 3 . The lip is made of rolled steel plates of up to 3,000 mm wide and 12,000 mm long and up to 250 mm thick, wherein the steel has flow characteristics between 600 and 900 MPa. The noses and holes used to build the lip are drilled and the shape of the noses is provided by templates or gauges. A method for manufacturing such a rolled lip is also provided.
| 4
|
CROSS-REFRENCES TO RELATED APPLICATIONS
This application claims under 35 U.S.C. §119(a) the benefit of Taiwanese Application No. 101136641, filed Oct. 4, 2012, the entire contents of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method for hydroxylation of phenol and, more particularly, to a method for catalyzing the hydroxylation of phenol by using solid catalyst containing cobalt.
2. Description of Related Art
In accordance with the variable properties of resorcinol, hydroquinone and pyrocatechol, they are important chemical products which can be applied in various industries, such as electronics, medicine, and chemistry. They are employed in organic synthesis industry such as developer, polymerization inhibitor, skin whitening agent, antioxidant, germicidal agent, rubber additive, electroplating additive, light stabilizer, dye, spice reductant, special ink and the like.
In general, hydroquinone and pyrocatechol are prepared by hydroxylation of phenol using hydrogen peroxide as oxidant with the addition of catalyst to enhance the progression of hydroxylation. At present, zeolite is used as catalyst for the hydroxylation of phenol and it provides the advantage of easily separating catalyst and product after the reaction. The more commonly utilized zeolites are TS-1, ZSM-5, β and Y-type molecular sieve, in which the commercially available TS-1 type molecular sieve has better effects.
U.S. Pat. No. 4,396,783 discloses a titanium-silicon solid catalyst added with a modified metal for use in the hydroxylation of phenol. However, the patent actually used iron, chromium or vanadium to carry out the modification and the yield of diphenol prepared by the hydroxylation of phenol is 8.58% and the highest ratio of hydroquinone and pyrocatechol (H/P) is 0.6.
U.S. Pat. No. 5,399,336 discloses the synthesis of a silicon catalyst (S-1) containing stannum and zirconium, and further discloses performing the hydroxylation of phenol with hydrogen peroxide (70 wt %). The yield of diphenol is 27.5% using S-1 catalyst containing stannum. The yield of diphenol is 28% using S-1 catalyst containing zirconium. Both of these not only have the safety concerns, but also fail to significantly increase the yield of diphenol.
UK Patent No. 2116974 discloses a TS-1 solid catalyst having MFI structure as catalyst for the hydroxylation of phenol. The obtained H/P ratio is 1, and the selectivity of hydrogen peroxide is 73.9%. Likewise, European Patent No. 0266825 discloses a TS-1 solid catalyst containing gallium for carrying out the hydroxylation of phenol. The solid catalysis rate of hydrogen peroxide is 74.7%, and the H/P ratio is 0.79.
From the above, the application of solid catalyst in the conventional techniques for the hydroxylation of phenol still has low H/P ratio of diphenol product and low selectivity of hydrogen peroxide. Besides, the conventional techniques do not employ the solid catalyst containing cobalt in the hydroxylation of phenol.
Therefore, the development of a solid catalyst to increase H/P ratio of the products, selectivity of diphenol, and selectivity of hydrogen peroxide has become an urgent issue to be solved.
SUMMARY OF THE INVENTION
The present invention provides a method for hydroxylation of phenol, comprising the step of performing a reaction of phenol and hydrogen peroxide to form diphenol in the presence of a solvent and a solid catalyst with zeolite framework, wherein the solid catalyst comprises silicon oxide, titanium oxide and cobalt oxide. In one embodiment, the solid catalyst used in the method of the present invention has MEI zeolite framework.
In one preferred embodiment, the solid catalyst used in the method of the present invention is obtained from the hydrothermal reaction of titanium source, silicon source and cobalt source, wherein, the molar ratio of titanium from the titanium source to silicon from the silicon source is 0.01 to 0.05. The molar ratio of cobalt from the cobalt source to the silicon from the silicon source is 0.00001 to 0.002.
In the method of the present invention, the reaction is performed at a temperature in a range from 20 to 100° C., preferably from 30 to 80° C., and more preferably from 50 to 70° C. In the method of the present invention, the molar ratio of hydrogen peroxide to phenol is from 0.2 to 1, preferably 0.25 to 0.8, and more preferably 0.33 to 0.6.
In the method of the present invention, the amount of the solid catalyst ranges from 0.5 to 10 wt %, preferably from 1 to 8 wt %, and more preferably from 1.5 to 6.5 wt/%, based on the total weight of phenol and hydrogen peroxide. The solvent may be, but not limited to, alcohol, ketone, nitrile, organic acid or water.
In the present invention, the method for preparing diphenol has high utilization rate of hydrogen peroxide, high conversion rate of phenol, increased product H/P ratio, and increased selectivity of diphenol, and it is suitable for industrial mass production.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an X-ray pattern of the solid catalyst of according to the first embodiment of the present invention; and
FIG. 2 shows an X-ray pattern of the solid catalyst according to the fifth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following specific embodiments are used for illustrating the present invention. A person skilled in the art can easily conceive the advantages and effects of the present invention based on the contents disclosed in this specification. The present invention can also be implemented or applied by different specific embodiments, the details of the specification can also be applied based on different perspectives and applications in various modifications and changes without departing from the spirit of the disclosure.
In one preferable example, the solid catalyst of the present invention is prepared by the following preparation, in which silicon source, titanium source and a template reagent are evenly mixed to form a mixed colloidal at 5° C.; and a compound containing cobalt is added to the mixed colloidal for obtaining mixed colloidal containing cobalt. The mixed colloidal containing cobalt is treated hydrothermally. The mixed colloidal containing cobalt treated hydrothermally is sintered to obtain the solid catalyst of the present invention. In the preparation of the solid catalyst of the present invention, the molar ratio of titanium to silicon from the silicon source and the titanium source is 0.01 to 0.05. The molar ratio of cobalt to silicon from the compound containing cobalt and the silicon source is 0.00001 to 0.002. Further, the molar ratio of titanium to silicon and the molar ratio of cobalt to silicon of the solid catalyst can be controlled as 0.01 to 0.05 and as 0.00001 to 0.002 respectively.
In addition, in the preparation of the solid catalyst of the present invention, after forming the mixed colloidal containing cobalt, water or colloidal silica is mixed into the mixed colloidal containing cobalt. Then, the colloidal mixture mixed with water or colloidal silica is subjected to a hydrothermal step.
The silicon source used in the preparation of the solid catalyst of the present invention can be, but not limited to, a silicate ester or a compound represented by formula (I), wherein n is an integer of 1 to 5.
In one embodiment, the used silicon source can be, but not limited to, tetramethyl silicate, tetraethyl silicate, tetrapropyl silicate, tetrabutyl silicate or the combinations thereof. The silicon source may be polyethoxysilane, such as ES-28 (n=1-2), ES-32 (n=3-4) and ES-40 (n=4-5) (Colcoat Corporation).
The titanium source used in the preparation of the solid catalyst of the present invention may be, but not limited to, tetraalkyl titanate. Preferably, the titanium source used in the present invention may be, but not limited to, tetraethyl titanate, tetra-n-propyl titanate, tetra-isopropyl titanate, tetra-n-butyl titanate or the combinations thereof.
The template reagent used in the preparation of the solid catalyst of the present invention may be, but not limited to, tetra-n-propyl ammonium hydroxide, tetra-n-butyl ammonium hydroxide, tetra-n-propyl ammonium bromide, aqueous or alcohol solution of tetra-n-butyl ammonium bromide, wherein the alcohol solution includes an alcohol having 1 to 5 carbon atoms, such as one or more solvent(s) selected from the group consisting of methanol, ethanol, isopropanol, n-butanol and tert-butanol.
The compound containing cobalt used in the preparation of the solid catalyst of the present invention may be, but not limited to, alkoxide, halide or acetate of cobalt. For example, the alkoxide of cobalt may be, but not limited to, methoxyethoxy cobalt; the halide salt of cobalt may be, but not limited to, cobalt chloride, cobalt bromide or its combinations thereof; the cobalt acetate may be, but not limited to, cobalt nitrate, cobalt carbonate, cobalt acetate, acetopyruvate cobalt or a combination thereof.
The following specific embodiments are used for illustrating the present invention. A person skilled in the art can easily understand the other advantages and effects of the present invention by contents disclosed in the present specification. The below embodiments are used to illustrate the present invention. The examples illustrated below should not be taken as a limit to the scope of the invention.
EXAMPLES
Comparative Example 1
The conventional titanium-silicon solid catalyst is prepared as comparative example 1.
A 250 mL round-bottom flask was sealed with nitrogen under vacuum, and tetraethyl silicate (30.00 g), tetra-n-propyl ammonium hydroxide (56.00 g, 20 wt %) and tetra-n-butyl titanate (1.46 g) were added in the round-bottom flask at 5° C. The mixture was stirred for 1 hour. 44 g of water was added dropwise to the mixture and stirred for 1 hour, followed by stirring for another 1 hour at room temperature. Alcohol was removed at 80° C. for 2 hours. 10.80 g of AS-40 colloidal silica solution was dispersed in 73 g of water to provide a dispersion. The dispersion was then added to the round-bottom flask, and stirred for 1 hour. The alcohol-removed colloidal mixture containing the dispersion was sealed in stainless steel autoclave with Teflon-lining and then treated by a hydrothermal step at 180° C. for 120 hours. After separating the solid from the liquid, the solid was rinsed with water to neutral, then dried at 100° C. and sintered at 550° C. for 8 hours to obtain the catalyst (TS-1A).
Comparative Example 2
The conventional titanium-silicon solid catalyst is prepared as comparative example 2.
A 250 mL round-bottom flask was sealed with nitrogen under vacuum, and tetraethyl silicate (30.00 g), tetra-n-propyl ammonium hydroxide (56.00 g, 20 wt %) and tetra-n-butyl titanate (1.90 g) were added in the round-bottom flask at 5° C., and stirred for 1 hour. 44 g of water was added dropwise to the mixture and stirred for 1 hour, followed by stifling for another 1 hour at room temperature. Alcohol was removed from the mixture at 80° C. for 2 hours. 10.80 g of AS-40 colloidal silica solution was dispersed in 73 g of water to provide a dispersion. The dispersion was then added to the round-bottom flask, and stirred for 1 hour. The alcohol-removed colloidal mixture containing the dispersion was sealed in stainless steel autoclave with Teflon-lining, and then treated by a hydrothermal step at 180° C. for 120 hours. After separating the solid from the liquid, the solid was rinsed with water to neutral, then dried at 100° C. and sintered at 550° C. for 8 hours to obtain the catalyst (TS-1B).
Preparation of Solid Catalyst of the Present Invention
Embodiment 1
A 250 mL round-bottom flask was sealed with nitrogen under vacuum, and tetraethyl silicate (30.00 g), tetra-n-propyl ammonium hydroxide (56.00 g, 20 wt %) and tetra-n-butyl titanate (1.46 g) were added in the round-bottom flask at 5° C. and stirred for 1 hour. 0.0626 g of hydrated cobalt nitrate was dissolved in 44.00 g of water to form a cobalt source solution. The cobalt source solution was added dropwise to the round-bottom flask, and stirred for 1 hour, followed by stirring for another 1 hour at room temperature. Alcohol was removed at 80° C. for 2 hours. 10.80 g of AS-40 colloidal silica solution was dispersed in 73 g of water to provide a dispersion. The dispersion was then added to the round-bottom flask, and stirred for 1 hour. The alcohol-removed colloidal mixture containing the dispersion was sealed in stainless steel autoclave with Teflon-lining and then treated by a hydrothermal step at 180° C. for 120 hours. After separating the solid from the liquid, the solid was rinsed with water to neutral, then dried at 100° C. and sintered at 550° C. for 8 hours to obtain the solid catalyst of the present invention (catalyst A), in which the molar ratio of titanium to silicon in the solid catalyst is 0.02, and the molar ratio of cobalt to silicon in the solid catalyst is 0.001.
Embodiment 2
A 250 mL round-bottom flask was sealed with nitrogen under vacuum, and tetraethyl silicate (30.00 g), tetra-n-propyl ammonium hydroxide (56.00 g, 20 wt %) and tetra-n-butyl titanate (1.46 g) were added in the round-bottom flask at 5° C. and stirred for 1 hour. 0.0313 g of hydrated cobalt nitrate was dissolved in 44.00 g of water to provide a cobalt source solution. The cobalt source solution was added dropwise to the round-bottom flask, and stirred for 1 hour, followed by stifling for another 1 hour at room temperature. Alcohol was removed from the mixture at 80° C. for 2 hours. 10.80 g of AS-40 colloidal silica solution was dispersed in 73 g of water to provide a dispersion. The dispersion was then added to the round-bottom flask, and stirred for 1 hour. The alcohol-removed colloidal mixture containing the dispersion was sealed in stainless steel autoclave with Teflon-lining and then treated by a hydrothermal step at 180° C. for 120 hours. After separating the solid from the liquid, the solid was rinsed with water to neutral, then dried at 100° C. and sintered at 550° C. for 8 hours to obtain the solid catalyst of the present invention (catalyst B), in which the molar ratio of titanium to silicon in the solid catalyst is 0.02, and the molar ratio of cobalt to silicon in the solid catalyst is 0.0005. The X-ray pattern of the catalyst B is shown in FIG. 1 . In comparison with Power Diffraction File (PDF) database, the catalyst B has the MFI structure.
Embodiment 3
A 250 mL round-bottom flask was sealed with nitrogen under vacuum, and tetraethyl silicate (30.00 g), tetra-n-propyl ammonium hydroxide (56.00 g, 20 wt %) and tetra-n-butyl titanate (1.46 g) were added in the round-bottom flask at 5° C. and stirred for 1 hour. 0.0063 g of hydrated cobalt nitrate was dissolved in 44.00 g of water to provide a cobalt source solution. The cobalt source solution was added dropwise to the round-bottom flask, and stirred for 1 hour, followed by stifling for another 1 hour at room temperature. Alcohol was removed from the mixture at 80° C. for 2 hours. 10.80 g of AS-40 colloidal silica solution was dispersed in 73 g of water to provide a dispersion. The dispersion was then added to the round-bottom flask, and stirred for 1 hour. The alcohol-removed colloidal mixture containing the dispersion was sealed in stainless steel autoclave with Teflon-lining and then treated by a hydrothermal step at 180° C. for 120 hours. After separating the solid from the liquid, the solid was rinsed with water to neutral, then dried at 100° C. and sintered at 550° C. for 8 hours to obtain the solid catalyst of the present invention (catalyst C), in which the molar ratio of titanium to silicon in the solid catalyst is 0.02, and the molar ratio of cobalt to silicon in the solid catalyst is 0.0001.
Embodiment 4
A 250 mL round-bottom flask was sealed with nitrogen under vacuum, and tetraethyl silicate (30.00 g), tetra-n-propyl ammonium hydroxide (56.00 g, 20 wt %) and tetra-n-butyl titanate (1.90 g) were added in the round-bottom flask at 5° C. and stirred for 1 hour. 0.0626 g of hydrated cobalt nitrate was dissolved in 44.00 g of water to provide a cobalt source solution. The cobalt source solution was added dropwise to the round-bottom flask, and stirred for 1 hour, followed by stifling for another 1 hour at room temperature. Alcohol was removed at 80° C. for 2 hours. 10.80 g of AS-40 colloidal silica solution was dispersed in 73 g of water to provide a dispersion. The dispersion was then added to the round-bottom flask, and stirred for 1 hour. The alcohol-removed colloidal mixture containing the dispersion was sealed in stainless steel autoclave with Teflon-lining and then treated by a hydrothermal step at 180° C. for 120 hours. After separating the solid from the liquid, the solid was rinsed with water to neutral, then dried at 100° C. and sintered at 550° C. for 8 hours to obtain the solid catalyst of the present invention (catalyst D), in which the molar ratio of titanium to silicon in the solid catalyst is 0.026, and the molar ratio of cobalt to silicon in the solid catalyst is 0.001.
Embodiment 5
A 250 mL round-bottom flask was sealed with nitrogen under vacuum, and tetraethyl silicate (30.00 g), tetra-n-propyl ammonium hydroxide (56.00 g, 20 wt %) and tetra-n-butyl titanate (1.90 g) were added in the round-bottom flask at 5° C. and stirred for 1 hour. 0.0313 g of hydrated cobalt nitrate was dissolved in 44.00 g of water to provide a cobalt source solution. The cobalt source solution was added dropwise to the round-bottom flask, and stirred for 1 hour, followed by stifling for another 1 hour at room temperature. Alcohol was removed from the mixture at 80° C. for 2 hours. 10.80 g of AS-40 colloidal silica solution was dispersed in 73 g of water to provide a dispersion. The dispersion was then added to the round-bottom flask, with and stirred for 1 hour. The alcohol-removed colloidal mixture containing the dispersion was sealed in stainless steel autoclave with Teflon-lining and then treated by a hydrothermal step at 180° C. for 120 hours. After separating the solid from the liquid, the solid was rinsed with water to neutral, then dried at 100° C. and sintered at 550° C. for 8 hours to obtain the solid catalyst of the present invention (catalyst E), in which the molar ratio of titanium to silicon in the solid catalyst is 0.026, and the molar ratio of cobalt to silicon in the solid catalyst is 0.0005. The X-ray pattern of the catalyst E is shown in FIG. 2 . In comparison with Power Diffraction File (PDF) database, the catalyst E has the MFI structure.
Embodiment 6
A 250 mL round-bottom flask was sealed with nitrogen under vacuum, and tetraethyl silicate (30.00 g), tetra-n-propyl ammonium hydroxide (56.00 g, 20 wt %) and tetra-n-butyl titanate (1.90 g) were added in the round-bottom flask at 5° C. and stirred for 1 hour. 0.0063 g of hydrated cobalt nitrate was added in 44.00 g of water to provide a cobalt source solution. The cobalt source solution was added dropwise to the round-bottom flask, and stirred for 1 hour, followed by stifling for another 1 hour at room temperature. Alcohol was removed from the mixture at 80° C. for 2 hours. 10.80 g of AS-40 colloidal silica solution was dispersed in 73 g of water to provide a dispersion. The dispersion was then added to the round-bottom flask, and stirred for 1 hour. The alcohol-removed colloidal mixture containing the dispersion was sealed in stainless steel autoclave with Teflon-lining and then treated by a hydrothermal step at 180° C. for 120 hours. After separating the solid from the liquid, the solid was rinsed with water to neutral, then dried at 100° C. and sintered at 550° C. for 8 hours to obtain the solid catalyst of the present invention (catalyst F), in which the molar ratio of titanium to silicon in the solid catalyst is 0.026, and the molar ratio of cobalt to silicon in the solid catalyst is 0.0001.
Embodiment 7: Hydroxylation of Phenol
The solid catalysts prepared in Comparative example 1 and Embodiments 1-6 were used to carry out the hydroxylation of phenol in the following procedure.
Phenol (0.178 mole), pure water (1.066 mol) and the catalyst (1.844 g) were added in a 250 mL three-necked bottle under nitrogen and the temperature was raised to 60° C. 35% Hydrogen peroxide (0.089 mole) was introduced in the mixture by pump for 3 hours, followed by standing the reaction for 3 hours. When the temperature was dropped to room temperature, the reaction liquid and the catalyst were separated, and the reaction liquid was analyzed by gas chromatography. The results are shown in Table 1.
TABLE 1 Solid catalyst X ph S diph S BQ X H2O2 S H2O2 H/P ratio TS-1 A 43.47 86.62 0.13 100.00 75.51 2.1 catalyst A 41.09 92.27 3.04 100.00 75.61 3.0 catalyst B 44.79 87.83 4.96 100.00 78.32 2.5 catalyst C 43.31 95.94 2.16 99.95 82.79 2.2 catalyst D 46.99 88.72 8.93 100.00 83.04 2.9 catalyst E 48.28 95.77 3.39 100.00 92.13 2.4 catalyst F 43.31 90.49 7.66 99.97 78.32 2.7 X ph = conversion rate of phenol = moles of consumed phenol/moles of introduced phenol × 100%; S diph = selectivity of diphenol = (moles of generated hydroquinone + moles of generated pyrocatechol)/moles of consumed phenol × 100%; S BQ = selectivity of benzoquinone = moles of generated benzoquinone/moles of consumed phenol × 100% X H2O2 = conversion rate of hydrogen peroxide = moles of consumed hydrogen peroxide/moles of introduced hydrogen peroxide × 100% S H2O2 = selectivity of hydrogen peroxide = moles of generated diphenol/moles of consumed hydrogen peroxide × 100% H/P ratio = hydroquinone/pyrocatechol ratio = moles of generated hydroquinone/moles of generated pyrocatechol
Embodiment 8: Hydroxylation of Phenol
The solid catalysts (with the same molar ratio of titanium to silicon) prepared in Comparative example 2 and Embodiment 5 were used to carry out the hydroxylation of phenol at different temperatures in the following procedure.
Phenol (0.178 mole), pure water (1.066 mol) and the catalyst (1.844 g) were added in a 250 mL three-necked bottle under nitrogen and at 55° C., 65° C. and 70° C., respectively. 35% hydrogen peroxide (0.089 mole) were introduced in the mixture by pump for 3 hours, followed by standing the reaction for 3 hours. When the temperature was dropped to room temperature, the reaction liquid and the catalyst were separated, and the reaction liquid was analyzed by gas chromatography. The results are shown in Table 2.
TABLE 2
solid
reaction
H/P
catalyst
temperature
X ph
S diph
S BQ
X H2O2
S H2O2
ratio
TS-1B
55° C.
36.24
81.18
13.37
100.00
59.08
2.5
TS-1B
65° C.
40.48
91.95
5.77
100.00
74.35
2.1
TS-1B
70° C.
41.73
90.63
4.50
99.95
75.43
2.0
catalyst E
55° C.
37.83
87.67
7.69
100.00
66.12
3.4
catalyst E
65° C.
47.23
93.84
2.13
100.00
88.52
2.7
catalyst E
70° C.
42.81
92.99
3.47
98.66
80.33
2.0
As shown in the above embodiments, the solid catalyst of the present invention used in the hydroxylation of phenol attains high conversion rate of phenol without the use of high concentration hydrogen peroxide, and further enhances the selectivity of diphenol and H/P ratio of the product. The solid catalyst containing cobalt of the present invention not only reduces the safety concerns of using high concentration hydrogen peroxide, but also has a wider range of active temperature and enhances production efficiency.
The above embodiments are only used to illustrate the principles and effects of the present invention, and should not be construed as to limit the present invention. The above embodiments can be modified and altered by those skilled in the art, without departing from the spirit and scope of the present invention. Therefore, the protection scope of the present invention is defined in the following appended claims.
|
A method for hydroxylation of phenol is disclosed. The method includes the step of performing a reaction of phenol and hydrogen peroxide to form diphenol in the presence of solid catalyst with zeolite framework, wherein the solid catalyst includes silicon oxide, titanium oxide and cobalt oxide. The solid catalyst used in the preparation of diphenol of the present invention has high conversion rate of diphenol, selectivity of diphenol and higher utilization rate of hydrogen peroxide without using high concentration of hydrogen peroxide.
| 2
|
BACKGROUND OF THE INVENTION
The invention relates to the indication of the level of a liquid in a container by the use of a total-reflection refractive optical device, whose properties of transmitting a light ray are modified when the surface of reflection is wetted by the liquid.
The detection of one or more fixed levels using one or more fixed prisms or cones combined with fibre optics, is known, in particular according to French Pat. No. 2,213,487. Such a device provides information only at the instant when a given level is reached but gives no exact indication of the level in other circumstances.
A device with an optical prism integrated with the light transmitter and receiver and which allows remote operation by means of electrical wires rather than fibre optics, is also known, from British Pat. No. 888,941. However, here again the prisms are always in a fixed position, with the same drawbacks as above.
Also a level indicator device which, in one particular form, makes use of prisms which are able to move vertically by means of a screw, but in which the light transmitter and receiver are always fixed with remote transmission of the light, is also known, in particular according to French Pat. No. 1,593,760. The optical, electronic and mechanical assembly is then complex and delicate.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a level indicator device by optical means of the above type, but which is accurate, reliable and simple, both in design and fitting, and which furthermore will satisfy the safety conditions imposed for petroleum products or the like.
Thus according to the present invention there is provided a liquid level indicator comprising a totally internally reflecting optical sensor having a light emitter and receiver, means for moving the optical sensor upwardly and downwardly relative to the liquid level so as to allow the optical sensor to be totally or partially immersed in the liquid, the optical sensor communicating with means for indicating the liquid level, and means for indicating the maximum liquid level.
The invention also includes a method for measuring the liquid level in a container by menas of a liquid level indicator as herein above described in which (a) in a setting phase, the rotation of the stepping motor is controlled in the direction of ascent until the logic state corresponding to the arrival of the sensor at the high level is detected, the motor then being stopped and a high level value determined experimentally and contained in a memory is transferred to a reversible counter; (b) in a utilisation phase, operating in successive measuring cycles, during each of which the rotation of the stepping motor is controlled in the direction of descent at a slow speed until the logic state corresponding to the commencement of immersion of the optical sensor is detected, the contents of the reversible counter are then transferred into a display memory representing the measurement sought, then the stepping motor rotation is controlled in the direction of re-ascent at a rapid speed and for a given number of steps so that the otpical sensor reaches a certain distance above the liquid level, after which the motor is stopped until the next cycle; and (c) in a filling phase, the rotation of the stepping motor is controlled in the direction of high-speed re-ascent each time the logic state corresponding to a commencement of immersion of the sensor is detected, and at least until the logic state corresponding to immersion is detected, the reversible counter in all cases being incremented and decremented synchronously with the steps of ascent and descent respectively of the motor.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example only and with reference to FIGS. 1 to 4 of the accompanying drawings.
FIG. 1 shows a view in elevation of the mechanical diagram of the level indicator;
FIG. 2 shows a detailed view of the operation of the sensor and counterweight;
FIG. 3 shows the electronic circuitry of the detector; and
FIG. 4 shows the electronic circuitry of the remotely located receiver.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As can be seen from FIGS. 1 and 2, the apparatus comprises an optical sensor having a cone 2 of refractive material oriented with its apex downwards, and the horizontal upper face 3 or which comprises, side by side, an electroluminescent diode (DE) and a photoresistance (PR). When the cone is partially immersed in a liquid, the total internal reflections lose their intensity and the resistance of the photoresistance (PR) abruptly increases, the change of resistance being detected remotely.
The optical sensor is mounted on a mobile support 4 suspended on the end of a cable 5 of non-extensible material, for example a cable 0.6 mm in diameter in stainless steel. The upper part of this cable 5 is wound round a drum 6 which has a helical groove to enable good winding of the cable and has a fixing point 7 for the corresponding end of the cable. This drum is mounted on bearings (not shown) and driven via a coupling 8 from a stepping motor 9. The diameter of the drum 6 and the number of pulses per revolution of the motor 9 are chosen so as to have the desired accuracy (fraction of an mm).
A cable or wire 10 with several conductors is attached to the lower end of the support 4 by a cable clamp 11, the surplus strand 12 of this wire being electrically connected to the sensor 1, whilst the lower strand passes into a mobile-groove pulley 13, which is integral with a counterweight 14. The wire passes vertically upwards as far as the drum, where it is mechanically fixed to resist the tension of the weight and electrically connected to a detector 15.
The wire 10 and the weight 14 thus give the necessary tension for the cable 5 to provide good winding on the drum 6, and also the electrical connection of the elements of the mobile sensor with the fixed part, whilst avoiding any inadvertent formation of loops in the cable.
The device also comprises a magnetic sensor or pick up 16 co-operating with a small magnet 17 to detect the arrival at the top position or maximum liquid level of the sensor 1 and its support 4. In the example shown, the sensor 16 comprises a magnetic reed relay located in a fixed position and connected by a wire 18 to the detector 15, whereas the magnet 17 is fixed on the support 4 or the cable 5 above the support 4. The electrical connection is shown in FIG. 3. In this case, the wire 10 comprises three conductors corresponding to wires a, b and c respectively in FIG. 3. But it is also possible to integrate the whole of the top part of the detector 15 with the sensor 1, so as just to have two connecting wires, shown by wires d and e in FIG. 3, and even likewise to integrate the magnetic sensor 16 with this sensor 1, so as still only to have two connecting wires, corresponding to terminals A and B on FIG. 3. In this latter case, that is to say if it is the magnetic sensor 16 which is mobile, it is the magnet 17 which is located in a fixed place, and the upper end of the wire 10 is then connected directly to the terminal box 19.
The stepping motor 9 is of a comparatively powerful type and gives several hundred pulses per revolution. It is enclosed in an explosion-proof casing 20, shown diagrammatically in FIG. 1, with an explosion-proof outlet 21 for the shaft 22 driving the drum 6, and a connection terminal box with stuffing box 23 for the linking cable 24 which is of the simple or explosion-proof hermetic type. The rest of the device may be located in an ordinary casing 25 with a non-hermetric terminal box 19.
The detector 15, whether located in the casing 25 or the sensor 1, comprises the minimum of electronics to facilitate fitting and maintenance in places which may be cramped and difficult of access. The detector 15 comprises several circuits in parallel between its terminals A and B; a resistance R1 in series with DE, a resistance R2 in series with PR, a resistance R4 in series with a Darlington assembly T1, T2, and R3, controlled by the voltage at b, and finally the magnetic detector 16. The detector 15 is connected by a double line (not shown) to the receiver of the level indicator proper located remotely, and the resistances R1 to R4 are determined so that, bearing in mind the resistance of this line and the receiver located at the other end, the following values occur in the line, depending on the cases:
When the detector 1 is immersed and is not in the high position, PR is at its maximum value, the transistors T1 and T2 are blocked and 16 is open. This is the minimum current case, and R1 is determined so that this minimum current is 5 mA. For example, R1 has a value of 1500 ohms for a 12-volt supply.
When the detector 1 is not immersed and is not in the top position, PR is illuminated and assumes its minimum value. Transistors T1 and T2 thus become conductors, and to the previous current there is added the current passing via R4 and T2. The resistances R2, R3 and R4 are determined so that under these conditions the current is 15 mA. For example, R2=100,000 Ohms, R3=1,800 Ohms and R4=240 Ohms.
Finally, when the optical sensor 1 is in the top position, whether immersed or not, the magnetic sensor 16 is closed and one has a current of 25 mA in the line.
In this way, with only two junction wires, the three states necessary for the determination of the level can be measured. For this purpose, at the other end of the junction line, a receiver 26 is located whose input terminals A' and B' are connected by this line to the terminals A and B of the detector 15.
This receiver 26 comprises firstly an assembly of resistances in series R5, R6, R7, R8 and R9 and Zener diodes in parallel Z1, Z2 and Z3, with in addition a fuse F to provide an inherent safety barrier.
Next, this receiver 26 comprises a detector with two thresholds and three states consisting of an integrated circuit 27 which detects thresholds receiving at an input B8 the measuring signal determined by a measuring resistance R10 of a precise value, and receiving at another input B7 a low reference voltage defined by a potentiometric connection with two resistances R11 and R12, and at a third input B6 a high reference voltage determined by another potentiometric connectio n ith two resistances R13, R14.
The resistances R11 and R14 are determined for example so that the low reference voltage at B7 is 6 volts and the high reference voltage at B6 is 9 volts, and the resistance R10 is determined so that for the three currents indicated above of 5, 15 and 25 mA respectively, the voltage at B8 is 10.5 volts; 7.5 volts and 4.5 volts respectively.
In this way the two outputs B2 and B14 assume respectively logic states which provide information on which of the three cases envisaged is present:
States 1 and 0 correspond to the first case, sensor immersed,
States 1 and 1 correspond to the second case, sensor not immersed, and
States 0 and 1 correspond to the third case, sensor at high level.
These two logic outputs are then picked up by a microprocessing device which increases and decreases a digital reversible counter by increments or decrements of one unit respectively for each pulse of the motor 9 in the direction of ascent and descent, and which applies the following measuring procedure.
In a regulating phase, which of necessity occurs when the device is initialised, (but which may be repeated each time it appears necessary [re-timing]) the stepping motor is controlled in the direction of the ascent until the third logic state is detected, that is to say the high level corresponding to the closure of the magnetic sensor 16. This closure then has two effects, one being a safety effect preventing any further rotation of the stepping motor 9 in the direction of ascent, and the other the initialisation of the digital reversible counter of the level indicator to a value determined experimentally and stored in the memory.
In a second phase of utilisation of the tank, the liquid level of which is therefore stable or going down slowly, one operates by successive measuring cycles regularly spaced out in time, and for each cycle the stepping motor 9 is controlled in the direction of descent and at slow speed, at the rate of one pulse per second, as long as one is in the second logic state, that is to say with the sensor 1 not immersed. For each pulse of the motor 9, one unit is naturally counted down in the counter of the level indicator. When the logic state corresponding to the immersed sensor is detected, the rotation of the motor 9 is stopped, the contents of the digital counter are noted in a read-out memory, then the rotation of the motor 9 is brought about in the direction of ascent and at rapid speed, of about 1 cm/second, for a given number of pulses corresponding to a re-ascent of the sensor 1 sufficient for it still to be in the period of rest above the liquid level.
Still in this second phase of utilisation, the content of the reversible counter is continually compared with a low-level memory initially loaded in order to trigger an alarm if the level drops below the value of this low level.
Finally, in a third phase of filling of the tank, the rotation of the motor 9 is actuated continuously, no longer by successive cycles but throughout the entire duration of the filling, in the direction of ascent at rapid speed (1 cm/second) each time the immersed state of the sensor 1 has been detected. The sensor 1 therefore speeds upwards constantly avoiding contact with the liquid and if necessary triggers a loud alarm when the logid state corresponding to the high level is reached.
Naturally, the processing device connected to the outputs B2 and B14 and making up the level indicator proper may be associated with several detection devices corresponding to several tanks by carrying out a sequential scan of these tanks and alternating the measuring cycles. Furthermore, this processing device may comrpise all the desired peripherals for exploiting these data, including display, alarm, data processing, for example for the correction calculations, or again a printer to print out the results or a remote link-up by modem.
The installation assembly, especially the assembly proper to each tank, is relatively simple, compact and easy to install, the two casing 20 and 25 being combined at the upper end of a damping tube 28 which contains the mobile assembly and which is connected hermetically to the top of the tank by a passage of reduced diameter. Furthermore, the measurement is accurate, reliable and particularly well adapted to data processing, whilst having good safety characteristics.
|
Liquid level indicator in a tank of the type having a total-reflection optical sensor (1). The sensor is mobile vertically, so as to be able to be immersed or partially immersed in relation to the liquid level. The optical sensor (1) has an integrated light transmitter (DE) and receiver (PR) and is suspended by a non-extensible cable (5) wound onto an upper drum (6), the drum being driven upwards or downwards by a stepping motor (9) relative to the liquid level. The sensor (1) is connected with a wire (10) through a pully (13) ballasted with a weight (14) and fastened at its upper end so as to provide both the mechanical tension of the cable (5) and the electrical connection of the mobile sensor (1). The indicator also comprises a magnetic sensor (16) co-operating with a magnet (17), one of these two units being fixed in the top position and the others being mobile with the cable (5), so as to detect the arrival of the sensor (1) at a given higher level or maximum liquid level.
| 6
|
BACKGROUND OF THE INVENTION
A number of processes and apparatus have been developed to carry out an "open-end" spinning process or a "round-about" spinning process. For example, as discussed on pages 322-327 of the book "Textile Yarns Technology, Structure, & Applications" by B. C. Goswami et al, John Wiley & Sons, New York (1977), the open-end spinning process may also be referred to by the term "break spinning" since a roving is broken at one point into individual fibers and the fibers transferred to another point for reassembly into a thread or yarn. In a round-about spinning, a continuous core thread or filament is fed along the line of thread formation with the individual fibers being reassembled therearound as a sheath or outer layer.
A typical method of open-end spinning is disclosed in Malliand Textilberichte 1975, Vol. 9, pages 690 ff., where a card sliver or roving of staple fibers is first separated into the individual fibers by means of a rapidly rotating roller, the fibers then being transferred to a rotating cylindrical sieve drum. Rotation of this drum introduces a moment of torsion into the collected fiber mass so that the individual fibers are assembled into a more or less compact bundle along a line of filament or thread formation on the drum with a real twist imparted to form the thread or yarn. This process presents certain disadvantages because the thread being formed tends to be very unstable in its position on the drum, resulting in uneven thread diameters and frequent thread breakage.
Another known process of this type is disclosed in the German Offenlegungsschrift No. 24 49 583 wherein the individual fibers are twisted into a thread or yarn in the nip between two rollers or sieve drums which rotate in the same direction around parallel axes. The individual fibers are fed perpendicularly to the direction in which the formed thread is drawn off from the nip. Inside of each of the drums is an air suction device, the open end of which is directed toward the nip in which the thread is formed. Air currents produced by the suction devices press the fibers against the drum walls in the region of the nip. This particular method is disadvantageous in that the air currents produced by suction oppose the desired direction of twisting the thread. Again, it is most difficult to achieve stable thread forming conditions except by using extraordinary measures.
According to the specifications of the German Offenlegungsschriften No. 26 56 787 and No. 27 39 410, the individual fibers are introduced by an air stream through a feed channel into the thread forming zone extending in the narrowest gap between rollers. Here, the feed channel is inclined toward the thread forming zone in such a way that the air stream has a vector of movement in the draw-off direction of the thread. German Offenlegungschriften No. 27 39 410 corresponds to U.S. application Ser. No. 937,798, filed Aug. 29, 1978, now U.S. Pat. No. 4,165,600.
An especially useful open-end or round-about spinning process with suitable apparatus is disclosed in our earlier U.S. application with coinventors Dammann and Schippers, Ser. No. 782,310, now U.S. Pat. No. 4,130,983. In this case, various feed arrangements are used to convey the individual fibers into the thread forming zone, i.e. into the narrowest gap formed between oppositely moving air-permeable surfaces of paired sieve belts, drums or rollers, said gap lying between parallel belts or in a plane substantially normal to the curved surfaces of the drums or rollers. The individual fibers may be fed perpendicularly to the line of rotating thread formation in said gap but are generally introduced into the gap by an air stream with a substantial component or vector of movement in the same direction as the thread draw-off.
When spinning fibers of a certain origin in the earlier described processes, a problem has existed in that a relatively large proportion of the spinning fibers tend not to be twisted into the thread or to be only incompletely twisted into the thread, thereby causing an impairment of the strength, workability, handle and appearance of the thread or yarn product. This problem is only partially avoidable by means of a very sensitive machine adjustment, the processing variables being difficult to control and never precisely reproducible.
SUMMARY OF THE INVENTION
It is an object of the present invention to avoid the problems and disadvantages found in the earlier open-end and round-about spinning processes and to improve the quality and properties of the thread or yarn produced by these processes, particularly so as to achieve a more compact and uniform thread in which unbound or partly unbound fibers are reduced to a degree which is of little or no consequence in practice. The optimum thread or yarn product produced by the process of the invention is substantially free of loose fibers or poorly bound fibers.
It is also an object of the invention to substantially completely avoid the adverse effect on thread quality caused by differences in velocity as between the feed velocity of the individual fibers to the thread forming zone and the velocity at which the thread is drawn off from said forming zone. Thus, it has been found that by feeding discrete fibers perpendicularly to the thread draw-off direction and with components in the thread suction means determiner according to the setting of the feed velocity and thread draw-off velocity, a deformation of the individual fibers takes place as they impinge on the thread during its formation. Because of this deformation, the discrete, individual fibers fail to become bound or fastened into the thread or else become only incompletely bound or fastened into the formed thread. Such disadvantageous effects can be overcome with the process and apparatus proposed by the present invention.
The objects and advantages of the invention are essentially achieved by directing the air stream feeding the discrete fibers so as to impinge upon the thread formation line at an impingement angle of less than 45° with a vector of movement of the air stream being counter to the thread draw-off direction. This particular step results in a surprisingly effective improvement in thread quality, eliminating the harmful effects caused by differences in velocity as between fiber feed velocity and thread draw-off velocity.
The improvement of the invention is generally adapted to the known process for spinning individual fibers into a thread or yarn by the open-end or round-about technique wherein discrete fibers are fed in an air stream to the narrowest gap which is formed by two air-permeable rollers or drums rotating in the same direction, the discrete fibers being pressed against the roller surfaces by means of air suction devices disposed within the rollers and being twisted together into a thread along a line of rotating thread formation in the region or zone of the narrowest gap by the oppositely moving contact of the roller surfaces. Of these known processes, especially good results are obtained by following the teaching of the Dammann et al U.S. Pat. No. 4,130,983, particularly by including that feature in which the coacting air currents of the suction devices are directed in a twist-assisting flow direction, i.e. such that vectors of movement of the roller surfaces and the vectors of movement of said suction air currents are the same as the direction of rotating thread formation. These suction air currents are preferably disposed on opposite sides of the yarn forming zone so as to provide vectors of movement together with those of the roller moving surfaces which collectively encircle the yarn being formed. In order to avoid unnecessary repetition, the disclosure of U.S. Pat. No. 4,130,983 is incorporated herein by reference as fully as if set forth in its entirety.
The improvement in apparatus according to the present invention is likewise based upon known apparatus, especially that disclosed in said U.S. Pat. No. 4,130,983, which can be described as having two rollers with air-permeable mantle surfaces arranged for rotation in the same direction and spaced from each other to provide a thread forming zone bounded by two mantle lines lying on substantially one common plane and corresponding to the respective generatrix lines of the rollers along the narrowest gap therebetween. This known apparatus further includes an air suction means in each roller to draw or suction off air currents in the area of the thread forming zone, preferably to produce suction air currents on either side of the thread forming zone in the direction of thread rotation according to said U.S. Pat. No. 4,130,983. According to the present invention, the improvement in the apparatus requires a feed channel for the individual fibers which is inclined at an angle of less than 45° with reference to the thread forming zone, i.e. as defined by said mantle lines or, more precisely, by the axis of rotation of the thread being formed between said mantle lines. The feed channel must also be arranged to direct the fiber-feeding air stream counter to the direction in which the formed thread is drawn off.
In both the process and apparatus of the invention, it has been found to be desirable to provide a feed channel and its fiber-directing air stream with an angle of impingement on the thread formation line which is as small as possible as well as being counter to the direction of thread draw-off. Especially advantageous results can be achieved if the impingement angle is less than 10°. In general, the best results are obtained with an impingement angle of not more than about 30° and preferably below about 15°.
Especially good results are also observed in the process and apparatus of the invention if the roller surfaces acting to twist the fiber mass or to form a round-about sheath are so constructed and arranged as to provide a vector of movement which imparts an axial conveying motion to the thread in its direction of draw-off. The air stream of the fiber feed channel is then also directed against or counter to this component of conveying motion.
In order to provide this conveying motion to the formed thread, it is especially useful to use rollers formed as the hyperboloids earlier described in said U.S. Patent No. 4,130,983, or with one roller being cylindrical in shape and the other roller being hyperboloid in shape, each having a generatrix arranged substantially parallel to that of the other on either side of the nip or narrowest gap bounding the thread forming zone.
Preferred hyperboloids according to the apparatus of the present invention are those which are asymmetrical in shape with a smaller cross-sectional diameter on the outlet side where the thread is drawn off than on the inlet side, e.g. such that the feed channel is directed inwardly into the thread forming zone represented by the nip or narrowest gap from said outlet side of smaller diameter. Here, the rollers as hyperboloids are best cut off on their outlet side in the region of their narrowest diameter.
It should be noted that the fiber feed channel, as seen in the running direction of thread draw-off, has a front wall and a rear wall which are not parallel to one another. The angle of impingement of the air stream feeding the individual fibers, as measured with reference to the line of thread formation or the angle of inclination of the feed channel with reference to its mouth which opens parallel to the nip or narrowest gap is to be defined in the sense of the present invention by the larger of the two angles. This angle of impingement or angle of inclination will therefore usually be measured from the rear wall since it is most desirable for the feed channel to widen out as it approaches the zone of thread formation.
In order to control the distribution and orientation of individual fibers in the air stream flowing through the feed channel, it is preferable to provide a plurality of air jets directed into the channel in the direction of fiber transfer toward the thread forming zone. It is especially desirable to provide at least one air jet in the front wall of the feed channel to provide an air stream vector counter to the thread draw-off direction and almost parallel or at a very slight angle thereto, e.g. less than 10°. Such a jet stream assists in an orientation of the entrained fibers so that they will lie more parallel to the line of thread formation as they enter the nip or narrowest gap between the rollers.
Staple fibers of any source can be used for the process of the present invention and the thread or yarn being produced can vary from very low to relatively high yarn sizes (denier). It is also possible to use mixtures of different fibers and a separate feed channel for each type of fiber to provide a combined mixing and spinning process (see U.S. Pat. No. 4,130,983).
THE DRAWINGS
FIG. 1 is a sectional view along the axis of thread formation of one preferred embodiment of the invention, including a schematic representation of suitable means of supplying a continuous core filament;
FIG. 2 is a sectional view similar to FIG. 1 but illustrating another preferred embodiment using a different set of air-permeable rollers; and
FIG. 3 is a schematic view of a preferred arrangement of suction devices within the two air-permeable rollers.
DESCRIPTION OF PREFERRED EMBODIMENTS
The individual embodiments of the invention given by way of preferred examples are quite similar in construction and arrangement so that the same or similar reference numerals are used in each of the different figures. In FIG. 1, the two rollers 1 and 2 are constructed as asymmetrical hyperboloids, each having its front end, viewed in the direction of the running thread 11, being cut off at the point of narrowest diameter of the hyperboloid. In FIG. 2, one of the rollers 18 is the same hyperboloid as in FIG. 1, while the other roller 17 is in the form of a cylinder having its axis of rotation parallel to the line of rotating thread formation. FIG. 3 may be considered together with either FIG. 1 or FIG. 2, illustrating the direction of roller movement as in two cylindrical rollers 1' and 2' and also the direction of suction air currents acting together around the rotating thread 11 as it is being formed.
Each of the rollers shown in the drawing is perforated and permeable to air, these rollers being driven at the same speed and in the same direction of rotation by suitable drive motors (not shown here but see FIGS. 4 and 4a of U.S. Pat. No. 4,130,983).
Air suction devices are arranged inside of each of the rollers as shown schematically in FIG. 3 and in greater detail in said U.S. Pat. No. 4,130,983, so that the mouths of these suction devices run parallel to the mantle lines or generatrices of the rollers which define the nip (narrowest gap) formed between the rollers. The air suction lines or conduits 3, 4 or 3',4' are connected to an air vacuum or air exhausting means to create the desired air suction currents, preferably in the manner illustrated by the arrows labeled "air" in FIG. 3.
Each suction mouth preferably lies in front of the line of thread formation, as viewed in the direction of movement of the respective roller surface in the nip region, and there may be provided an overlapping to a slight extent of the opposing suction mouths up to about ten times the thread diameter, e.g. as set forth in detail in the description of FIG. 2a of U.S. Pat. No. 4,130,983. This preferred construction and arrangement of the suction devices may be adopted for purposes of the present invention.
Into the nip or curved wedge opening between the rollers in each embodiment, the fiber feed channel 5 is positioned at its open end or mouth 15 substantially parallel to the nip or so-called narrowest gap. At the entry end of the feed channel 5, there is added or connected a housing 6 containing means to loosen and separate the initial roving or sliver 22 into the individual fibers 10. This roving 22 is introduced by means of the intake or feed roller 7 and the individual fibers separated in known manner by means of the toothed carding or loosening roller 8 for transfer of the fibers 10 as discrete linearly oriented particles or fibrous bodies. The axis of rotation of the carding roller 8 can be arranged as shown to extend transversely or perpendicularly to the line of thread formation; however, this carding roller axis may also lie in the same plane as the line of thread formation, i.e. so as to lie parallel to the fiber feed channel 5.
The individual fibers 10 are positively conveyed and oriented in the feed channel 5 by means of the air stream produced by the injectors or jet nozzles 9 so as to direct these separated fibers toward and into the nip (narrowest gap) between the two rollers. The individual fibers tend to impinge upon the roller surfaces as directed further by the air suction currents which act to press the fibers and hold them briefly along the roller surfaces on each side of the line of thread formation. The two moving surfaces of the rollers, which move in opposite directions on each side of the thread forming zone, create a twisting moment in the fiber mass which results in the formation of the twisted thread 11 or, as indicated in FIG. 1, a sheath spun around the core filament 21 drawn off from the delivery bobbin 19 by means of the paired feed rolls 20. The produced thread 11 is preferably drawn off by means of a similar set of paired conveyance or draw-off rollers 12, also indicated by FIG. 1 and by FIG. 2.
The feed channel itself consists essentially of the front wall 13 and the back or rear wall 14, as viewed in the cross-section given by FIGS. 1 and 2 and viewed in the direction of the thread draw-off, together with its mouth 15 substantially parallel to the narrowest gap between the rollers. This mouth 15 preferably extends over more than one-third of the gap length. The side walls 13 and 14 are inclined with reference to the line of thread formation and thus the corresponding mouth position at the angle α, i.e. as measured from the rear wall 13 which has the largest angle.
Although it has been known to provide an inclined feed channel to supply the individual fibers, it was surprising to discover that the open-end or round-about spinning would be remarkably improved by the simple expedient of inclining the feed channel in a direction such that the individual fibers 10 impinge upon the line of thread formation with a component or vector of movement against or counter to the draw-off direction 16 of the thread 11. Contrary to expectation, this arrangement of the feed channel results in a highly desirable linear incorporation of the discrete fibers into the spun thread such that practically every fiber is bound in or fastened within the thread over the entire fiber length. In this manner, the compactness of the produced thread or yarn is considerably improved. Furthermore, a stripping off of unbound fibers is avoided and the appearance of so-called "belly binders" formed by only partly bound fibers is also substantially avoided.
As previously noted, the side walls 13 and 14 need not be parallel to one another. The angle α is defined as the angle between the steepest side wall, in this case the rear wall 13, and the mouth 15 or the line of thread draw-off 16, this critical angle α always being less than 45°, preferably under 30°, and especially below about 10° or 15°. The smaller the chosen angle, the more favorable is the result in terms of thread quality. It will be obvious that the lower limit for this critical angle is dependent upon the geometry of the rollers and the practical mechanical construction of the feed channel and the other machine elements.
If, for any reason, it is desirable to form and draw off the thread in another direction than that illustrated here, e.g. opposite to the arrow 16, then the fiber feed channel must also be correspondingly modified to provide the essential angle of inclination.
The particular embodiment of FIG. 2 is identical in all essential details to that of FIG. 1 except that the primary spinning assembly consists of the cylindrical roller 17 on the one hand and the hyperboloid roller on the other hand. The cylindrical roller is arranged such that its generatrix forms the nip or narrowest gap with a straight line generatrix of the hyperboloid roller 18, the thread being formed by the action of both rollers moving in opposite directions on either side of the narrowest gap. Both rollers 17 and 18 are permeable to air and also contain the required suction devices on their interior as indicated by the air suction conduits 3 and 4. This combination of a cylindrical and hyperbolic roller permits a somewhat simpler execution of the wedge-like narrowing of the nip between the rollers, since there are no objectionable intersections or overlapping projections as occurs in machine construction using two hyperboloids.
It is an important advantage to provide at least one roller in the form of a hyperboloid because this combination offers a useful thread conveying function of the rollers. Thus, when using two hyperboloids or one hyperboloid and one cylinder as the rollers, they produce a vector of movement imparting an axial conveying motion to the formed thread in its desired draw-off direction. This conveying movement can also be assisted by a slight narrowing of the nip in the draw-off direction or by disc members at the outlet end of the rollers or other suitable means.
The present invention not only improves the process of open-end or round-about spinning but also leads to an essentially improved yarn or thread product characterized by its greater compactness, uniform diameter and a substantial absence of loose fibers or undesirable "belly binds" or the like. The invention is not to be restricted to the preferred embodiments described above. The invention is also advantageously used on spinning devices having two cylindrical rollers, hyperboloid rollers of different shapes or configurations, truncated conical rollers, or all such rollers combined with suction devices installed within the rollers in ways other than that described. On the other hand, the best mode of the invention is believed to reside in the particular embodiments shown, especially when adopting the essential features of the earlier Dammann et al patent, U.S. Pat. No. 4,130,983. In this most preferred form of the invention, there is an arrangement of the rollers and suction devices whereby these elements cooperate in a twist-assisting flow direction and which tend to ensure a stable thread formation in a safe and well-controlled spinning operation and to guarantee a high thread quality, especially at low thread deniers.
|
A process and apparatus for producing a thread from staple fibers by the open-end or round-about spinning methods wherein the individual fibers are transported by an air stream to the thread forming zone in the nip between two air-permeable rollers with suction applied from within the rollers, characterized by the use of a fiber-transporting air stream directed at an angle of impingement with reference to the thread forming zone of less than 45°, preferably 10° or even less, with a vector of movement of the air stream being counter to the thread draw-off direction. An improved thread or yarn product is obtained by this process, being more compact and free of loose fibers.
| 3
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to construction components for buildings and to methods of constructing and utilizing such construction components. The present invention relates more specifically to improvements and additional components for a system of extruded aluminum post construction. The basic post structure of the present invention has a tubular configuration with a substantially constant wall thickness and a number of longitudinal grooves arranged on its outer periphery. Each groove has an arcuate wall portion and an intersecting, substantially flat wall portion adapted to retain a variety of brackets, adapters and interconnecting components for mounting the posts and connecting one to another.
2. Description of the Related Art
In general, posts and support assemblies in the past for such constructed objects as privacy fences, boat docks, cyclone fencing, highway signs, storage sheds, buildings, homes, warehouses and the like have utilized various devices that are cumbersome and require frequent maintenance and replacement. It has been recognized that metallic posts and other building construction components alleviate some of the wear and deteriorating properties of wooden posts and the like. Special attachments and hardware requirements for such metallic construction elements have slowed the use of such primary posts and beam components in the applications mentioned above.
Various attempts to solve or rectify the problems associated with connecting, mounting and utilizing metallic posts and cross-beams have mostly proven unsuccessful. The most significant prior art attempts to utilize such metallic building components are exemplified by applicant's prior issued U.S. Pat. No. 4,142,343, issued Mar. 6, 1979, entitled "Post Apparatus and Methods of Constructing and Utilizing Same", and U.S. Pat. No. 4,194,338, issued Mar. 25, 1980, entitled "Construction Components, Assemblies Thereof, and Methods of Making and Using Same."
The two issued patents identified above describe the basic components for a metallic post based building system upon which the present invention improves. Since the issuance of the above referenced patents, others have attempted to base improvements on the fundamental design disclosed in the patents, but with little success.
Among the more significant efforts to improve upon the basic metallic post building system concept are the following patents. U.S. Pat. No. 5,003,741, issued Yeh on Apr. 2, 1991, entitled "Structure of Multi-Function Frame Members", utilizes an octagonal tube with an interior square cross-section. A multi-legged orthogonally structured connector is utilized to attach one octagonal tube to another.
U.S. Pat. No. 4,577,449, issued Celli on Mar. 25, 1986, entitled "Prefabricated Structural Connector for Steel Frame Building", describes a rectangular tube structure designed to fit around a standard cylindrical post and to retain a number of plates at orthogonal positions about the tube. The connector attaches to the post and is fixed in position by an arrangement of set screws.
U.S. Pat. No. 4,461,596, issued to Davidson on Jul. 24, 1984, entitled "Arrangement for Frame and the Like", describes tubular struts much in the nature of the Yeh patent identified above. Two piece connector devices are used to attach one tubular strut to another.
U.S. Pat. No. 4,583,359, issued to Staeger on Apr. 22, 1986, entitled "Profile Tubes for the Production of Readily Assembled and Dismantled Structures" describes a variety of tubular posts with star-shaped cross-sections and a clamping connector designed to attach the end of one such tube to the side of another.
The present invention is an array of structural improvements to assembly and system components and the addition of new system components that improves upon the basic structure and function of the earlier issued patents.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide an improved anodized aluminum post structure that is light-weight, rigid, easy to manufacture and versatile in its applicability to the construction of buildings, signs, posts, fences, frames and the like.
It is another object of the present invention to provide an improved array of brackets, adapters, and interconnecting components for mounting to the improved post design and for facilitating the attaching of post to post and wall sections to post frames. It is another object of the present invention to provide an extruded tubular aluminum post support member having a double-wall cross-section with each wall having a substantially constant wall thickness to form a post with improved rigidity and versatility.
It is another object of the present invention to provide an improved aluminum post support structure that is of simple construction and pleasing in appearance and which is suitable for both interior construction and exterior construction.
It is another object of the present invention to provide an aluminum post support system with brackets adapters and interconnecting components that attach to the metallic post support member without the necessity of deforming either the post or the brackets, adapters, or interconnecting components, and without the necessity of any bolts protruding into any part of the post.
Accordingly, the present invention provides an assembly of structural building components for use in conjunction with an improved anodized aluminum post having a generally cylindrical cross section and longitudinal grooves disposed therein for the receipt of the various components. The improved aluminum post has a double wall extruded construction to increase rigidity and versatility. The component assemblies include improved bracket structures insertable into the longitudinal grooves, double bracket structures, improved post connectors for joining one post to another at various angles, terminal post clamps and caps, and various utility structures adapted specifically for use in conjunction with the improved post design.
The foregoing and other objects and advantages of the present invention will become apparent from the following disclosure describing several preferred embodiments of the invention in detail and illustrated in the appended drawings. It is anticipated that minor variations in the structural features and arrangement of parts in the devices described may occur to those skilled in the art without departing from the spirit of the invention and without sacrificing any of the advantages or objects of the present invention.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 discloses a cross-sectional view of a prior art assembly of construction components.
FIG. 2 discloses a cross-sectional view of the improved longitudinal post support member of the present invention.
FIG. 3A discloses a cross-sectional view of the improved single plate bracket of the present invention.
FIG. 3B discloses a cross-sectional view of the improved double plate bracket of the present invention.
FIG. 3C discloses a side view of the improved single plate bracket of the present invention.
FIG. 4A discloses a cross-sectional view of a T-plate connector member of the present invention.
FIG. 4B discloses a perspective view of the T-plate member of the present invention.
FIG. 5A discloses a cross-sectional view of the L-shaped plate connector member of the present invention.
FIG. 5B discloses a perspective view of the L-shaped plate member of the present invention.
FIG. 6 discloses a cross-sectional view of a two-piece parallel casting clamp of the present invention.
FIG. 7 discloses a cross-sectional view of the one-piece corner casting clamp of the present invention.
FIG. 8 discloses a side view of a pivoting end cap connector of the present invention.
FIG. 9 discloses a side view of a pivoting in-line connector of the present invention.
FIG. 10 discloses a side view of a 14° pitch post connector of the present invention.
FIG. 11 discloses a side view of a peak three-post connector of the present invention.
FIG. 12 discloses a cross-sectional view of a base plate adapter of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is made first to FIG. 1 for a brief description of the prior art that forms the basis for the improved structures of the present invention.
FIG. 1 discloses in cross-section an assembly of a prior art tubular support member with two different prior art bracket members attached. FIG. 1 shows in cross-section an elongated tubular support member (10) having a major longitudinal central axis (12) and being generally cylindrical in shape with a regularly varying radius projected from central axis (12). Tubular support member (10) has an average radius based upon the distance between central axis (12) in primary peripheral wall (14).
Positioned within peripheral wall (14) at a number of radial positions are grooves (16). In this early embodiment, grooves (16) were of one of two mirror image configurations. In each case, grooves (16) incorporated side walls (18) and an arcuate wall section (20). The combination of side walls (18) and arcuate wall section (20) provided a means for gripping attachment to the tubular member (10) by the associated brackets, attachments and the like.
A first example of an attachable bracket (22) is shown in position on support member (10). The purpose of bracket (22) was to provide a flat projecting attachment surface for wall sections, plates and the like. Bracket (22) was slid onto support member (10) from one end of support member (10) by engagement of two opposing grooves (16). Once slid into position, bracket (22) was fixed in place on support member (10) by tightening bolt (24). As indicated, bracket (22) provides two projecting flat surfaces with mounting holes (26) for the attachment of plates, wall sections and the like.
Bracket (28) is a two-piece bracket comprised of mirror image sections that may be attached to support member (10), again by way of grooves (16), but without the necessity of sliding into grooves (16) from the top or bottom of tubular member (10). Bracket (28) is attached in two pieces with each piece being insertable into an opposing groove (16). Once each piece of bracket (28) is positioned, plate sections (32) may be compressed together by bolt (38), typically with a plate section (36) interspaced between, so as to draw bracket (28) together and position it on support member (10). Screw (30) and bolt (34) provide an additional means for securing bracket (28) into position on support member (10).
Reference is now made to FIG. 2 for a detailed description of the improved structural design of the tubular support member of the present invention. Support member (40), shown in FIG. 2, has a peripheral structure essentially the same as that shown in FIG. 1. A primary wall (44) extends at a generally fixed radius from a major longitudinal central axis (42). Likewise, grooves (46) are comprised of side walls (48) flat base walls (47) and arcuate walls (50) in a manner that permits attachment of brackets and the like.
Distinct from the cross-section in FIG. 1, however, is the additional interior cylindrical wall (52) that improves the rigidity and versatility of the device. Whereas use of the support member (10) shown in FIG. 1 had included the insertion of various geometrically shaped connectors and the like into the interior cross-section of the support member, it has been found that exterior connectors and attachments provide a more suitable means for assembling the components of the present invention. Therefore, in lieu of providing a mechanism for inserting connectors into the interior space of the support member, it is possible to improve the rigidity and versatility of support member (40) by adding the interior cylindrical wall (52) as shown. The result is an extruded aluminum tubular component with the same peripheral groove structure and an interior cylindrical structure suitable for conduit-type applications. In addition, smaller, generally rectangular conduit sections (54) and (56) are created by the addition of interior cylindrical wall (52).
Reference is now made to FIGS. 3A-3C for a detailed description of improved brackets suitable for attachment to the support member described in FIG. 2. FIG. 3A discloses a cross-sectional view of the improved single-plate bracket of the present invention. Unlike the two-piece bracket described above in conjunction with the prior art shown in FIG. 1, FIG. 3A shows a one-piece, single-plate bracket suitable for attachment to a pair of opposing grooves on the support member of the present invention. Single-plate bracket (60) incorporates plate section (62) and two opposing groove inserts (64). Single-plate bracket (60) requires attachment to the pair of opposing grooves (64) at one end of the tubular support member. Positioning single-plate bracket (60) on the tubular support member involves the use of a bolt positioned in bolt slot (66) and the attachment of a threaded screw through aperture (68) in a manner that is shown and described in FIG. 1.
Plate section (62) provides a flat planer surface for the attachment of a variety of wall sections, connectors, T-shaped attachments, L-shaped attachments (as described below), and a host of other types of building and sign construction components.
FIG. 3B shows a similarly constructed bracket with a double-plate design still of single piece construction. Double-plate bracket (70) is comprised of first plate section (72) and second plate section (73) separate by insert slot (75). Attachment to the grooves and the tubular support member is again made by way of groove inserts (74). Positioning on the tubular support member is again accomplished by way of bolt slot (76) and apertures (78). As with the single plate bracket shown in FIG. 3A, double-plate bracket (70) shown in FIG. 3B is capable of connecting a variety of plates, walls, signs, sections, etc., to the tubular support member.
FIG. 3C discloses what is essentially either of the brackets shown in FIGS. 3A and 3B from the side, showing the flat plate area (62) appropriate for attachment of a variety of components and the groove insert section (64). The side view of the bracket (60), shown in FIG. 3C, is representative only of the types of brackets that could be constructed with the cross-sections described in FIGS. 3A and 3B. The length of such a bracket could be any length up to the entire length of the tubular support member and could be of a width appropriate for any type of surface connection.
Reference is now made to FIGS. 4A and 4B, and FIGS. 5A and 5B for a detailed description of two types of connectors typically used in conjunction with the brackets and tubular support members described above. FIGS. 4A and 4B show a T-shaped connector appropriate for attachment to either the bracket described in FIG. 3A, or the double-plate bracket described in FIG. 3B. T-shaped member (80) comprises two single-plate sections (82) and (84) and a single double-plate section made up of arms (86) and (88). A slot (87) is defined between arms (86) and (88). Ridges (85) provide gripping surfaces for the attachment of various other building components. FIG. 4B discloses in perspective view the structure of a typical T-shaped attachment clip or connector.
The attachment of the connectors shown in FIGS. 4A and 4B to plates to the single and double-plate bracket, shown in FIGS. 3A and 3B, is made by way of insertion of plate section (62) into slot (87), or by way of the insertion of plate sections (82) or (84) into slot (75). In this manner, a variety of connections, attachments and bracket arrangements can be configured in association with the tubular support member.
In FIGS. 5A and 5B, a similarly structured L-shaped connector device (90) is shown having a single first wall (92) and a single second wall (94). Ridges (95) again provide appropriate attachment surfaces.
Reference is now made to FIGS. 6 and 7 for cross-sectional views of two casting clamps appropriate for use in association with the improved tubular support member described above. It is noted once again that the improvements in the present invention are, in some respect, direct towards use of the tubular support member by way of attachment to and clamping on the exterior peripheral surface of the support member rather than insertion into an positioning within an interior circumference of the support member. The casting clamps shown in FIGS. 6 and 7 continue this general improvement approach. FIG. 6 discloses a two-piece parallel casting clamp attachable around the outer periphery of the tubular support member shown generally as (100) in FIG. 6. The two-piece parallel casting clamp of the present invention, shown in FIG. 6, is comprised of identical clamping components (110) and (112). Clamping components (110) and (112) fit opposite each other about the cylindrical structure of the tubular support member (100) and are sized so as to be slightly smaller in circumference than tubular support member (100). This allows a gap to exist between clamping components (110) and (112) sufficient to permit their tight attachment to tubular support member (100). Casting clamp components (110) and (112) are structurally designed to provide flat attachment arms (118), (120), (122) and (124). Casting clamp components (110) and (112) would typically be used where wall section or other flat plate structures are attachable to a tubular support member (100) in, for example, a wall section of a building, or a post section for a sign. Component (110) and (112) are attached one to another by way of clamping plates (126), (128), (130) and (132). Appropriate bolts are placed through apertures (134) and (136) to draw plate (126) and (128) together and to draw plates (130) and (132) together. In this way, circumferential walls (114) and (116) are tightly adhered to the peripheral wall of tubular support member (100).
FIG. 7 discloses a corner casting clamp similar in configuration to the parallel casting clamp shown in FIGS. 6. In this case, however, corner casting clamp (140) is of single piece construction and must be slid over one end of tubular support member (100). Once positioned, corner casting clamp (140) is held in place by insertion of an appropriate bolt through apertures (158) so as to draw bolt plates (154) and (156) together, thereby drawing circumferential walls (150) and (152) tightly against the peripheral wall of tubular support member (100).
Once in place, corner casting clamp provides flat plate-like surfaces (142) and (148) to an exterior area of tubular support member (100) and plates (144) and (146) to an interior orthogonally arranged area of tubular support member (100). Here again, the structure is appropriate for presenting attachment means for corner walls on both an interior and exterior surface.
Reference is now made to FIGS. 8 and 9 for two types of pivoting connectors appropriate for use in conjunction with the tubular support member of the present invention. FIG. 8 describes a pivoting end cap connector designed to fit over one end of a tubular support member. End cap (160) is comprised of pivoting plate section (162) and end cap (164). End cap (164) is a cylindrical cup-shaped section of cast aluminum with an interior wall (166). Aperture (168) is provided as a means for securing the tubular support member within end cap section (164). Pivoting plate section (162) incorporates pivot attachment aperture (170) and positioning attachment aperture (172). This arrangement permits a 90° variation in the angle for the pivotal attachment of the end cap (160). Apertures (170) and (172) may incorporate appropriate bolts, screws or the like for attachment to any of the plates and bracket sections described above. As indicated in the preferred embodiment, pivoting end cap (160) is constructed from cast aluminum and pivot plate (162) is integrally cast with cylindrical cap section (164) in a manner well-known in the art.
FIG. 9 discloses and describes a pivoting arrangement for an in-line connector for attaching two separate tubular support members end-to-end or for supporting a tubular support member at a middle section. In-line connector (180) is comprised of pivoting plate (182) and connecting cylinder (184). Apertures (188) and (190) are positioned as appropriate for securing the tubular support members within cylindrical connector section (184). Interior wall (186) has an inside diameter appropriate for insertion of the tubular support members therein. Section (184) incorporates an angled end (192) appropriate for ease of placement of tubular support member within the section (184). As with the pivoting end cap (160), pivoting plate (182) incorporates pivot attachment point (194) and 90° aperture (196).
Reference is now made to FIGS. 10 and 11 for a description of two fixed-angle post connectors of the present invention. FIG. 10 discloses a side view of a 14° pitch post connector suitable for use in conjunction with tubular support members of the present invention. 14° pitch post connector (200) incorporates means for attaching three separate tubular support members, a first in vertical post section (202), a second in riser post section (204), and a third, if necessary in lower post section (206). Vertical post connector section (202) is defined by interior diameter walls (208) and by wall stop (222), which ensures the proper positioning of the vertical tubular support member within section (202). Aperture (220) provides an appropriate means for secure attachment of the tubular support member within the connector.
Riser section (204) and optional lower section (206) are defined by walls (212) and (210), respectively. Sections (204) and (206) are generally cylindrical in structure with an outer diameter and an inner diameter appropriate for insertion of the tubular support members therein. Apertures (216) and (218) provide appropriate attachment means for securing tubular support members within the connector. As with the above described components, lower section (206) has angled wall section (214) that facilitates the insertion of tubular support member therein. Use of connector (200) is most appropriate in, for example, the edge of a roof structure where a vertical tubular support member meets rafter support members at a typical 14° angle. Additional tubular support members may or may not be utilized in lower section (206) depending upon the positioning of connector (200).
FIG. 11 describes a three-post connector appropriate for use at a peak position in a building construction framework. Peak three-post connector (230) incorporates three cylindrical compartments or sections for receipt of three separate terminal ends of tubular support members. Vertical section (232) is defined by cylindrical walls (238) and by post-stop wall (252). Aperture (250) provides an appropriate means for secure attachment.
Riser sections (234) and (236) are mirror images of each other and are positioned appropriate for the receipt of terminal peak ends of two rafter-type tubular support members. Apertures (246) and (248) provide means for securing the tubular support members within cylindrical inner diameter walls (240) and (242) as shown.
Reference is now made to FIG. 12 for a detailed description of the improved base plate adapter of the present invention. Base plate (260) comprises a generally flat rectangular plate structure with base surfaces (264) from which rises a cylindrical support structure (270). Inner diameter (262) is appropriate for acceptance of a tubular support member within the cylindrical void (274). Base plate adapter (260) is appropriate for attachment of a tubular support member to a flat foundational surface or the like. Attachment of base plate adapter (260) to the foundation structure is made by way of apertures (268) positioned at each corner within wall sections (266). Cylindrical section (270) is cast as a single piece in conjunction with base section (264) and is provided with a supporting gradient (272).
It is anticipated that a variety of dimensions are appropriate for each of the fixtures defined in the preceding description of the preferred embodiment. Just as wood and other metal-based construction components are made available in a variety of dimensions depending upon the particular applications of concern, the improved components of the present invention are anticipated as being constructed in a number of standard dimensions. In general, the diameter of the tubular support member that forms the basis of the present invention would be sized to dimensions appropriate for constructing walls of thicknesses standard in the building industry. Thus, dimensions anywhere from one inch to twelve inches are appropriate for the diameter of the tubular support member. The various other brackets, components, and attachments described herein would thereby have dimensions defined according to the basic diameter dimension of the tubular support member.
|
An assembly of structural building components for use in conjunction with an improved anodized aluminum post having a generally cylindrical cross section and longitudinal grooves disposed in a peripheral wall therein for the receipt of the various components. The improved aluminum post has a double wall extruded construction to increase rigidity and versatility. The component assemblies include improved bracket structures insertable into the longitudinal grooves, double bracket structures, improved post connectors for joining one post to another at various angles, terminal post clamps and caps, and various utility structures adapted specifically for use in conjunction with the improved post design.
| 4
|
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/992,060 filed Nov. 18, 2004.
TECHNICAL FIELD
[0002] The present invention relates to well production and more specifically to determining wellbore parameters.
BACKGROUND
[0003] In the life of most wells the reservoir pressure decreases over time resulting in the failure of the well to produce fluids utilizing the formation pressure solely. As the formation pressure decreases, the well tends to fill up with liquids, such as oil and water, which inhibits the flow of gas into the wellbore and may prevent the production of liquids. It is common to remove this accumulation of liquid by artificial lift systems such as plunger lift, gas lift, pump lifting and surfactant lift wherein the liquid column is blown out of the well utilizing the reaction between surfactants and the liquid.
[0004] Common to these artificial lift systems is the necessity to control the production rate of the well to achieve economical production and increase profitability. It is common for the production cycle of a particular lift system to be estimated based on known well characteristics and then adjusted over time through trial and error. Prior art systems have been utilized to automate the control system such that incremental changes are automatically implemented in the production cycle until the lift system fails, and then the production cycle is readjusted to a point before failure. A need still exists for a method and system for obtaining wellbore parameters in real-time to optimize an artificial lift system in real-time.
SUMMARY
[0005] One embodiment of a system for determining a wellbore parameter includes a pulse generator positioned in fluid communication with a wellbore such that a fluid can flow from the wellbore through the pulse generator, wherein the pulse generator selectively releases the fluid to flow through the pulse generator causing pressure pulses in the wellbore; a receiver in operational connection with the wellbore, the receiver detecting the pressure pulses; and a controller in functional connection with the receiver, the controller determining a wellbore parameter from receipt of a signal from the receiver in response to the detected pressure pulses.
[0006] An embodiment of a method for determining a wellbore parameter includes the step of releasing a burst of fluid from the wellbore causing a pressure pulse in the wellbore; detecting the pressure pulse; and determining a wellbore parameter utilizing the detected pressure pulse.
[0007] The foregoing has outlined some of 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
[0008] The foregoing and other features and aspects of the present invention will be best understood with reference to the following detailed description of a specific embodiment of the invention, when read in conjunction with the accompanying drawings, wherein:
[0009] FIG. 1 is a schematic drawing of a well production optimizing system of the present invention;
[0010] FIG. 2 is a schematic drawing of a well production optimizing system utilizing plunger lift;
[0011] FIG. 3 is a partial cross-sectional view of a flow-interruption pulse generator of the present invention; and
[0012] FIG. 4 is a view of another embodiment of a flow-interruption pulse generator of the present invention.
DETAILED DESCRIPTION
[0013] Refer now to the drawings wherein depicted elements are not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views.
[0014] As used herein, the terms “up” and “down”; “upper” and “lower”; and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements of the embodiments of the invention. Commonly, these terms relate to a reference point as the surface from which drilling operations are initiated as being the top point and the total depth of the well being the lowest point.
[0015] FIG. 1 is a schematic drawing of a well production optimizing system of the present invention, generally denoted by the numeral 10 . The figure is illustrative of well under artificial lift production, which may include systems such as, but not limited to, gas lift, surfactant lift, beam pumping, and plunger lift. The well includes a wellbore 12 extending from the surface 14 of the earth to a producing formation 16 . Wellbore 12 may be lined with a casing 18 including perforations 20 proximate producing formation 16 . The surface end of casing 18 is closed at surface 14 by a wellhead generally denoted by the numeral 24 . A casing pressure transducer 26 is mounted at wellhead 24 for monitoring the pressure within casing 18 .
[0016] A tubing string 22 extends down casing 18 . Tubing 22 is supported by wellhead 24 and in fluid connection with a production “T” 28 . Production “T” 28 includes a lubricator 30 and a flow line 31 having a section 32 , also referred to as the production line, upstream of a flow-control valve 34 , and a section 36 downstream of flow-control valve 34 . Downstream section 36 , also referred to generally as the salesline, may lead to a separator, tank or directly to a salesline. Production “T” 28 typically further includes a tubing pressure transducer 38 for monitoring the pressure in tubing 22 .
[0017] Wellbore 12 is filled with fluid from formation 16 . The fluid includes liquid 46 and gas 48 . The liquid surface at the liquid gas interface is identified as 50 . With intermittent lift systems it is necessary to monitor and control the volume of liquid 46 accumulating in the well to maximize production.
[0018] Well production optimizing system 10 includes flow-control valve 34 , a flow-interruption pulse generator 40 , a receiver 42 and a controller 44 . Flow-control valve 34 is positioned within flow line 31 and may be closed to shut-in wellbore 12 , or opened to permit flow into salesline 36 .
[0019] Flow-interruption pulse generator 40 is connected in flow line 31 so as to be in fluid connection with fluid in tubing 22 . Although pulse generator 40 is shown connected within flow line 31 it should be understood that pulse generator 40 may be positioned in various locations such that it is in fluid connection with tubing 22 and the fluid in wellbore 12 .
[0020] Pulse generator 40 is adapted to interrupt or affect the fluid within the tubing 22 in a manner to cause a pressure pulse to be transmitted down tubing 22 and to be reflected back upon contact with a surface. Pulse generator 40 is described in more detail below.
[0021] Receiver 42 is positioned in functional connection with tubing 22 so as to receive the pressure pulses created by pulse generator 40 and the reflected pressure pulses. Receiver 42 recognizes pressure pulses received and converts them to electrical signals that are transmitted to controller 44 . The signal is digitized, and the digitized data is stored in controller 44 .
[0022] Controller 44 is in operational connection with pulse generator 40 , receiver 42 and flow-valve 34 . Controller 44 may also be in operational connection with casing pressure transducer 26 , tubing pressure transducer 38 and other valves (not shown). Controller 44 includes a central processing unit (CPU), such as a conventional microprocessor, and a number of other units interconnected via a system bus. The controller includes a random access memory (RAM) and a read only memory (ROM), and may include flash memory. Controller 44 may also include an VO adapter for connecting peripheral devices such as disk units and tape drives to the bus, a user interface adapter for connecting a keyboard, a mouse and/or other user interface devices such as a touch screen device to the bus, a communication adapter for connecting the data processing system to a data processing network, and a display adapter for connecting the bus to a display device which may include sound. The CPU may include other circuitry not shown herein, which will include circuitry found within a microprocessor, e.g., an execution unit, a bus interface unit, an arithmetic logic unit (ALU), etc. The CPU may also reside on a single integrated circuit (IC).
[0023] Controller 44 may be located at the well or at a remote locations such as a field or central office. Controller 44 is functionally connected to flow-control valve 34 , receiver 42 , and pulse generator 40 via hard lines and/or telemetry. Data from receiver 42 may be received, stored and evaluated by controller 44 utilizing software stored on controller 44 or accessible via a network. Controller 44 sends signals for operation of pulse generator 40 and receives information regarding receipt of the pulse from pulse generator 40 via receiver 42 for storage and use. The data received by controller 44 is utilized by controller 44 to manipulate the production cycle, during the production cycle in real-time, to optimize production. Controller 44 may also be utilized to display real-time as well as historical production cycles in various formats as desired.
[0024] An example of the operation of optimizing system 10 is described with reference to FIG. 1 to determine the liquid level in tubing 22 . Controller 44 sends a signal to pulse generator 40 to create a pressure pulse within tubing 22 . Pulse generator 40 and its operation is disclosed in detail below. The pressure pulse travels down tubing 22 and is reflected back up tubing 22 upon encountering objects or surfaces such as liquid surface 50 , plungers, collars, sub-surface formation and the like. Receiving unit 42 , which is in fluid or sonic connection with pulse generator 40 and tubing 22 receives the pulse from pressure generator 40 and the reflected pressure pulses. The pulse received is converted to an electrical signal and transmitted to controller 44 for storage and use. This data received by controller 44 may be filtered and analyzed by the controller to determine well status information such as, but not limited to, the position of liquid surface 50 , liquid volume in the well, and the change in liquid level 50 over time. Controller 44 may then utilize this information to operate flow-control valve 34 between the open and closed position as necessary.
[0025] FIG. 2 is a schematic drawing of a well production optimizing system 10 utilizing a plunger-lift system. The well includes a wellbore 12 extending from the surface 14 of the earth to a producing formation 16 . Wellbore 12 may be lined with a casing 18 including perforations 20 proximate producing formation 16 . The surface end of casing 18 is closed at surface 14 by a wellhead generally denoted by the numeral 24 . A casing pressure transducer 26 is mounted at wellhead 24 for monitoring the pressure within casing 18 .
[0026] A tubing string 22 extends down casing 18 . Tubing 22 is supported by wellhead 24 and in fluid connection with a production “T” 28 . Production “T” 28 includes a lubricator 30 and a flow line 31 having a section 32 , also referred to as the production line, upstream of a flow-control valve 34 , and a section 36 downstream of flow-control valve 34 . Downstream section 36 , also referred to as the salesline, may lead to a separator, tank or directly to a salesline. Production “T” 28 typically further includes a tubing pressure transducer 38 for monitoring the pressure in tubing 22 .
[0027] A plunger 52 is located within tubing 22 . A spring 54 is positioned at the lower end of tubing 22 to stop the downward travel of plunger 52 . Fluid enters casing 18 through perforations 20 and into tubing 22 through standing valve 56 . Lubricator 30 holds plunger 52 when it is driven upward by gas pressure. A liquid slug 58 is supported by plunger 52 and lifted to surface 14 by plunger 52 .
[0028] Well production optimizing system 10 includes flow-control valve 34 , a flow-interruption pulse generator 40 , a receiver 42 and a controller 44 . Flow-control valve 34 is positioned within flow line 31 and may be closed to shut-in wellbore 12 , or opened to permit flow into salesline 36 .
[0029] Plunger-lift systems are a low-cost, efficient method of increasing and optimizing production in wells that have marginal flow characteristics. The plunger provides a mechanical interface between the produced liquids and gas. The free-traveling plunger is lifted from the bottom of the well to the surface when the lifting gas energy below the plunger is greater than the liquid load and gas pressure above the plunger.
[0030] In a typical plunger-lift system operation, the well is shut-in by closing flow-control valve 34 for a pre-selected time period during which sufficient formation pressure is developed within casing 18 to move plunger 52 , along with fluid collected in the well, to surface 34 when flow-control valve 34 is opened. This shut-in period is often referred to as “off time.”
[0031] After passage of the selected “off-time” the production cycle is started by opening flow-control valve 34 . As plunger 52 rises in response to the downhole casing pressure, fluid slug 58 is lifted and produced into salesline 36 . In the prior art plunger-lift systems when plunger 52 reaches the lubricator its arrival is noted by arrival sensor 60 and a signal is sent to controller 44 to close flow-control valve 34 and end the cycle. It also may be desired to allow control-valve 34 to remain open for a pre-selected time to flow gas 48 . The continued flow period after arrival of plunger 52 at lubricator 30 is referred to as “after-flow.” Upon completion of a pre-selected after-flow period controller 44 sends a signal to flow-control valve 34 to close. Thereafter, plunger 52 falls through tubing 22 to spring 54 . The production cycle then begins again with an off-time, ascent stage, after-flow, and descent stage.
[0032] Optimizing system 10 of the present invention permits the production cycle of the plunger-lift system to be monitored and controlled in real-time, during each production cycle, to optimize production from the well. Controller 44 may be initially set for pre-selected off-time and after-flow. To control and optimize the well production, controller 44 intermittently operates pulse generator 40 creating a pressure pulse that travels down tubing 22 and is reflected off of liquid surface 50 and plunger 52 . The pressure pulse and reflections are received by receiver 42 and sent to controller 44 and stored as data. Controller 44 may receive further data such as casing pressure 26 , tubing pressure 38 and flow rates into salesline 36 . Additional, data such as well fluid compositions and characteristics may be maintained by controller 44 . This cumulative data is monitored and analyzed by controller 44 to determine the status of the well. This status data may include data, such as, but not limited to liquid surface 50 level, fluid volume in the well, the rate of change of the level of liquid surface 50 , the position of plunger 52 in tubing 22 , the speed of travel of plunger 52 , and the in-flow performance rate (IPR). The status data may then be utilized by controller 44 to alter the operation of the production system. This status data may also be utilized by controller 44 or an operator to determine the wear and age characteristics of plunger 22 for replacement or repair.
[0033] For example, during the off-time the well status data may indicate that the downhole pressure is sufficient to lift the accumulated liquid 46 to surface 14 before the pre-selected off-time has elapsed. Or that the liquid volume is accumulating to a degree to inhibit the operation of plunger 52 . Controller 44 may then open flow-control valve 34 to initiate production.
[0034] In another example, as plunger 52 ascends in tubing 22 , the well status data calculated and received by controller 44 may indicate that the rate of ascension is too fast and may result in damage to plunger 52 and/or lubricator 30 . Controller 44 may then signal flow-control valve 34 to close or restrict flow through valve 34 thereby slowing or stopping the ascension of plunger 52 .
[0035] In a further example, controller 44 may recognize that plunger 52 is ascending too slow, stalled or falling during the ascension stage. Controller 44 may then close flow-control valve 34 to terminate the trip, or further open flow-control valve 34 or open a tank valve to allow plunger 52 to rise to lubricator 30 .
[0036] In a still further example, during after-flow the controller 44 well status data may indicate that liquid 46 is accumulating in tubing 22 , therefore controller 44 can signal flow-control valve 44 to close and allow plunger 52 to descend to spring 54 . Then a new production cycle may be initiated.
[0037] As can be determined by the examples of operation of optimizing system 10 , an artificial lift system can be controlled in real-time in a manner not heretofore recognized. Although operation of optimizing system 10 of the present invention is disclosed with reference to a plunger-lift system in FIG. 2 , optimizing system 10 is adapted for operation in any type of artificial or intermittent lift system including gas lift and surfactant lift.
[0038] FIG. 3 is a partial cross-sectional view of a flow-interruption pulse generator 40 of the present invention. Pulse generator 40 includes a valve body 62 forming a fluid channel 64 , a cross-bore 66 intersecting channel 64 and a piston 68 . Electromagnetic solenoids 70 and 72 are connected to the first and second ends 66 a and 66 b of bore 66 respectively. Solenoids 70 and 72 are functionally connected to controller 44 ( FIGS. 1 and 2 ) for selectively venting bore 66 and motivating movement of piston 68 . Operation of solenoids 70 and 72 moves piston head 74 from the second end 66 b of bore 66 into channel 64 and then back into bore 66 .
[0039] Operation of pulse generator 40 to create a pressure pulse is described with reference to FIGS. 1 through 3 . Pulse generator 40 is connected within flowline 31 through channel 64 . Controller sends a signal to solenoid 70 to vent motivating piston 68 and moving piston head 74 into channel 64 . Controller 44 then sends a signal to solenoid 72 to vent motivating piston 68 and moving piston head 74 from channel 64 and toward second bore end 66 b . This fast acting movement of piston head 74 into flow channel 64 creates a pressure pulse that travels through the fluid in flowline 31 and tubing 22 .
[0040] FIG. 4 is a view of another embodiment of a flow-interruption pulse generator 40 of the present invention. Pulse generator 40 includes a fast acting, motor driven valve 76 in fluid connection with flowline 31 . Motor driven valve 76 is in operational connection with controller 44 . To create a pressure pulse in flowline 31 and tubing 22 , controller 44 substantially instantaneously opens and closes valve 76 releasing gas from flowline 31 . Pulse generator 40 may include a vent chamber 78 connected to fast-acting valve 76 . Vent chamber 78 may further include a bleed valve 80 to facilitate bleeding gas captured in vent chamber 78 to be discharged to the atmosphere.
[0041] From the foregoing detailed description of specific embodiments of the invention, it should be apparent that a method and apparatus for monitoring and optimizing an artificial lift system that is novel and unobvious has been disclosed. Although specific embodiments of the invention have been disclosed herein in some detail, this has been done solely for the purposes of describing various features and aspects of the invention, and is not intended to be limiting with respect to the scope of the invention. It is contemplated that various substitutions, alterations, and/or modifications, including but not limited to those implementation variations which may have been suggested herein, may be made to the disclosed embodiments without departing from the spirit and scope of the invention as defined by the appended claims which follow.
|
One embodiment of a system for determining a wellbore parameter includes a pulse generator positioned in fluid communication with a wellbore such that a fluid can flow from the wellbore through the pulse generator, wherein the pulse generator selectively releases the fluid to flow through the pulse generator causing pressure pulses in the wellbore; a receiver in operational connection with the wellbore, the receiver detecting the pressure pulses; and a controller in functional connection with the receiver, the controller determining a wellbore parameter from receipt of a signal from the receiver in response to the detected pressure pulses.
| 4
|
PRIORITY CLAIM
This application is a continuation of U.S. application Ser. No. 11/365,572 filed Mar. 1, 2006, Now U.S. Pat. No. 7,377,644 B2 which claims the benefit of U.S. Provisional Application Ser. No. 60/748,445 filed Dec. 8, 2005 and entitled THE SLIT LAMP FIXATION ALARM.
FIELD OF THE INVENTION
This invention relates generally to slit lamps for observing ocular features and, more particularly to fixation lights for slit lamps.
BACKGROUND OF THE INVENTION
The slit lamp is an instrument used in eye care that provides an illuminated and magnified view of a patient's eye. The slit lamp typically includes a light projected through a slit to allow for observation of optical cross sections of the eye using an optical portion. The light is typically mounted on an articulated arm that is adjustable for observation of different portions of the eye. During examination, the patient's face is positioned against chin and forehead rests. While one eye is being examined by the optical portion, the patient is instructed to focus the other eye on a fixation light such that the examined eye is properly oriented. A small shield secures to the slit lamp and protects the examiner from coughs and sneezes, though in prior systems the shield is much too small to be effective.
In prior systems, the fixation light is a single light mounted on an arm that is attached to the portion of the slit lamp bearing the chin and forehead rests. The examiner is required to move the fixation light from one side of the slit lamp to the other when examining both eyes. When moving the optical portion from focusing on one eye to the other, the fixation light and its mounting arm tend to cause obstruction. Furthermore, since the fixation light is constantly being moved between eyes, the mechanisms enabling articulation of its mounting arm become worn, resulting in drift of the fixation light. In prior system the fixation light is positioned close to the patient's eye such that bumping of the light or its mounting arm can cause injury to the patient. The mounting arm is typically movable to a storage position to the side of the slit lamp. However, the fixation light and its mounting arm are still an obstacle to movement of the optical portion and the examiner's hand.
Further complications during examination of a patient using a slit lamp occur as the patient's face moves. It is typical for a patient to move the forehead away from the forehead rest. As a result, the examiner must “chase” the eye. As the patient moves away the eye also moves out of the range of focus of the slit lamp. As a result, the examiner typically must frequently remind the patient to stay forward against the forehead rest.
In view of the foregoing it would be an advancement in the art to provide a slit lamp facilitating the convenient non-obstructive positioning of a fixation light. It would be a further advancement in the art to provide a convenient means for maintaining a patient's forehead against a forehead rest during examination.
SUMMARY OF THE INVENTION
A slit lamp includes a rest for receiving a portion of a patient's face, such as the patient's forehead. The slit lamp further includes an optical portion for observing the patient's eye. A fixation light is positioned near the optical portion to direct the patient's line of sight toward the optical portion. A sensor, such as a touch sensor, secures to the rest and detects proximity of the user's face to the rest. The output of the sensor controls the fixation light such that the fixation light is turned on upon detecting the positioning of the user's face at the rest. When the patient moves away from the rest, the fixation light is turned off, indicating to the patient to return to the rest. In some embodiments, the sensor is coupled to a wireless transmitter configured to transmit signals corresponding to the output of the transmitter to a receiver controlling the light.
In some embodiments a shield secures to the optical portion and first and second fixation lights secure to the shield at either side of the optical portion. First and second flanges secure to the shield and extend from the shield toward the rest. The first shade positioned proximate the first fixation light between the first fixation light and the optical device and the second shade positioned proximate the second fixation light between the second fixation light and the optical device.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings.
FIG. 1 is a perspective view of a slit lamp in accordance with an embodiment of the present invention;
FIG. 2 is a perspective view of a sensor for use in a slit lamp forehead rest in accordance with an embodiment of the present invention;
FIG. 3 is a process flow diagram of a method for using a slit lamp in accordance with an embodiment of the present invention;
FIG. 4 is a perspective view of a shield in accordance with an embodiment of the present invention;
FIG. 5 is a perspective view of a fixation light in accordance with an embodiment of the present invention; and
FIG. 6 is a top plan view of a slit lamp examining a patient's eyes in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , a slit lamp 10 includes an optical portion 12 housing optical structures such as magnification lenses. The optical portion 12 is mounted to a base 14 facilitating movement of the optical portion 12 relative to a patient to enable examination of both eyes and different portions of the eye. A chin rest 16 and forehead rest 18 secure to a frame 20 and receive the face of a patient during examination. In the preferred embodiment, a forehead sensor device 22 may mount to the forehead rest 18 to facilitate sensing the proximity of the forehead to the forehead rest. A shield 24 secures to the slit lamp 10 between the examiner and the patient. In the illustrated embodiment, the shield 24 secures near the eye pieces 26 of the optical portion 12 .
One or more fixation lights 28 a , 28 b secure to the slit lamp 10 in positions to enable the lights 28 a , 28 b to project light into one of a patient's eyes while the other eye is being examined. In the illustrated embodiment, the fixation lights 28 a , 28 b secure to the shield 24 on opposite sides of the optical portion 12 .
Referring to FIG. 2 , while still referring to FIG. 1 , the forehead sensor device 22 includes a sensor 30 used to detect proximity of the patient's forehead to the forehead rest 18 . The sensor 30 may detect proximity of the patient's forehead in a variety of ways, for example, optically, thermally, or by detecting contact of the patient's forehead with the forehead rest, e.g., via a capacitance touch sensor. The sensor 30 may include membrane switches, small mechanical switches or motion sensing switches. The sensor 30 of the forehead sensor device 22 may mount to the forehead rest 18 at the point where the forehead rest 18 secures to the frame 20 or to another portion of the slit lamp 10 . For example, the sensor 30 may detect strain in the frame 20 to determine whether the patient has pressed the forehead against the forehead rest 18 .
In the illustrated embodiment, the sensor 30 is a touch sensor secured within a laminate 32 or like structure that secures to the forehead rest 18 . The sensor 30 may produce an output in response to the touch thereon or produce an output indicating proximity of the forehead when the pressure exerted thereon exceeds a predetermined threshold. The laminate 32 may have an adhesive backing 34 adhering the laminate 32 to the forehead rest 18 . A protective layer 36 may cover the adhesive backing 34 prior to securement to the forehead rest 18 .
In certain embodiments of the invention, the output of the sensor 30 controls power to the fixation lights 28 a , 28 b such that the lights 28 a , 28 b turn on when the patient's forehead is sufficiently close to the forehead rest 18 . The sensor 30 may connect to the lights 28 a , 28 b through a wire or a wireless communication channel. In alternative embodiments, the output of the sensor 30 is used to control an audible, tactile or optical indicator or alarm that is turned on when the patient moves away from the forehead rest 18 in order to notify the patient of the need to return to the forehead rest 18 . For example, a buzzer audible to the patient or a vibrating device in contact with the patient may be used. In such embodiments, the indicator may be configured to turn off when the patient returns to the forehead rest 18 .
In still other embodiments, a sensor (not shown) is mounted on or near the chin rest 16 such that the fixation lights 28 a , 28 b are turned on only when the patient's chin is within the chin rest and the patient's forehead is against the forehead rest. In certain embodiments, separate indicators are coupled to the sensor 30 and the sensor mounted to the chin rest. For example, contact of the patient's forehead may trigger turning on of the fixation lights 28 a , 28 b whereas lack of contact of the patient's chin with the chin rest triggers and audible, tactile or optical alarm.
In the illustrated embodiment, the sensor 30 is electrically coupled to a transmitter 40 transmitting signals causing the fixation lights 28 a , 28 b to turn on or off in correspondence with proximity of the patient's forehead to the forehead rest 18 . The transmitter 40 may transmit infrared, optical, radio frequency, acoustic or like signals. The output of the sensor 30 may be conducted to the transmitter 40 by means of a wire 42 coupled thereto. The output of the sensor 30 may be processed by a sensor circuit 44 and the output of the sensor circuit 44 provided to the transmitter. The sensor circuit 44 may condition the output of the sensor 30 , interpret the output of the sensor to determine whether the fixation lights 28 a , 28 b should be turned on or off, or both condition and interpret the output. The transmitter 40 and sensor circuit 44 may mount within a housing 46 secured to the frame 20 by means of clips 48 or the like. The housing 46 may also contain a battery 50 or other power source powering the transmitter and sensor circuit 44 . In an alternative embodiment, in order to conserve power life, a microprocessor (not shown) may be used to regulate power consumption. A switch 52 may secure to the housing and be used to turn off the transmitter 40 and sensor circuit when the slit lamp 10 is not in use or when the functionality of the transmitter 40 is not needed.
FIG. 3 describes a method for using the slit lamp 10 in accordance with one embodiment of the present invention. At block 56 , a patient is instructed to look at one of the fixation light 28 a , 28 b with the eye that is not being examined and to maintain the forehead against the forehead rest 18 such that the fixation lights 28 a , 28 b remains on. At block 58 , the patient's face is positioned such that the patient's forehead is against the forehead rest 18 and the patient's chin is on the chin rest 16 . At block 60 , the proximity sensors sense the proximity of the patient's face to the forehead rest 18 . If the proximity sensors determine that the patient's face is proximate, at block 62 , the fixation lights 28 a , 28 b are illuminated. At block 64 , the proximity sensors again sense the proximity of the patient's face from the forehead rest 18 . If the proximity sensors determine that the patient's face is no proximate, at block 66 the fixation lights 28 a , 28 b are turned off.
Referring to FIG. 4 , the shield 24 may be embodied in any number of shapes such as a square or rectangular sheet and may be formed of PLEXIGLAS or like material. The shield 24 may have an aperture 68 , slot 68 , or like structure formed therein and sized to receive a portion of the optical portion 12 of the slit lamp 10 . In the illustrated embodiment, the aperture 68 is sized to secure to the optical portion 12 behind the eye pieces 26 . Fasteners 70 , such as set screws or the like, secure to the shield 24 proximate the aperture and fix the position of the shield 24 relative to the optical portion 12 . Fasteners 70 may also be embodied as VELCRO, adhesives, ring clamps, vise like attachments or the like. There are various types of slit lamps 12 having differently sized optical portions. Accordingly, the shield 24 may be formed of two or more pieces that are movable relative to one another and securable to one another in various configurations around the optical portion 12 . Alternatively, the aperture 68 may be shaped and sized to receive most optical portions 12 and have fasteners 70 sufficiently adjustable to accommodate different optical portions 12 . For example, VELCRO straps of adjustable length may be used.
Referring to FIG. 5 , while still referring to FIG. 4 , the fixation lights 28 a , 28 b may secure to the slit lamp 10 by various means including fixed or articulated arms secured to the slit lamp 10 . In the illustrated embodiment, the fixation lights 28 a , 28 b secure to the shield 24 on either side of the aperture 68 . The fixation lights 28 a , 28 b may include a light housing 72 having a light source 74 such as an LED, incandescent lamp or the like. A receiver 76 is coupled to the light source 74 and to a battery 78 . The receiver 76 receives signals from the transmitter 40 and permits electrical power from the battery 78 or other power source to reach the light source when the signals indicate that the patient has properly positioned the forehead against the forehead rest 18 . In an alternative embodiment, in order to conserve power life, a microprocessor (not shown) may be used to regulate power consumption.
A magnet 80 secured to the housing 72 and engages an opposing magnet 82 , preferably formed in a handle 84 . The handle 84 is positioned opposite the shield 24 from the housing 72 . In this embodiment, the attraction of the magnets 80 , 82 maintains the housing and handles 84 in position. The handle 84 may be gripped by the examiner to move both the handle 84 and housing 72 in order to position the light source 74 relative to the eye of the patient.
Referring to FIG. 6 , while still referring to FIG. 5 , a flange 86 extends outwardly from the housing 72 to shield the light source 74 from view from certain angles in order to avoid confusing the patient being examined. For example, the fixation light 28 b may have a flange 86 positioned between its light source 74 and the optical portion 12 whereas the fixation light 28 a has a flange 86 positioned between its light source 74 and the optical portion 12 . In use, a patient's first eye 88 a is positioned lying on the optical axis 90 of the optical portion 12 such that the eye 88 a can be observed through the slit lamp. The patient's second eye 88 b is positioned as illustrated such that light from the fixation light 28 a is visible along the direct line of sight 92 a of the second eye 88 b . However, along peripheral line of sight 94 , the fixation light 28 b is not visible due to the flange 86 thereof. The flanges 86 of both fixation lights 28 a , 28 b shield the eye 88 a being examined from the light sources 74 . When the second eye 88 b is being examined the flanges 86 likewise shield the second eye 88 b from the light sources 74 while permitting the first eye 88 a to observe the fixation light 28 b.
Various alternative means of preventing a patient from viewing the incorrect fixation light 28 a , 28 b are possible. The fixation lights 28 a , 28 b may be positioned relative to the optical portion 12 such that the body of the optical portion 12 prevents viewing. One of the fixation lights 28 a , 28 b may be switched off manually or automatically by electrical or mechanical means when it is not needed. An LED with a small viewing angle may be used to prevent off-axis viewing. In an alternative embodiment, a Fresnel lens preventing off-axis viewing may be used. The fixation lights 28 a , 28 b may have different colors or shapes such that the patient can be instructed which light 28 a , 28 b to look at with the unexamined eye.
While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.
|
A slit lamp includes a rest for receiving a patient's face such as the patient's forehead. The slit lamp further includes an optical portion for observing the patient's eye. A fixation light is positioned near the optical portion to direct the patient's view toward the optical portion. A sensor secures to the rest and detects proximity of the user's face to the rest. The output of the sensor controls the fixation light such that the fixation light is turned on upon detecting the positioning of the user's face at the rest. In one embodiment, a shield secures to the optical portion and first and second fixation lights secure to the shield at either side of the optical portion. First and second flanges secure to the shield proximate the fixation lights and such that each fixation light is only viewable when directly in front of the patient's eye.
| 0
|
BACKGROUND OF THE INVENTION
The present invention relates to a loom.
Looms comprising heald devices of shafts are known, in which for the movement of the heald devices, levers are used. The levers have pivot axes which are aligned with one another and extend at right angles to the planes spanned by the heald devices. When a greater number of heald devices is present in such looms for the weaving of patterned fabric, different heald devices are frequently displaced different distances from their rest positions in the formation of the sheds in order to attain a favorable deflection of the warp threads. In order to produce these different displacements, the levers operatively connected with the heald devices have different lengths. The levers have drive output points, where the levers are connected with the heald devices, which are in most of the levers inevitably removed relatively far from the plane of symmetry of the center plane which extends through the centre points of the heald devices parallel to the direction of motion of the heald devices and at right angles to the planes spanned by the heald devices. In a known type of loom, the levers at the drive output points engage parts which are rigidly fastened to the heald devices. In operation, turning moments arise in respect of the center points of the heald devices. These turning moments must be absorbed by heald device guides and therefore cause noise, increase the wear and limit the maximum possible weaving speed.
In another loom, the levers are connected with the heald devices through flexible tension ropes. Although it is possible in that case to deflect the tension ropes by means of rollers and to fasten the tension ropes to the heald devices in the plane of symmetry or central plane, the additionally necessary deflecting rollers cause the manufacturing costs to be increased. Moreover, tension ropes deflected over rollers tend to deflect out laterally at great speeds, whereby the maximum weaving speed is limited.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a loom in which the heald shafts are displaceable by different distances without the aforementioned disadvantages occurring.
According to the present invention there is provided a plurality of heald devices each reciprocatably displaceable along respective paths and each generally disposed in a respective one of a plurality of parallel planes. The plurality of heald devices are disposed so that a common plane extends centrally of each of the plurality of heald devices, parallel to the paths and perpendicular to each of the parallel planes. Each of a plurality of levers is pivotable about a pivot axis to cause the displacement of a respective one of the plurality of heald devices. Each of a plurality of intermediate elements is connected between a respective one of the heald devices and a respective one of the levers. The pivot axis of at least two levers is differently spaced from the respective intermediate element to provide a different displacement stroke for each which corresponds to at least two heald devices and the pivot axis of each of said levers is differently spaced from said common plane.
Thus, it is an object of the invention to provide a loom having a plurality of heald devices, each of the heald devices being generally disposed in a respective one of a plurality of parallel planes, and each of the heald devices being reciprocatably displaceable along a respective path in its respective one of the parallel planes. The plurality of heald devices is so disposed that a common plane extends centrally of each of the plurality of heald devices. The common plane is disposed parallel to the paths and perpendicular to each of the parallel planes. The loom includes a plurality of levers each pivotable about a pivot axis to cause the reciprocatory displacement of a respective one of the plurality of heald devices. The loom further includes a plurality of intermediate elements each connected between a respective one of the heald devices and a respective one of the levers. The pivot axis of each of at least two of the levers is differently spaced from the respective intermediate element connected thereto so as to provide a respectively different displacement for each heald device connected thereto. The pivot axis of each of the at least two said levers is differently spaced from the common plane.
It is a further object of the invention to provide a loom which is simple in design, rugged in construction and economical to manufacture.
For an understanding of the principles of the invention, reference is made to the following description of typical embodiments thereof as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be more particularly described by way of example and with reference to the accompanying drawings in which:
FIG. 1 shows a schematic longitudinal section through a shed-forming device and the shed formed by the device,
FIG. 2 shows a side view of the shed-forming device of in FIG. 1, wherein only the foremost and rearmost of the heald devices shown in FIG. 1 are illustrated,
FIG. 3 shows a plan view of the levers for displacing the heald devices,
FIG. 4 shows a view of an alternate embodiment of a heald device driving means, in which the levers are arranged on different sides of a cam disc shaft,
FIG. 5 shows a view of still another alternative embodiment of the heald device driving means with one-armed levers,
FIG. 6 shows a view of even still another alternate embodiment of the heald device driving means in which the cam discs are arranged on two devices extending parallely beside one another,
FIG. 7 shows a plan view of the levers of the heald device driving means illustrated in the FIG. 6, and
FIG. 8 shows a plan view of the levers of a modification of the heald device driving means, in which the levers engage at the heald device in two planes displaced from one another.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show parts of a tape loom including the shed-forming device thereof. The shed-forming device comprises several heald devices or heald shafts are arranged behind one another in the longitudinal direction of the warp threads and of which five are shown in FIG. 1 and designated by 1, 2, 3, 4 and 5. The heald device 1 is disposed foremost, i.e. nearest to a reed 11 which is pivotably mounted in a bearing 13 of the machine frame. The remaining heald devices then follow one another sequentially so that the heald device 5 is furthest from the reed 11. Each device comprises a frame 1a, 2a, 3a, 4a and 5a and vertically, extending healds 1b, 2b, 3b, 4b and 5b and with thread guide eyelets 1c, 2c, 3c, 4c and 5c.
The warp threads are, prior to their entry into the shed-forming device, guided by means of a thread guide 15 so that they lie in, plane. The warp threads then extend through the shed-forming device. In operation, a weft thread loop is introduced into the just formed shed 20 by means of a weft-introducing needle 17 during each shed change. The fabric arising at the reed abutment point 19 is then guided and spooled by means of rollers (not shown).
In the shed-forming device, each warp thread is guided through one of the thread guide eyelets 1c, 2c, 3c, 4c and 5c. In the formation of a shed 20 the warp threads are deflected in layers by the heald devices, for which the heald device 1 holds the warp thread layer 21, the head device 2 the layer 22, the heald device 3 the layer 23, the heald device 4 the layer 24 and the heald device 5 the layer 25. In the illustrated position of the heald devices, the warp thread layers 22 and 24 form the lower boundary of the shed 20. In the region of the shed 20, i.e. between the foremost heald devices 1 and the abutment point 19 of the reed 11, the lower warp thread layers 22 and 24 lie at least approximately in the same plane. Correspondingly, also the upper warp thread layers 21, 23 and 25 lie at least approximately in the same plane in the region of the shed 20. This deflection of the warp threads is attained thereby due to different displacements of different heald devices.
Vertical rods 31 are fastened to the upper frame limbs of the heald devices 1, 2, 3, 4 and 5. These are guided to be vertically displaceable above the warp threads in schematically illustrated guides 33 fastened to the frame of the loom. Furthermore, only schematically illustrated tension springs 35 are shown, which at one end are fastened to the frame part 37 and at the other end engage at the rods 31 and pull the heald devices upwardly.
A heald device driving means comprises a shaft 53, which is rotatably journalled by means of bearings 51 in the frame of the loom and which extends at right angles to the planes containing the heald devices. A cam disc 55, for each heald device, is fastened rotationally fast on shaft 53. Cams 57 can be mounted on cam disc 55 at points uniformly distributed around the disc circumference. The cams can, for example, be mounted at circumferential points which are spaced from one another by 60° or a multiple thereof. For the remainder, the cam discs and cams are all identically constructed apart from the fact that the different cam discs can be equipped with differently arranged and different number of cams. In particular, all cam discs have the same diameter and all cams the same height.
The heald device driving means furthermore comprises a lever for each heald device. The levers associated with the devices 1, 2, 3, 4 and 5 are shown in FIG. 3 and designated by 61, 62, 63, 64 and 65. The levers are pivotably mounted by pins, the pivot axes of which are designated by 71, 72, 73, 74 and 75, in bearings 81, 82, 83, 84 and 85 fastened on the frame of the loom. Mounted at one end of each lever is a feeler roller 59, which bears against the circumferential surface of the cam disc 55 associated with the lever concerned and tracks the surface.
Guide rods 41, 42, 43, 44 and 45 are each united by means of a hinge pin 47 to a respective lever 61, 62, 63, 64 and 65 at the end of the lever remote from the feeler roller 59. The other end of each of the guide rods are united, by means of hinge pins 49 with straps which are rigidly fastened to the lower frame limbs of the heald devices. As is evident from FIG. 2, the pivot axes of the hinge pins 47 and 49 connecting the guide rods with the levers and heald device, respectively, extend at right angles to the planes containing the heald devices. Furthermore, the pivot axes of the hinge pins 49 lie in the plane extending parallel to the direction of displacement of the heald device, i.e. vertically, which forms a central plane 90 common to all heald devices 1, 2, 3, 4 and 5 as well as a plane of symmetry of the shaft frames. In one or two of the lever positions resulting during the following of the cam discs 55, the guide rods 41, 42, 43, 44 and 45 extend exactly vertically so that then the pivot axes of the hinge pins 47 lie in the central plane 90. In the remaining lever positions occuring in operation, the pivot axes of the hinge pins 47 are slightly displaced from the central plane 90. During the raising and lowering of the heald devices, the hinge pins, which form the drive output points of the levers, thus move along circular arcs which have a tangent as well as chords which run parallel to the central plane 90. Lever arms 61a, 62a, 63a, 64a and 65a, to which the feeler rollers 59 are journalled, are inclined with respect to the lever arms 61b, 62b, 63b, 64b and 65b which are connected with the guide rods 41, 42, 43, 44 and 45. The levers are arranged in such a manner that the lever arms 61b, 62b, 63b, 64b and 65b extend horizontally in the case of the mean pivot positions of the levers occurring in operation, i.e. at right angles to the direction of displacement of the heald devices.
The pivot axes 71, 72, 73, 74 and 75 of the different levers 61, 62, 63, 64 and 65 are disposed at different distances from the common central plane 90 of the heald devices. The feeler rollers 59 of all levers at corresponding lever positions all have approximately the same position with respect to the cam discs. When the feeler rollers 59 have been deflected to approximately half the height of the cams 57, their geometrical axes all lie approximately in one radial plane 93, through which the geometric axis of the shaft 53 extends. The pivot axes 71, 72, 73, 74 and 75 all lie in one plane 95, which extends parallel to the geometric axis of the shaft 53 as well as at right angles to the radial plane 93. At half the deflection of the feeler rollers 59 into half the height of the cam, the axes of the feeler rollers lie at least approximately in the plane 95. The latter thus extends parallel to a tangential plane which touches the cam disc 55 at the radial plane 93. The different levers have different transmission ratios, i.e. they produce different strokes of the heald devices at equal deflections of their feeler rollers 59 forming lever drive points. When, for example, the levers 61 and 65 have been pivoted by identically constructed cams engaging at their feeler roller, the feeler rollers, of both levers are deflected an equal distance measured radially of the shaft 53. Since the lever arm 65a on the drive side of the lever 65 is shorter than the lever arm 61a on the drive side, the lever 65 is pivoted through a larger angle than the lever 61. Furthermore, the lever arm 65b on the output side is longer than the lever arm 61b on the output side. Therefore, the hinge pin 47 forming the drive output point of the drive output lever arm 65b is displaced in vertical direction through a greater travel than the hinge pin 47 forming the drive output point of the drive output lever arm 61b. The positions of the pin axes 71, 72, 73, 74 and 75 are now chosen in such a manner that the heald device strokes become so great that the warp thread layers 22 and 24 as well as also the warp thread layers 21, 23 and 25 in the region of the shed each lie in a common plane and that the axes of the hinge pins 47 each according to the instantaneous lever position lie more or less exactly in the central plane 90.
In operation of the tape loom, the shaft 53 with the cam discs 55 is rotated. Thereby, the heald devices are drawn downwardly against the force of the spring 35 each time the cam 57 of an associated cam disc pivots an associated lever. During a complete revolution of the cam discs, six shed changes and weft insertions take place. Different patterns can thus be produced by appropriate arrangement of the cams on the cam discs.
Since the geometric axes of the hings pins 49 lie in the central plane 90 and this is more or less exactly the case for the hinge pins 47 according to the instantaneous lever position, the levers 61, 62, 63, 64 and 65 or the guide rods 41, 42, 43, 44 and 45, respectively, exert substantially only vertically directed forces, which engage in the central plane 90, on the heald devices. The latter and their guides 33 therefore do not have to absorb turning or tilting moments. Therefore, great weaving speeds are possible. For example, 3000 or more shed changes and weft insertions per minute can readily take place.
Five heald devices are shown in FIG. 1. For the production of complicated patterns, however, more heald devices, for example twenty, can be provided. In that case, each of these heald devices is connected with a separate lever which follows a cam disc. In this case the pivot axis of each lever could also be displaced from that of the adjacent lever. Since in the case of a great number of heald devices they are arranged closely beside one another, for reasons of spacing, it is difficult in some circumstances for all levers to have pivot bearings displaced from one another.
With a great number of heald devices, one can however, construct some adjoining levers identically and journal them on a common hinge pin. For example, between the levers 61 and 62 it is possible to arrange four additional levers which are similar to the lever 61 and also pivotable around the same pivot axis 71. If in an analogous manner four additional levers are arranged beside each of the remaining levers 62, 63, 64 and 65, twenty levers altogether are then present, by which twenty heald devices can be raised and lowered.
The mutually adjacent, identical levers, pivotable about a common pivot axis, also provide equal transmission ratios and heald device strokes. Since the heald devices belonging to one group of identical levers are disposed closely beside one another, only relatively small deviations from the ideal position aimed at, in which all lower and all other warp threads each lie in a common plane, nevertheless arise during the deflection of the different warp thread layers in the region of the shed 20. In so far as the forces exerted on the heald devices are concerned, no turning moments are exerted on the shafts even if a few adjacent levers are pivotable around a common pivot axis, because all levers are connected with a guide rod approximately at the central plane 90.
When the heald devices are arranged closedly beside one another, the heald device driving means can be constructed as shown in FIG. 4. A shaft 153 is journalled in the machine frame and carries a cam disc 155 fixedly fastened to the shaft to rotate therewith and provided with cams 157.
Two groups of levers are present. The one lever group, of which only the lever 161 is shown, is disposed above the shaft 153 and the cam discs. The other lever group, to which the lever 162 belongs, is disposed below the shaft 153 and the cam discs. Feeler rollers 159, which track the associated cam discs, are journalled on the lever arms 161a and 162a of levers 161 and 162, respectively. The lever arm 161b and 162b are connected through a guide rod 141 and 142, respectively, with a heald device (not shown). The geometric axes of hinge pins 147, which connect the levers and guide rods with one another, again in accordance with the instantaneous lever position lie at least approximately in the vertical central plane 190 of the heald devices. The levers 161 and 162 are journalled by means of bearings 181 and 182 in the machine frame, while the pivot axes 171 and 172, about which the levers are pivotable, have different spacings from the central plane 190.
In the heald devices driving means illustrated in FIG. 4, levers or lever groups, which are connected with successive heald shafts or heald device groups, can be arranged alternately above and below the shaft 153. The pivot axes of the upper levers or lever groups as well as also the pivot axes of the lower levers or lever groups are displaced from one another. In this manner, the spacings between the levers or lever groups can be enlarged so that more space is at disposal for the journalling of the levers and the hinge connections between the levers and guide rods.
The heald device driving means shown in FIG. 5 comprises a shaft 253, journalled in the frame and carrying cam discs 255 provided with cams 257. Several levers are present, of which two are illustrated and designated by reference numerals 261 and 265. The levers each have a respective feeler roller 259 following a cam disc 255. Each lever 261 and 265 is journalled in a bearing 281 and 285, respectively, while the pivot axes 271 and 275 of the levers are disposed at different spacings from the central plane 290 of the heald devices. The levers 261 and 265 are one-armed, i.e. the guide rods connecting them with the heald device, of which the guide rod 241 is visible, are connected by means of hinge pins 247 on the same side of the pivot axes 271 and 275, on which the feeler rollers are also disposed. The axes of the hinge pins 247 again lie at least approximately on the central plane 290.
The heald device driving means shown in FIG. 6 comprises two shafts 353 journalled in the machine frame and extending parallelly beside one another in a horizontal direction. Several cam discs 355 provided with cams 357 are fastened to each of these shafts. Both the shafts 353 are arranged in mirror image symmetry on different sides of the central plane 390 of the heald device. Serving to follow the cam discs are levers, that include feeler rollers 359, two of which are illustrated in FIG. 6 and designated by 361 and 362. The levers 361 and 362 are journalled by means of bearings 381 and 382, respectively, on the frame of the loom. Illustrated in FIG. 7 in addition to the levers 361 and 362 are two other levers 363 and 364 as well as the shafts 353 of the cam discs, the cam discs themselves being omitted for simplicity. The pivot axes, about which the levers are pivotable, are designated by 371, 372, 373 and 374. The spacings of the pivot axes 371, 372, 373 and 374 from the central plane 390 increase in the sequence of the reference numbers, while successive levers are arranged alternately on different sides of the central plane. Coreespondingly, also the cam disc followed by the feeler rollers 359 of successive levers are likewise arranged alternately on the two shafts 353. Connected to the levers by means of hinge pins 347 are guide rods, of which the guide rod 341 is shown in FIG. 6. The axes of the hinge pins 347 again according to the instantaneous lever position lie more or less exactly in the vertical central plane 390, along which the heald devices are displaced.
Some adjacent levers can be identical and be pivotable about a common axis in groups in the case of the heald device driving means shown in FIGS. 6 and 7. Since the levers are distributed over two different sides of the central plane 390, they can be employed for the displacement of heald devices disposed relatively closely on one another.
Three levers 461, 462 and 463 each with a respective feeler roller 459 are shown in FIG. 8. The levers are pivotable about pivot axes 471, 472 and 473. The pivot axes 471, 472 and 473 are disposed at different spacings from the central plane 490 of the heald devices. The feeler rollers all have approximately the same spacing from the central plane so that they can follow cam discs which all sit on the same shaft. Approximately vertically extending guide rods 441, 442 and 443 are connected by means of hinge pins (not shown) to the ends of te levers remote from the feeler rollers. The axes 446 and 448 of the joints connecting the guide rods with the levers do not lie in the central plane 490, but are displaced with respect to this on different sides. Due to the axes 446 and 448 being displaced from each other, more space is available for the hinge connections. The spacings of the axes 446 and 448 from the central plane 490 are however, small by comparison with the heald device width measured in the same direction and amount at most to 10% of the heald device width. Only relatively small turning moments are therefore exerted on the heald devices in the arrangement shown in FIG. 8.
In the heald device driving means described with reference to the drawings, the pivot axes of the different levers of the lever groups are thus displaced from one another transversely to the axial direction and have different spacings from the central plane, which is common to all heald devices and runs parallel to the direct on of displacement of the heald devices. During the following of several cam discs, which are arranged on the same or at most on two different devices and are identical apart from the different cams, it thereby becomes possible to attain different transmission ratios of the levers and thereby different heald device strokes and nevertheless to arrange the drive output points of all levers, at which the latter transmit their motion to the heald devices, at least approximately in the central plane. The levers can in that case be arranged in such a manner that their drive output arms extend approximately at right angles to the named central plane. During the pivoting of the levers, their drive output points describe a circular arc which displays a tangent, and preferably also chords, which extend parallel to the direction of displacement of the heald devices as well as the central plane. It thereby becomes possible to transmit the movement of the levers to a point, lying in the named central plane, of the heald devices without turning moments worthy of mention being exerted on the heald devices.
The looms can be modified in different aspects. The number of heald devices can be varied within wide limits in accordance with the desired patterning of the woven fabric. In order that a pattern can be produced at all, several heald devices, i.e. at least three, are of course required. Since a lever is present for each heald device, the number of the levers is of course also to be determined in accordance with the patterns.
The cam pitch divisions can also be varied in the case of the cam discs. At most two, four, six or more cams can be arranged on each cam disc. Furthermore, the levers can be pivoted, instead of by cam discs, by contoured discs or other drive elements, for example, cam chains or punched cards. In all these cases, it is possible to use driving means of like kind for all levers on the driving side, thus for example cam discs or cam chains, which all have identically constructed cams and correspondingly impart approximately equal strokes to all levers.
Furthermore, also the connections between the levers and heald devices can be modified in a different manner. For example, in place of the described guide rods, one could also provide rods rigidly fastened to the heald devices. The lower ends of these rods could then for example be provided with a pin which engages into a slot extending in the longitudinal direction of the drive output lever arm and present in the latter. In this case, the cam discs and bearings of the levers can be fastened to a support which is displaceable transversely to the common central plane of the heald shafts and to the direction of the displacement of the heald devices. Through displacement of the support, the size of the shed, i.e. the opening or angle between the upper and lower warp threads at the reed abutment location 19 could be varied. Another possibility is to provide flexible tension ropes in place of the guide rods.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
|
A loom includes a plurality of reciprocatably displaceable heald devices each generally disposed in a respective one of a plurality of parallel planes, and a plurality of levers each coupled through an intermediate element to a respective one of the heald devices. The respective pivot axis of each of at least two levers is differently spaced from the respective intermediate element to cause a respectively different displacement stroke for each of the at least two heald devices connected thereto. The respective pivot axis of each of the at least two levers is differently spaced from a plane which extends centrally of each heald device, parallel to the line of displacement thereof and perpendicularly to the planes of the heald devices.
| 3
|
BRIEF SUMMARY OF THE INVENTION
This invention relates to fuel preparation processes, and particularly to a process for preparing a fuel consisting at least in part of coal which reduces the sulfur content of the combustion products and which increases the heat content per pound of fuel.
While coal is by far the most plentiful fossil fuel, its use in the electric power industry has recently become subject to objections which are difficult to overcome economically. Chief among these is the objection to sulfur dioxide in the combustion products of the coal because of its airpolluting character. The electric power industry accordingly has been required to purchase more expensive low-sulfur coal, and in some instances, plants have been forced to use products of petroleum as fuel rather than coal even though petroleum is much more expensive and less plentiful.
The principal object of this invention is to enable power plants to use coal as a fuel while satisfying strict air quality standards. In order to accomplish this object, the coal which is to be burned is passed through a cleaning apparatus in which oil is used as a cleaning medium. The sulfur content of coal is mostly in the form of iron pyrites (FeS 2 ) and gypsum (CaSO 4 2H 2 O). That part of the sulfur content which is in the form of iron pyrites is greatly reduced by cleaning with oil. Even more importantly, however, the process of cleaning with oil eliminates the entrainment of water by the coal in the cleaning process and also removes some of the water which is inherently present in the coal. The elimination of entrainment and the removal of water greatly increases the heat content of the coal per unit weight.
The coal preparation process in accordance with the invention may be used to produce a coal-oil fuel consisting of coal particles suspended in oil. The coal-oil fuel has all of the advantages of ordinary fuel oil: low sulfur content, reduction of fly ash, elimination of the need for ash removal, and ease of handling. Furthermore, the treatment of coal using oil as a cleaning medium produces a fuel having a high efficiency in terms of cost per B.T.U. of heat generated. The invention is capable of use in producing a low-sulfur coal-oil fuel which is especially suitable for producing heat for electric power generation.
BRIEF DESCRIPTION OF THE DRAWING
The single FIGURE is a schematic diagram of an apparatus for producing and burning a coal-oil fuel, the apparatus being adapted for the preparation of fuel for use in an electric generating plant.
DETAILED DESCRIPTION
The plant shown in the drawing is designed to receive a low grade of coal and oil, and to convert the coal and oil into a coal-oil fuel with hot oil being used to effect removal of pyrite, water and other unwanted products from the coal.
Coal is stored in a main storage and blending bin 2. From bin 2, the coal is delivered to a vibrating screen 4 from which small particles are passed to a second storage bin 6. The large particles which are separated out by the screen are reduced by a pair of rolls 8 and then delivered to bin 6. The coal particles in bin 6 are thus more consistent with one another in size than those in main storage bin 2.
Oil is stored in tank 10. The oil may be any grade of petroleum oil, preferably having a low sulfur content. If desired, by reason of its availability, ordinary sludge of the kind obtained in the sulfuric acid refining of lubricating oil may be used. The sludge is preferably neutralized as by the process described in U.S. Pat. No. 2,309,633 which issued on Feb. 2, 1943 to F. I. Du Pont and myself. Further, the sludge is heated to reduce its viscosity to an extent making it suitable as a cleaning medium and may have other heated petroleum products added to reduce its viscosity further.
The oil which is delivered from the storage tank passes through a heat exchanger 11 so that the oil is maintained in a hot (preferably above the boiling point of water) condition.
Coal is delivered from bin 6 through a weightometer 12 to a heater 14 which raises the temperature of the coal prior to its introduction into the concentrator in order to prevent the heat of the oil from being utilized primarily to heat the coal rather than to remove water. The weightometer controls a proportioning valve 16 which controls the flow of oil from heat exchanger 11. If necessary to prevent agglomeration of small particles, dispersing agent stored in tank 18 may be added to the oil passing out of proportioning valve 16 by means of a proportioning valve 20 designed to maintain a substantially constant percentage of dispersing agent in the oil. The oil and coal are mixed together and fed into a chip and wood remover 22 and the mixture is delivered from the chip and wood remover to a mill 24 in which the coal particles are reduced in hot oil to the desired size for the concentrator 26. The chip and wood remover may also include magnetic iron removing means. The mill may be, for example, a rod mill, a ball mill, or a cylindro-conical mill, and is desirably jacketed in order to maintain the oil at a high temperature. A water outlet is provided at 25.
The mixture is delivered from the outlet of the mill to a concentrator 26 which effects cleaning of the coal. For the purpose of this application, a concentrator is any device which utilizes a liquid medium to accomplish separation of particles in which particles having a high specific gravity settle out of the liquid under the influence of gravity and particles of lower specific gravity are carried away from the settled particles by the liquid. A wide variety of concentrators may be used in accordance with the invention. For example, concentrators which utilize sliding friction such as Wilfley tables, Deister tables, or Vanners may be used. Similarly, devices which utilize primarily the properties of a liquid to effect gravity concentration may be used. Examples of the latter include launderers and rake classifiers, and concentrators of the hindered settling type. Hindered settling concentrators are preferred for use in the practice of this invention, and when so used are characterized by an upward current of hot oil which effect separation of coal particles from undesired components. The Fahrenwald classifier is an example of a suitable hindered settling concentrator. Surface current classifiers such as the Spitzkasten classifier and numerous other types of concentrators may also be used.
When used in the invention, all of the above processes utilize heated oil instead of the usual liquid medium. The oil is preferably heated to a temperature above the boiling point of water for the most effective removal of water from the coal being treated. However, oil at a temperature substantially above ambient will cause effective evaporation of water, the higher the temperature, the greater the evaporation. "Hot" and "heated" as used herein refer to temperatures above approximately 50°C.
Heavy particles, which include a large proportion of the pyrites content of the coal are removed by concentrator 26, and are delivered through thickener 28 to Deister table 30 which effects a further separation of pyrites from coal in the mixture which settled out in concentrator 26.
Pyrites which is separated out by table 30 is delivered along with oil to basket centrifuge 32, which effects a separation of oil from the pyrites, the oil being delivered to the inlet of mill 24, and the pyrites being delivered to a storage tank 34.
Refuse and oil are delivered from the table 30 to a second basket centrifuge 36 which partially separates oil and refuse, delivering the separated oil to the inlet of mill 24, and delivering the remaining oil and refuse to burner 37, the exhaust of which is used to operate heater 14 and heat exchanger 11. The exhaust is delivered to the atmosphere through a sulfur dioxide and nitrogen oxide absorption tower 39. A precipitator may be used if desired, to remove particulate matter.
Coal and oil separated out by table 30 are returned along path 38 to the inlet of mill 24.
A coal-oil mixture is delivered by concentrator 26 to a storage tank 42. Additional oil may be added by means of a proportioning valve 43 controlled by weightometer 40. The mixture in the storage tank is mechanically agitated in order to keep the coal particles in suspension.
A burner is indicated at 44, and it receives the coal-oil mixture from storage tank 42 through a pair of pressure feed tanks 46 and 48. The mixture in tank 42 is delivered to pressure feed tank 46 through valve 50 and to pressure feed tank 48 through valve 52. A compressor 54 is provided with an accumulator 56 and is arranged to deliver air to tanks 46 and 48 through valves 58 and 60 respectively and the four valves associated with the pressure feed tanks are operated automatically so that valves 52 and 58 are open while valves 50 and 60 are closed and valves 50 and 60 are open while valves 52 and 58 are closed. The valves are alternated between the above two conditions so that a constant flow of coal-oil fuel is delivered to burner 44.
The apparatus and process exemplified by FIG. 1 and the foregoing description produce a number of beneficial results.
In the first place, the invention provides a simple process for producing a coal-oil fuel having a low sulfur content. By using oil as a cleaning medium to clean raw coal which has been comminuted, the process of producing a coal-oil fuel is greatly simplified.
The second principal benefit afforded by the invention is the production of low sulfur fuel having a high efficiency in terms of cost per B.T.U. of heat generated. The greater efficiency of the fuel results partly from the fact that sulfur-containing compounds are separated from the coal without the addition of water to the coal. The low water content of the fuel means that the large quantity of heat which would otherwise be wasted in converting water in the coal to steam is available for useful purposes. The use of oil not only prevents cleaning water from entering the coal, but actually removes water from the coal which is residually present as a result of prior washing or as a result of natural causes. The removal of residual water is enhanced by the use of hot oil. In addition, the hot condition of the oil reduces its viscosity and therefore increases the effectiveness of the oil as a separation medium. The removal of residual water by the oil is further enhanced by the fact that the coal is reduced to a comminuted condition by mill 24.
Other subsidiary benefits of the apparatus and process disclosed above include the fact that the use of oil removes moisture from the comminuted coal without resulting in a dangerously explosive dry dust. Another benefit results from the use of refuse to produce heat used in the process. In addition, part or all of the refuse removed from basket centrifuge 36 may be treated by additional tabling to recover sulfur compounds which may then be used for manufacturing or agricultural purposes. In the event that the refuse is so treated, the residue from the treatment may be burned to provide heat for the overall process. The fuel produced by the process disclosed above is a very high B.T.U., low sulfur coal-oil fuel, an ideal fuel for power generation, particularly in view of the relatively innocuous characteristic of its combustion products and its low cost per available B.T.U. The process, of course, may be readily modified, by providing for the separation of oil from the coal particles to produce a high quality solid fuel having a low sulfur content and, because of the substantial absence of water, a very high heat content per unit weight.
Various modifications of the apparatus and process specifically disclosed herein may be made without departing from the scope of the invention which is defined in the following claims.
|
A fuel is produced by cleaning coal using an oil as a cleaning medium whereby the sulfur content of the fuel is substantially reduced and the heat content per pound is substantially increased by the reduction of water and other non-combustibles. The process may be used to produce a coal-oil fuel directly.
| 2
|
RELATED APPLICATIONS
The present application is related to U.S. Pat. No. 3,648,308, issued Mar. 14, 1972, for ELEVATED TRACTION PILLOW, by Greenawalt, included by reference herein.
The present application is related to U.S. Pat. No. 3,829,917, issued Aug. 20, 1974, for THERAPEUTIC PILLOW, by De Laittre, included by reference herein.
The present application is related to U.S. Pat. No. 4,320,543, issued Mar. 23, 1982, for MEDICAL PILLOW, by Dixon, included by reference herein.
The present application is related to U.S. Pat. No. 4,424,599, issued Jan. 10, 1984, for CERVICAL PILLOW, by Hannouche, included by reference herein.
The present application is related to U.S. Pat. No. 4,494,261, issued Jan. 22, 1985, for HEAD AND NECK CUSHION, by Morrow, included by reference herein.
The present application is related to U.S. Pat. No. 4,918,774, issued Apr. 24, 1990, for MEDICAL SUPPORT PILLOW, by Popitz, included by reference herein.
The present application is related to U.S. Pat. No. 5,581,831, issued Dec. 10, 1996, for ERGONOMIC PILLOW, by Xiang, included by reference herein.
The present application is related to U.S. Pat. No. 6,446,288 B1, issued Sep. 10, 2002, for MEDICAL SUPPORT PILLOW FOR FACILITATING ENDOTRACHEAL INTUBATION, by Pi, included by reference herein.
The present application is related to U.S. Pat. No. 6,751,818 B2, issued Jan. 22, 2004, for AIRWAY MANAGEMENT APPARATUS AND METHOD, by Troop, included by reference herein.
FIELD OF THE INVENTION
The present invention relates to a supportive pillow for medical and surgical procedures and more particularly to a supportive pillow which allows the patient to maintain an open and adequate airway while in the lateral position.
BACKGROUND OF THE INVENTION
Medical practice and patient care has experienced significant changes over the recent past including huge increases in the number of outpatient medical, surgical, and radiologic procedures. The use of flexible fiberoptic endoscopy for diagnostic and therapeutic procedures has grown worldwide. Conscious sedation and short-acting anesthetic agents have enabled a much greater variety of procedures to be accomplished on an outpatient basis. Because of the brief duration of many of these procedures and the use of conscious sedation, the placement of a mechanical airway is omitted. This may result in manipulation or support of the patient by the nursing or anesthesia staff to maintain an adequate airway during and after a procedure until the patient is fully recovered. Many of these procedures are performed in the lateral position, further complicating patient position and airway management.
The state of medical practice dictates the care of more elderly and of more obese patients, further complicating the positioning and airway management of these patients during a procedure. The patient support addressed in the Troop patent (U.S. Pat. No. 6,751,818) discloses an airway management apparatus which supports the chest, neck, and head of a patient, allowing the abdominal mass to be displaced, thus improving airway position and ventilation. This cushion does not accommodate the lateral position which is widely used.
The Xiang patent (U.S. Pat. No. 5,581,831) addresses the support of a patient in the lateral position for comfort, but the chest is not supported independently of the shoulder, resulting in lateral angulation of the cervical spine and the airway. The shoulder is allowed to impinge on the neck, and the head is not supported in a position to maintain a secure airway. This device also does not support the patient from shifting laterally or easily rolling off of the cushion.
There has been a vast increase in the number of patients in rehabilitation hospitals and extended care facilities requiring the nursing staff to position and move them while they are recumbent. Supporting and cushioning patients to avoid soft tissue pressure injury over a bony prominence is a major priority of patient care. The morbidity and mortality from complications of pressure sores is great and consumes massive financial and personnel resources. Many patients require apnea monitoring during long term care and airway maintenance requires considerable time and attention from nursing and respiratory therapy staff. Techniques of padding and bolstering patients with common bed pillows in the lateral position yield inadequate results and require multiple staff members to reposition patients every two hours.
The treatment of gastroesophageal reflux and congestive heart failure, as well as other conditions, require elevation of the head of the patient's bed. The classic recommendation is to place blocks or bricks under the legs of the bed at the patient's head. Several drawbacks are apparent in this technique. The patient usually slides out the foot of the bed, and a bed partner is made uncomfortable by the position of the bed. The use of blocks or bricks is not possible with a water mattress. The expense of an adjustable hospital bed is prohibitive for most patients. The technique does not lend itself to maintaining good airway support in the head-elevated supine position or the lateral position. Many of these patients are obese and have sleep apnea and the elevated position does not support the head and neck, thus complicating the already compromised airway.
Because of the increased use of the lateral position in diagnostic and therapeutic procedures requiring sedation or anesthesia, without the use of a mechanical airway, attention is drawn to adequate support and positioning of the patient during and after these procedures. Likewise, the use of the lateral position in long term care requires attention to proper positioning, padding, and airway support. Therefore, a medical support pillow that meets these multiple needs is the object of the present invention.
It is therefore an object of the invention to support and stabilize the patient in the lateral position while maintaining an open airway.
It is another object of the invention to enhance spontaneous respiration by aligning the airway in the anterior-posterior, and lateral directions.
It is another object of the invention to assist the anesthesiologist in placing a mechanical airway prior to a procedure requiring the lateral position.
It is another object of the invention to support the patient with limited mobility in such a way to maintain an adequate airway and protect against soft tissue pressure injury.
It is another object of the invention to provide support and elevation of the head, neck and thorax of the patient in the supine, right, or left lateral positions.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a medical support pillow and method for supporting a patient in the lateral position while maintaining an open airway. The lateral airway support pillow includes a chest support, shoulder recess, head support, and posterior bolster. For purposes of the discussion, the following definitions are offered:
ANTERIOR—toward the direction the patient is facing while in the lateral position.
POSTERIOR—opposite the direction the patient is facing while in the lateral position.
CEPHALAD—toward the head of a patient on the lateral airway support pillow.
CAUDAL—toward the feet of a patient on the lateral airway support pillow.
The lateral airway support pillow supports the chest of the patient in the lateral position by elevating it above the level of the mattress of the patient support. This allows the shoulder recess to receive the shoulder and upper arm in a natural position without the shoulder compressing or impinging upon the head, the chest wall, or the neck. The anterior portion of the head support receives the head while maintaining a straight orientation of the thoracic and cervical spines in the lateral direction. The elevation of the chest and the head at an incline allows the abdominal contents to fall away from the diaphragm, thus easing spontaneous ventilation. In most patients, this will insure an open airway. In some patients, however, relaxation of the soft tissues of the pharynx will compromise the airway during and after sedation or anesthesia. These patients will benefit from the placing of the head and neck over a neck support and into a posterior recess of the head support. This aligns the oral, pharyngeal, and laryngeal axes for an open airway and unimpeded spontaneous respiration. The superior shoulder of the patient is moved posteriorly against the posterior bolster, allowing the head to be positioned in the posterior recess of the head support.
Another aspect of the of the present invention allows for the patient to be positioned supine on the lateral airway support pillow while induced under general anesthetic. The head could be placed in the posterior recess of the head support for aligning the oral, pharyngeal, and laryngeal axes of the airway, and then endotracheal intubation or the placement of a laryngeal mask could be easily achieved. The patient could be rolled to the lateral position for the surgical procedure. This technique would prove useful for thoracic surgery or hip surgery in the lateral position. The patient would supported securely and uniformly with the lateral airway support pillow without fear of pressure injury to the soft tissues. Post operative recovery, including airway management, would be facilitated by use of the lateral airway support pillow.
Another aspect of the invention allows for the support of a long-term care patient with limited mobility, in the lateral position, to prevent pressure injury to the soft tissue of the presacral area and other areas. A reversible version of the lateral airway support pillow without the posterior recess in the head support positions the patient in either the left or right lateral position while awake or asleep. This device is called the reversible lateral support pillow.
Another aspect of the invention is useful for patients requiring elevation of the head and thorax for the treatment of conditions such as gastroesophageal reflux, congestive heart failure and sleep apnea. This device has a middle portion for supporting the patient in the supine position with the thorax, neck, and head elevated and supported. Should the patient desire to recline in either the right or left lateral position, accommodation with bilateral chest supports, shoulder recesses, and head supports is presented. The head, neck, and chest are supported and elevated in the lateral positions as they are in the supine position. This version of the invention would also be useful in the long-term care setting. It is called the bilateral support pillow.
BRIEF DESCRIPTION OF THE DRAWINGS
A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent, detailed description, in which:
FIG. 1 is a perspective view of a lateral airway support pillow, viewed from the anterior and caudal aspects of the invention;
FIG. 2 is a perspective view of a lateral airway support pillow viewed from the cephalad end of the invention;
FIG. 3 is a top plan view of a lateral airway support pillow, in use, with the head of the patient positioned on the anterior planar surface of the head support;
FIG. 4 is a top plan view of a lateral airway support pillow, in use, with the head of the patient positioned in the posterior recess of the head support;
FIG. 5 is a perspective view of a patient on the lateral airway support pillow with the head in the posterior recess of the head support, demonstrating the extended neck and an open airway;
FIG. 6 is a left perspective view of an alternative embodiment of the invention, termed the reversible lateral support pillow;
FIG. 7 is a right perspective view of a reversible lateral support pillow, reversed to accommodate a patient in the right lateral position;
FIG. 8 is a top plan view of a reversible support pillow in use, with the patient supported in the straight left lateral position;
FIG. 9 is a rear view of a patient lying on the reversible lateral support pillow or the lateral airway support pillow; and
FIG. 10 is a perspective view of an additional embodiment of the lateral support pillow termed the elevated bilateral support pillow.
For purposes of clarity and brevity, like elements and components will bear the same designations and numbering throughout the Figures.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the invention are described below with reference to various examples of how the invention can best be constructed and be used. Like reference numerals are used throughout the description and the drawings to indicate corresponding parts.
Referring now to FIG. 1 ., the lateral airway support pillow is fashioned to support a patient in the lateral position. It fully supports the chest, neck, and head of the patient in such a position so as to preserve an adequate airway and to stabilize the patient in such a position to satisfactorily perform the required procedure. It is made to be used on a patient support such as a bed, transfer cart, or operating table. It has a base 10 having a substantially planar surface to allow positioning on the patient support. It has a posterior surface 16 and two ends, one designated as the caudal end 12 and an opposing margin as the cephalad end 14 .
Major components comprise a chest support 18 which is of size and thickness to lift the thorax of the patient a distance from the patient support, thus allowing the dependent shoulder and the upper arm of the patient to reside in the shoulder recess 20 . The shoulder recess 20 , which is arcuately shaped, is of adequate size to allow the shoulder and upper arm to assume a natural position, and not be compressed by the weight of the patient.
The head support 22 is substantially thicker than the chest support 18 and thus aligns the cervical spine with the thoracic spine. As the hips of the patient lie on the patient support, the cervical and thoracic spines are aligned with the lumbar spine. The head support 22 contains a posterior recess support surface and an anterior planar support surface, with the posterior recess support surface being substantially parallel to and located adjacent to an in a lower position than the anterior planar support surface. The posterior recess is coupled to the head support 22 and has a first substantially vertical surface disposed between the anterior planar support surface and the posterior recess support surface. The posterior recess, in turn, is disposed between the first substantially vertical surface and a second substantially vertical surface of the posterior bolster 30 , such that the first and second substantially vertical surfaces are substantially parallel to one another and separated by the posterior recess support surface. The anterior planar surface receives the head of the patient. The dependent side of a patient's head and face contact the anterior planar surface of the head support 24 . The posterior recess of the head support 26 receives the posterior portion of the patient's head when the patient is rolled posteriorly onto the posterior bolster 30 . This allows the neck of the patient to extend over and be supported by the neck support 28 . The neck support 28 includes a substantially planar top surface and first and second ends, the first end terminating into the shoulder recess and the second end terminating into the second substantially vertical surface of the posterior bolster 30 . In addition, the second substantially vertical surface extends vertically upward form the top surface of the neck support 28 and is configured to support the head of the patient when it is in the posterior recess and to support the back of the patient when the patient is rotated posteriorly. The airway is straightened in the anterior-posterior plane by this action and the tracheal, laryngeal, and oral axes of the upper airway are aligned. The lateral airway support pillow maintains this position once the patient's head is properly introduced into the poster recess of the head support 26 . Further traction or manipulation is not necessary to maintain a secure airway. The size and depth of the posterior recess of the head support 26 is sufficient to receive the head and straighten the airway.
Referring to FIG. 2 ., the lateral airway support pillow is viewed from the cephalad end 14 to illustrate the detail of the head support 22 . The size, depth, and position of the posterior recess of the head support 26 and its relationship to the anterior planar surface of the head support 24 are demonstrated. The posterior bolster 30 extends the full length of the lateral airway support pillow from the caudal end 12 to the cephalad end 14 . The posterior bolster 30 serves to support the head of the patient when it is in the posterior recess of the head support 26 , and to support the back of the patient when the patient is rotated posteriorly.
Referring to FIG. 3 ., the patient is depicted from overhead, lying in the lateral position on the airway support pillow with the head of the patient on the anterior planar surface of the head support 24 . The chest support 18 is shown positioned under the patient's chest to allow the dependent shoulder and upper arm to occupy the shoulder recess 20 . The posterior recess of the head support 26 is seen posterior to the patient's head.
Referring to FIG. 4 ., the superior shoulder of the patient is rotated posteriorly to rest on the posterior bolster 30 , allowing the head to be introduced into the posterior recess of the head support 26 , the neck to be extended, and the airway to be straightened. The neck is extended over and resting on the neck support 28 . The back of the patient is reclining on, and fully supported by the posterior bolster 30 .
Referring to FIG. 5 ., the patient is rotated posteriorly and fully reclined in the lateral airway support pillow. This view demonstrates the positions of the chest and head being fully supported by the chest support 18 and the head support 22 . The positions of the dependent shoulder and the upper arm are well demonstrated in this view. The head of the patient is in the posterior recess of the head support 26 and the straight orientation of the neck and airway is apparent.
Referring to FIG. 6 ., an alternative embodiment of the lateral airway support pillow is seen in the form of a reversible lateral support pillow. This perspective view from the caudal end 12 and anterior surface illustrates the detail of the chest support 18 and the caudal end 12 of end of the posterior bolster 30 . The position of the posterior bolster 30 and the thicker anterior edge of the chest support 18 , with the thinner mid-portion of the chest support 18 , provides a cradle for the lateral surface of the chest of the patient. Security from rolling off of the reversible lateral support pillow is afforded. The shoulder recess 20 is seen to occupy the space between the chest support 18 and the head support 22 . This accommodates the dependent shoulder and the upper arm of the patient. The head support 22 is seen to be in a similar configuration as the chest support 18 , with the posterior bolster 30 and the thicker portion at the anterior edge of the head support 22 providing a secure cradle for the head. The large size of the head support 22 accommodates a variety of positions for the head when the patient is in the straight lateral position or the posterolateral position.
Referring to FIG. 7 ., the reversible lateral support pillow is lying on the reverse side, thus accommodating a patient in the right lateral position. This view demonstrates that the reverse side is a mirror image to that depicted in FIG. 6 .
Referring to FIG. 8 ., the patient is in the straight lateral position on the reversible lateral support pillow. The patient's dependent shoulder and upper arm are placed in the shoulder recess 20 . The head support 22 is noted to provide adequate space for a variety of positions. The posterior bolster 30 allows the patient to be in a posterolateral position while keeping the sacrum from contacting the patient support and therefore preventing pressure induced soft tissue injury.
Referring to FIG. 9 ., the patient is shown in the lateral position reclined on either the lateral airway support pillow or the reversible lateral support pillow and demonstrating the straight-line orientation of the cervical, thoracic, and lumbar portions of the spinal column. This orientation provides support and comfort for the patient and assists in the maintenance of the open airway. The invention also supports the patient without pressure from the patient support on the sacrum.
Referring to FIG. 10 ., an alternative embodiment is depicted for use for a patient wishing to elevate the head and chest above the level of the patient support, and yet still be able to lie in the supine position or in the left or right lateral positions. This invention would be useful in the management of gastroesophageal reflux, congestive heart failure, or sleep apnea. The head, neck, and thorax remain elevated in the lateral position as illustrated in FIG. 9 . This embodiment contains a chest support 18 , a left shoulder recess 20 , a right shoulder recess 20 , and a head support 22 . The head support 22 is fashioned to cradle the head of the patient in the center of the head support 22 when the patient is in the supine position, or on either the left lateral planar surface or the right lateral planar surface of the head support 22 , depending on the position of the patient.
The alternative embodiment described as the reversible lateral support pillow demonstrates that all embodiments of this invention could be constructed to be reversible by reproducing a mirror image of the obverse side on the reverse side. Some applications such as flexible fiberoptic endoscopy are most commonly performed in the left lateral position and a pillow made without the reversible feature would perform satisfactorily. Alternatively, applications such as hip surgery or chest surgery would utilize a reusable, reversible lateral airway support pillow. A reversible lateral support pillow would found useful in the long-term care unit to be able to alternate lateral positions while supporting the patient and helping eliminate soft tissue pressure injury.
Materials for the construction of these units could include urethane foam material which is formed to a specific shape in a mold or is constructed of smaller pieces of foam fastened to each other with adhesive. Different densities of foam may be employed to render a pillow of a desirable shape to function as described herein.
Other options include constructing a pillow with one or more inflatable chambers. This would allow for adjustment of size and rigidity of each chamber, thus allowing different support characteristics to patients of varying sizes and weights. The individual chambers could be inflated by a recycling, variable pressure pump, thus stimulating the circulation to the soft tissue and preventing points of prolonged high pressure.
Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.
Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.
|
The present invention provides a medical support pillow and method for supporting a patient in the lateral position while maintaining an open airway. The lateral airway support pillow includes a chest support, a shoulder recess, a head support and a posterior bolster. The orientation of these components support the patient in the lateral position, with the spine and airway in a straight position, thus eliminating possible airway obstruction. One embodiment of the invention contains a head support with a posterior recess and a neck support which provides for straightening of the neck and airway and aligning the oral, pharyngeal, and laryngeal axes of the airway. Other embodiments position and elevate the patient in such a manner to treat or prevent soft tissue pressure injury, gastroesophageal reflux, congestive heart failure, or sleep apnea.
| 0
|
CROSS REFERENCES TO RELATED APPLICATIONS
This application relates to application Ser. No. 810,904, entitled "A System For Reception of Frequency Modulated Digital Communication Signals" filed June 28, 1977 in which the inventors are Josef Gammel, Karl Kammerlander, and Hans-Juergen von der Neyen assigned to the same assignee of the present application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to a system for receiving digital communication signals which are modulated on a carrier in the form of binary frequency modulation in a reflection affected propagation medium and in particular for a reception at mobile stations on long distance connections and scattered beam connections.
2. Description of the Prior Art
In digital communication transmission systems under heavily disrupted propagation conditions (multi-path propagation) the range is approximately inversely proportional to the bit rate to be transmitted. The limiting case determining the range is represented by the total signal extinction which as a consequence of the different transit times (propagation times) is caused by the indirect propagation path. The differential time delay of the reflected wave and the direct path amount at the reception point to 180° out of phase and therefore the waves mutually cancel each other. In a wide range before this limiting case occurs information losses occur as a result of the delay time distortion and amplitude distortion which give rise to very high error rates in data transmission.
SUMMARY OF THE INVENTION
So as to obtain substantial improvement of the transmission quality in these areas and in this manner to ultimately achieve an improvement in the range of digital communication systems with binary frequency modulation in particular between mobile stations and with a constantly varying propagation situation, it was proposed in co-pending application Ser. No. 810,904 to automatically detect the information losses occurring as a result of phase and amplitude distortions according to their causes in two mutually supplementary arrangements: one of which has a frequency discriminator behind which is connected a device for recognizing the interference peaks caused by reflection distortions as well as having a circuit which compensates for these interference peaks. The other arrangement contains an amplitude demodulator which is connected in parallel to the frequency demodulator in a second branch. In the process, the outputs of both demodulators are supplied to a switch which is controlled by an amplitude demodulation device which at a recognizable amplitude modulation of sufficient modulation index connects the amplitude demodulator to a common output and at a recognizable frequency modulation connects the frequency discriminator together with the interference peak recognizor to this output. The output of the AM demodulator has a polarity inverter connected behind it which is controlled by a polarity integrator which determines the polarity of the AM demodulation products as a function of the level of the FM demodulation product which belongs to the higher level of demodulated AM signal.
This proposed system has the underlying realization that the distortion caused as a consequence of multi-path propagation in binary frequency modulated digital communication signals are essentially expressed by two interference forms which can be clearly distinguished from each other especially with narrow band systems when the FM modulation index is smaller than one.
Other objects, features and advantages of the invention will be readily apparent from the following description of certain preferred embodiments thereof taken in conjunction with the accompanying drawings although variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the disclosure and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a waveform diagram describing the effects of multi-path propagation,
FIG. 2 is a receiver block diagram according to patent application Ser. No. 810,904,
FIG. 3 is a functional block diagram of the alternating voltage separation circuit according to the invention; and
FIG. 4 illustrates voltage diagrams for explaining the functioning of the alternating voltage separation circuit according to FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is of assistance in understanding multi-path propagation in binary frequency modulated digital communication systems.
FIG. 1 illustrates the frequency dependence of signals for the cases I, II and III. The amplitude characteristic of the signal voltage U res which result from the multi-path reception is plotted in the upper diagram. The resulting phase φ res is plotted in the diagram directly beneath this diagram. Left besides the upper diagram, a phasor diagram is drawn additionally which indicates the way how the received signal voltage, specifically the directly received signal voltage U d , and the signal voltage U u received over an indirect path add to each other so that the resulting received signal voltage U res is obtained.
As soon as the delay time differences of the signals incident at the point of reception of the direct ray and of the indirect ray are of the order of magnitude of the bit time the frequency difference of the minima of the distribution characteristic becomes so small that within the modulation deviation, the energy of the received signal can fluctuate almost arbitrarily with the modulated speed and as a function of the radio frequency ω ot and the depth of the minima. A consequence of these energy fluctuations caused by the phasor addition of the incident signals which are suppressed in the amplitude limiter of the reception system before demodulation are rapid phase alterations of the resulting signals which are necessarily generated because of phasor addition. These rapid phase alterations can naturally not be suppressed by the amplitude limiter and they, therefore produce a bit synchronous interference modulation at the output of the FM demodulator. The magnitude of this interference modulation can exceed the useful modulation by many times and, thus, destroys the detectability of the useful information.
The maximum phase speed of the resulting signal voltage occurs in the minima of the distribution characteristic increases with decreasing signal voltage at the minimum. In the ultimate case, at selective total cancelling, the phase speed can be arbitrarily large.
Depending on a function of whether the minimum is located in the middle of the frequency deviation range which in the case of the assumed modulation index being less than 1 is defined by the two sign frequencies or whether it is located in the vicinity of one of the sign frequencies the two different interference forms mentioned above occur. In FIG. 1, the sign frequencies for the three characteristic cases I, II and III are designated as f 0 /f 1 , f 0' /f 1' and f 0" /f 1" . The mean frequency between the respective sign frequencies is indicated by f m f m' and f m" .
(a) Minimum in the vicinity of a sign frequency in the deviation range
If the minimum is located inside or outside the deviation range but in the vicinity of one of the two sign frequencies, then the received energy at this sign frequency will be relatively small. The received energy at the other sign frequency is necessarily higher but on the other hand since it lies closer to the next maximum of the resulting signal voltage U res , this results in clear unequivocal bit-synchronous amplitude modulation occurring in the received signal ahead of the limiter and the polarity of the amplitude modulation depending on the position of the minimum is either in the same position or in an inverted position relative to the original modulation signal. The limiting which precedes demodulation customary with frequency modulation suppresses this amplitude modulation. Thus, the amplitude modulation does not become effective at the output of the demodulator. By contrast, the phase change occurring in the vicinity of the minimum when a change in polarity occurs is effective and it expresses itself as a large polarity distortion at the output of the demodulator. In case II, illustrated in FIG. 1, the sign frequency f 1' is in the minimum and the sign frequency f 0' is at a maximum of the frequency dependent receiving characteristics of the signal voltage U res . If the energy of the cutoff frequency f 1' falls below the internal noise level of the receiver, then a very essential limiting case of the operating characteristic is obtained. As a consequency of the negative signal to noise ratio at one of the sign frequencies, there appears instead of a logic symbol which correspond to this sign frequency (zero or one), only noise at the limiter and demodulator output. The signal demodulated with the FM demodulator will thus become unuseable. However, even in this situation the received signal in front of the limiter has a bit synchronous amplitude modulation so that using this amplitude modulation as far as responding to amplitude is available, a regeneration of the received signal is possible.
(b) Minimum with the deviation range near the mean frequency
If the frequency occurs in the middle area of the deviation range given by the two sign frequencies, then the interference caused by multi-path reception is shown in the following description. The phase alteration speed at the minimum is indicated at the limiter output and the demodulator output as frequency offset and can reach a multiple of the useful deviation. The duration of the deviation error depends on the modulation speed and on the relative depth of the minimum. If as a consequency of this interrelationship, the duration of the deviation error is smaller than the bit duration then this error deviation will show up with a sign interval as a peak voltage the size and characteristic of which depends on the depth of the minimum. The distortion peaks do not necessarily occur within each individual bit, however, but only at the time of the polarity change since it is exclusively in this process that the deviation range is passed through. In FIG. 1, in this case, in which the minimum at frequency f m occurs in the middle between the two cutoff frequencies f 0 and f 1 as indicated by I. This kind of interference can be eliminated to a great extent in that the interference peaks which occur are suppressed at the output of the frequency demodulator.
Case III illustrated in FIG. 1 represents practically the undisturbed reception of energy in which the two cutoff frequencies f 0" and f 1" occur at both sides of the maximum with sufficient amplitude and the amplitude modulation which is caused by phase distortion is practically negligible.
FIG. 2 of the drawings comprises a block diagram of the basic circuit of a system for receiving frequency modulated digital communication signals with built in interference suppression according to the referenced co-pending application. The specification and drawings of this co-pending application are hereby incorporated by reference. The input terminal ZF from an intermediate frequency stage is supplied to a demodulator stage ZD which forms a portion of a conventional receiver. The IF signal is fed to a IF filter 1 whose output is connected to a limiter 2 which supplies an output to a FM demodulator 3. A static distortion corrector SE also receives the output of the IF filter 1 so as to suppress interferences of the type described under paragraph (a) above. The output of the FM demodulator 3 is connected to the input of a dynamic distortion corrector DE which suppresses the interferences illustrated under paragraph (b) above in conjunction with multi-path propagation. The outputs of the dynamic distortion corrector DE and the static distortion corrector SE supply outputs to a data decision circuit DA connected at their outputs and to which the received signal is applied which has been cleared of interfering signals.
The distortion corrector DE includes a two position switch 5 which has one contact to which the output signal of the FM demodulator 3 is supplied and during interference free FM reception the output of the FM detector 3 passes through switch 5 directly to the decision circuit DA. During such condition, this passes through the two position switch 13 of the data evaluation circuit DA which supplies its output to the regenerator 15 and the output of the regenerator 15 is supplied to the data output terminal.
Under conditions when interference illustrated according to paragraph (b) above which are considered to be dynamic distortions occur, the limiting value switch 4 in the dynamic evaluator DE receives the output of the FM demodulator 3 and the switch 4 produces an output that is supplied to the switch 5 so as to change its position from the input shown in FIG. 2 so that the moveable switch contact moves to its second position so that the switch is connected to the output of the scanning hold circuit 7. The switch 5, for example, might be a magnetically controlled switch and when the output of the switch 4 is furnished to the switching coil of the switch 5 it changes its position. The output of switch 4 is also supplied to the scanning hold circuit 7. A transit time device 6 also receives the output of the FM demodulator 3 and supplies an input to the scanning hold circuit 7 and the output of the scanning hold circuit 7 is connected to the second contact of switch 5. Thus, at instances when an output is supplied by the limiting value switch 4, there will be present at the scanning hold circuit 7, a delayed signal whose momentary value corresponds to that of the demodulated signal before it exceeded the limiting value in a first approximation. For the duration of the time when the limiting value is exceeded, this momentary value is stored in the scanning hold circuit 7 and is supplied into the data flow through the second contact of switch 5. In this manner, the energy content of the original bit is maintained and its detection is assured in regenerator 15.
In case of interference according to paragraph (a) described above, which is considered as static distortion, the IF signal from the IF filter 1 has a bit synchronous amplitude modulation. This AM signal is fed from the IF filter 1 to the AM demodulator 9 through a logarithmic amplifier 8. The output of the amplitude demodulator 9 is provided with a capacitor for separating the DC and the alternating portions of its output signal. The output signal of amplitude demodulator 9 from which the DC signal portion has been removed by the capacitor is fed to a AM limiter 10 which supplies at its output an input to a controllable inverter 11. The output of the controllable inverter 11 is connected to the second fixed switch contact of the switch 13. Thus, the switch 13 is either connected to the output of switch 5 or to the output of controllable inverter 11. The polarity of the demodulated AM signal at the outputs of the amplitude demodulator 9 and at the output of the AM limiter 10 will either be in phase or out of phase with the demodulated FM signal at the output of switch 5 depending on whether the one or the other of the two cutoff frequencies has been cancelled as defined above. So as to create the necessary unambiguous conditions, the respective detectable portions of the FM demodulated signal is compared with the AM demodulated signal in the polarity integrator 12 and the inverter 11 which is controlled by the output of the polarity integrator 12 so as to switch it over as required.
As illustrated in FIG. 2, the output of the amplitude demodulator 9 of the static distortion corrector SE is connected to the input of the AM decision circuit 14 which is part of the data evaluation circuit DA and which automatically checks whether an error free bit synchronous amplitude modulation is present. Only in the case of the error free bit synchronous amplitude modulation being present the AM deciding circuit moves the moveable contact of switch 13 to the output of the inverter 11 with a suitable magnetic control, for example, so that the data obtained from the amplitude demodulator from the received signal will then be fed to the regenerator 15. For proper operation of the receiver arrangement illustrated in FIG. 2, it is necessary that the automatic switching from one of the distortion correcting systems to the other that is the switching over between the dynamic distortion corrector DE and the static distortion corrector SE can occur at the speed at which such interferences occur.
Relative to FIG. 1, the initial assumption was that the transmitter and receiver are stationary so that the received signal level will be essentially dependent in its energy distribution on the frequencies being used. A shifting of the minimum out of the frequency deviation range or into the frequency deviation range, can in the case of rigidly prescribed radio frequencies come about as a result of local changes of the reflectors or from fluctuations of the reflection and refraction phenomena in the course of the multi-path reception such as in ionospheric and tropospheric scatter reception. In general, these changes occur at relatively small velocities. The conditions are different when transmitter and receiver are mobile during operation as for example, when mobile operating terminal stations on moving vehicles. In this case, the received signal levels respond not only to the frequency-wise energy distribution but also additionally respond to the location dependent energy distribution which is interrelated therewith, the local spacing of the minima of the energy distribution is directly proportional to the radio frequency wavelength being used. In other words, in mobile operation under the influence of longer paths with fixed reflectors, the respective degree of distortion changes depending on the location with the relative speed of transmission and reception of the vehicles, and depends as a function on the radio frequency wavelength being used. For example, using a radio frequency of 300 MHz corresponding to a half wavelength of 0.5 m where the vehicle is moving at a velocity of ten meters per second (36 km/h) 20 minima per second will pass through a mobile station. As shown in FIG. 1, the scope of the distortions can be illustrated if the frequency axis is replaced by a time axis and the modulated band between the frequency f 0 and f 1 represented in case I is shifted to the right for example with a speed such that the time for passing through an amplitude and phase wave last for 1/20 of a second or where 20 such waves per second pass through with uniform speed. The distinctive cases of I, II and III illustrated in FIG. 1 will, thus, change from one to the other in rapid sequence corresponding to the traversing of the spatial distribution and will repeat themselves with corresponding period. The speed of substitution of the dynamic distortion corrector DE illustrated in FIG. 2 depends on the reaction time and the processing time of the integrated components used therein and thus the dynamic distortion correction is substantially faster than the maximum expected path change length between the transmitter and receiver.
The conditions are different with regard to the static distortion corrector SE. The logarithmically evaluated and rectified IF signal tapped off before the limiter where the bit synchronous alternating voltage necessary for obtaining the AM data is separated and which is demodulated by the amplitude demodulator 9 and supplied through the capacitor which removes the DC voltage which corresponds to the mean field strength. If during mobile operations, the mean field strength periodically changes then as a result of charging and discharging time constant of the capacitor the magnitude of the signal voltage occurring at the output of the amplitude demodulator 9 will be in error in those cases where the time constant are no longer negligibly small due to the alteration speed of the mean field strength. These variations of the alternating voltage make it more difficult to evaluate the AM data.
The invention has the underlying objective of further developing the system according to the above referenced co-pending application with regard to the static distortion corrector and has an objection that the error free automatic switch over is assured even if the different interference phenemona follow one another in rapid succession as is especially the case with a relative movement between transmission and reception stations for mobile operation.
The system according to the co-pending application referenced above, is modified according to the present invention such that the AM demodulator includes and has at its output an alternating voltage separation circuit which includes at its input first and second sampling circuits connected in parallel and wherein the first sampling circuit is controlled directly and the second sampling circuit indirectly by way of a switch by pulses derived at the receiver from the incoming signal and which contains a subtracting means at the output which has two inputs connected to the outputs of the sampling circuits. The invention further includes the provision that the switch for the pulse supplied to the second sampling circuit is energized as a function of the changes in amplitude characteristic of the output signal of the first sampling circuit.
The present invention is based on the realization that the alternating voltage distortion which occurs in the case of an ordinary alternating voltage separation using a capacitor as a coupling means results when there are rapid changes in the mean field strength. This will cause improper operation of the A.M decision circuit 14 illustrated in FIG. 2, and, thus, interferes with the proper timing of the switch 13 and also additionally, as a consequence of unsymmetrical pulse duty factors of the bit stream at the output of the AM demodulator 9 will cause the integration output of the polarity integrator to have an error. The evaluation of the data obtained by way of the amplitude modulation becomes very difficult due to these factors.
In the present invention a low pass filter is mounted at the input of the second sampling circuit path to the substractor so as in this manner to smooth the path changes to the same magnitude proportional to the mean field strength to a degree which is favorable for functioning of the complete system.
The control signal for the pulse feed supply to the second sampling circuit as a function of the changes of the amplitude characteristics of the output signal of the first scanning circuit is obtained in an advantageous manner by providing that the control input of the switch is connected to the output of the first sampling circuit through a differentiator that might possibly be linked with a pulse shaping stage.
FIG. 3 illustrates the alternating voltage separation circuit of the invention which replaces the capacitor coupling at the output side of the amplitude demodulator of the static distortion corrector SE of the co-pending system illustrated in FIG. 2. The alternating voltage separation circuit illustrated in FIG. 3 has two sampling circuits 16 and 17 to which the demodulated signal is respectively fed to their inputs as illustrated from terminal a. Both of the sampling circuits 16 and 17 are controlled by a pulse T derived from the incoming signal. Specificially sampling circuit 16 receives the pulse T directly from terminal b and sampling circuit 17 receives the pulse T indirectly through a switch 22 on lead d. The output of the alternating voltage separation circuit includes a substractor 18 which receives a first input on lead c from sampling circuit 16 and a second input from a low pass filter 19 which receives the output on lead e from sampling circuit 17. The switch 22 is controlled in position by the output of the sampling circuit 16 through differentiator 20 and the pulse former stage 21.
The voltage response characteristics illustrated in FIGS. 4a through 4f are plotted against time t and represent the voltage response characteristics at the corresponding designated locations in circuit 3 as indicated by the letters a through f. For example at input point a, the input demodulated signal appears which represents a data flow current which fluctuates between the values of the voltages U 1 and U 2 . Respectively, in the middle of a bit this input signal is sampled in a pulse shaped manner by the pulse having the pulse amplitude of U T at a time which is short compared to the bit length. Initially, this is true only for the sampling circuit 16 to which the pulse is directly fed. At the output of the sampling circuit 16, the regenerated input signal occurs with the symmetrical pulse duty factor in the form of a rectangular pulse sequence superimposed upon a direct current voltage. This rectangular pulse sequence is differentiated in the differentiator 20 and after passage through the pulse former stage 21 is fed to the control input terminal of switch 22. The circuit for the derivation of the control signal for the switch 22 from the output signal of sampling 16 is selected to be such that only the rising edges of the rectangular pulse sequence as shown in FIG. 4c change the switch from the opened state to the closed state. The results of this is that the sampling circuit 17 stores a sampled value from the input side of the demodulated signal only when the sample value has a maximum value corresponding to the voltage of U 1 . As a consequence, a direct voltage occurs as illustrated in diagram 4e which has a value of U 1 which occurs at the output of the sampling circuit 17.
This direct voltage is proportional to the respective mean value of the field strength of the received original signal and thus supplies the reference magnitude for the amplitude modulation of the AM demodulated signal. The limiting frequency of low pass filter 19 is dimensioned according to the highest used radio frequency (location dependent spacing of the attenuation maxima) and the maximally occurring relative speed between the transmission and reception vehicle. In this manner, it is assured that the maximum change in speed of the direct voltage at the output of the sampling circuit 17 will be completely transmitted through the low pass filter 19 whereas more rapid changes caused by interferences will be suppressed. Thus, at the output of the subtractor 18, the voltage wave illustrated by FIG. 4f is produced from the differences between the voltage U 1 -U 2 which are illustrated in FIG. 4a.
Thus, the invention provides an improved static distortion corrector and although it has been described with respect to preferred embodiments it is not to be so limited as changes and modifications may be made which are within the full intended scope as defined by the appended claims.
|
A receiving system for digital communication signals modulated on a carrier in the form of binary frequency modulation in a propagation medium which is affected by reflections in which the information losses occurring as a result of phase and amplitude distortions are automatically determined by two mutually supplemental arrangements. One of these arrangements includes in a first branch a frequency discriminator after which is connected a device for recognizing interference peaks caused by reflection distortions and further including a circuit which compensates for these interference peaks. The other arrangement contains an amplitude demodulator which is connected in parallel to the frequency demodulator in a second branch. The outputs of both branches are supplied to a switch which is controlled by an amplitude modulation evaluation device which at a recognizable amplitude modulation of sufficient magnitude connects the second branch to a common output, and at a recognizable frequency modulation connects the first branch to this output.
| 7
|
RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 13/436,093, filed 30 Mar. 2012.
FIELD
This invention relates to fan blades within evaporator blowers, and to acoustic performance of evaporators in vapor cycle cooling systems.
BACKGROUND
Centrifugal fans are inherently noisy machines, due to the design and airflow interaction of the fan wheel and blower outlet. Air is drawn in at an inlet by a motor-driven rotating impeller. The impeller includes a number of passages arranged in a spiral. Air accelerates through these passages and emerges at an outlet. A cut-off area between the impeller housing and the outlet causes a sudden change of radial and tangential airflow at the outlet. The change in airflow, which is proportional to the blower speed, causes a pressure pulse that results in noise generation.
Conventional efforts to reduce noise generated by centrifugal fans include insulating the fan housing and ducts, both upstream and downstream. Alternately, sound reducing equipment may be installed at the fan inlet or at the fan discharge. For example, U.S. Pat. No. 3,191,851 to Wood describes a two-part system including a square sheet of metal that extends towards and slightly over a small portion of the fan, plus a perforated fairing to decrease size of the fan outlet. U.S. Pat. No. 5,340,275 to Eisinger discloses a rotating cutoff device that is attached within a fan casing. Resonating chambers in the cutoff device are meant to absorb sound. U.S. Pat. No. 6,463,230 to Wargo describes a noise reduction device for smoothing airflow transition at a pinch point of a fan. Wargo focuses on reducing air stagnation at the point where the fan scroll is tangent to the scroll case. The noise reduction device has an airfoil cross section shape, and extends linearly over the fan opening. U.S. Pat. No. 6,575,696 to Lyons et al. combines a sound attenuating cavity, formed as part of the blower housing, with an angled cut off for disrupting pressure fluctuation near the intersection of the exhaust section and the fan scroll.
In another example, U.S. Pat. No. 5,536,140 to Wagner et al. discloses a furnace blower with a flat plate that is inserted parallel to a blower exhaust port. Notches cut in a specified pattern vary the quantity of airflow and reduce pulsing tones. U.S. Pat. No. 5,584,653 to Frank et al. discloses a device for reducing noise in a side channel fan, which appears to include notches or spikes cut into fan outlets and pointing into the intake/discharge, to reduce noise.
U.S. Pat. No. 3,034,702 to Larsson et al. is not concerned with noise suppression, but rather is directed towards a fan having great axial length and dual air inlets, one at each end. Larsson relies upon a series of baffles to provide uniform flow throughout the entire cross-section of the fan discharge opening.
U.S. Pat. No. 6,935,835 to Della Mora discloses various anti-noise stabilizers for centrifugal fans. In particular, Della Mora seeks to homogenize airflow and reduce vortices, in order to reduce noise and improve efficiency of the centrifugal fan. The stabilizers extend for the width of the discharge opening and include dual appendages that face the inlet cone of the fan, one on either side of the discharge opening. U.S. Pat. No. 6,039,532 to McConnell also discloses a device at a fan discharge opening. In particular, McConnell places a baffle in the outlet of a squirrel cage fan. The baffle either tapers continuously from one side of the fan outlet to the other side of the outlet, or is a rectangular insert with a plurality of holes that increase in size from one end to the other end of the baffle.
U.S. Pat. No. 3,687,360 also provides a noise suppressing baffle in a discharge duct. Prew's triangular baffle is inserted within the duct, proximate a chamber housing rotating blades (i.e., a centrifuge chamber). The baffle changes the effective shape of the opening between the duct and the chamber to a trapezoid, and further provides a gradual increase in cross-sectional area of the duct. This change in cross-section decreases velocity of material being discharged into the duct, in order to reduce tendency of the material to build up on walls of the duct.
SUMMARY
In an embodiment, an acoustic baffle for reducing noise of a centrifugal fan includes a base for mounting with a fan outlet. A projection extends from the length of the base at a back side of the base, and curves away from a top surface of the base. The projection continuously tapers from the base to an apex that aligns with a center line of the base. When the acoustic baffle is installed in the outlet, the projection extends over the fan wheel and tapers from left and right sides of the outlet to a fan tangency point at a midpoint of the outlet.
In an embodiment, an acoustic baffle for reducing noise of a centrifugal fan includes a base for mounting with a fan outlet. A projection extends from the length of the base at a back side of the base and curves away from a top surface of the base. The projection includes opposing left and right sides that are parallel to or aligned with left and right sides of the base, and an internal cutout forming a trough. A center point of the trough aligns with a center line of the base. Ends of the left and right sides opposite the base form left and right apices of the internal cutout. Opposing inner sides of the projection defining the cutout continually taper from the trough to the apices. When the acoustic baffle is installed in the outlet, the projection extends over the fan wheel and the left and right sides of the projection continually widen from left and right fan tangency points to the trough.
In an embodiment, an acoustic baffle for reducing noise of a centrifugal fan includes a base for mounting with a fan outlet. A projection extends from the length of the base at a back side of the base and curves away from a top surface of the base. The projection continuously tapers along at least one side, from an area proximate the base to an apex. The apex aligns with a fan tangency point, and the apex or a trough of the projection aligns with a midpoint of the outlet, when the acoustic baffle is installed in the outlet.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top, perspective view of an acoustic baffle having a linear, spike shape, according to an embodiment.
FIG. 2 is a top perspective view of an acoustic baffle shaped as a non-linear spike, according to an embodiment.
FIG. 3 is a top perspective view of an acoustic baffle shaped having a linear, vee shape, according to an embodiment.
FIG. 4 is a top perspective view of an acoustic baffle shaped as a non-linear vee, according to an embodiment.
FIG. 5 is a front view of a centrifugal fan with the baffle of FIG. 2 installed proximate the blower outlet, according to an embodiment.
FIG. 6 is a perspective view of the fan and installed baffle of FIG. 2 .
FIG. 7 is a cross-sectional view of a prior art centrifugal fan.
FIG. 8 is a cross-sectional view of the fan of FIG. 7 showing an installed acoustic baffle that lacks a fan case extension, according to an embodiment.
FIG. 9 is a cross-sectional view of the fan and baffle of FIG. 8 with a fan case extension, according to an embodiment.
FIG. 10 is a graph showing exemplary reduction of fan blade passage tones by the baffles of FIGS. 1-4 .
FIG. 11 is a graph similar to that of FIG. 10 , but illustrating level of tone reduction by the baffles of FIGS. 1-4 from a baseline level.
FIG. 12 is an exemplary bar graph comparing maximum fan blade passage tone levels achieved with the baffles of FIGS. 1-4 with a baseline level.
FIG. 13 is a graph comparing static pressure with evaporator flow rate, and illustrating performance of the baffles of FIGS. 2-4 as compared to baseline and distribution duct flow.
FIG. 14 is a partial view of the graph of FIG. 13 , further illustrating impact of the baffles of FIGS. 2-4 on evaporator flow rate.
DETAILED DESCRIPTION
FIG. 1 shows an acoustic baffle 100 having a base 102 for attaching with the outlet of a blower or fan (hereinafter, fans and blowers are referred to collectively as “a fan” or “the fan”). A spike-shaped extension 104 extends into the fan discharge or blast area and partially over a fan wheel or impeller of the fan, when baffle 100 is secured in the outlet. At least a back side 106 of spike extension 104 (alternately, most or all of spike extension 104 ) is curved or bent to conform to exterior geometry of the impeller. A fin 108 extends from a front surface 110 of spike extension 104 (and optionally, from base 102 as well) and tapers from base 102 to an apex 112 of extension 104 . Fin 108 may be formed with spike extension 104 and/or base 102 (for example, where baffle 100 is molded from plastic or other flowable material), or extension 104 may be formed as a separate part and attached with spike extension 104 and/or base 102 . Spike extension 104 and fin 108 effect a gradual change in airflow from the impeller to the outlet, in contrast to the sudden change in radial and tangential airflow typical at the outlet of a centrifugal fan.
At least one sidewall 114 provides an attachment point for bolting or otherwise fastening baffle 100 in the fan outlet. Base 102 may include a terminal lip 116 for extending over a bottom edge or end of the fan outlet, to facilitate positioning of baffle 100 with the outlet. Although not shown, base 102 , sidewall 114 and/or lip 116 may form openings for hardware to secure baffle 100 in place. An optional joiner 117 may be included to reinforce or stiffen the junction of sidewall 114 with base 102 and spike extension 104 .
A fan case extension 118 may be included on a bottom surface 119 of base 102 , for filling a gap between the fan impeller and the fan scroll cut off/blower case. Fan case extension 118 may include a longitudinal ridge 120 for fitting with the fan scroll cut off, to facilitate proper positioning of baffle 100 within the blower outlet. Fan case extension 118 tapers from bottom surface 119 to an end 121 , for example forming a roughly triangular shape, although shape of fan case extension 118 may vary depending on geometry of a gap to be filled.
In one aspect, a back side 122 of fan case extension 118 continues the curvature of back side 106 of spike extension 104 . In another aspect, back side 122 essentially forms an obtuse angle with back side 106 . When baffle 100 is secured with a fan outlet, fan case extension 118 fills in gaps that could otherwise remain between baffle 100 and the fan scroll cut off, thus enhancing acoustic performance of baffle 100 . A front side 123 of fan case extension 118 is curved or otherwise shaped for fitting with a blower case proximate the cut off, as shown in FIG. 9 (described below).
It will be appreciated that geometry of back side 106 and back side 122 , as well as length and width of baffle 100 and dimensions of fin 108 may vary depending upon dimensions of the fan to be outfitted with baffle 100 . It will also be appreciated that geometry of fan case extension 118 may vary depending upon dimensions of the fan to be outfitted with baffle 100 . For example, an angle between back side 106 and back side 122 may be determined based upon dimensions of an existing fan case, such that apex 112 is a minimal distance from the fan scroll without interfering with the fan scroll during service or use. Base 102 may also include a cutout 124 , dimensions and placement of which may also vary to accommodate preexisting features of the fan outlet.
Left and right sides 128 and 130 of spike extension 104 may taper from base 102 to apex 112 in a linear manner, as shown in FIG. 1 , or sides 128 and 130 may feature a non-linear taper from base 102 to apex 112 , as shown with respect to baffle 150 , FIG. 2 .
FIG. 2 shows an acoustic baffle 150 , which is similar to baffle 100 . Where baffle 100 has linearly tapering sides 128 and 130 , baffle 150 includes non-linearly tapering left and right sides 132 , 134 . That is, sides 132 and 134 taper from base 102 to apex 112 in a non-linear manner. Identical features of baffles 100 and 150 are noted using the same reference numbers.
FIGS. 3 and 4 show acoustic baffles 200 and 250 , respectively. Baffles 200 and 250 share multiple identical features, which are denoted with the same reference numbers from one drawing to the other. Baffles 200 and 250 each have a base 202 , which is similar to base 102 , described above. A v-shaped (“vee” shaped) extension 204 extends from base 202 and shaped to conform to exterior geometry of a fan impeller when baffle 200 / 250 is secured in the fan outlet. In particular, at least a back side 206 of vee extension 204 is curved or bent to conform to exterior curvature of the impeller. Left and right fins 208 , 209 extend from left and right sides 228 and 230 of vee extension 204 , forming sidewalls of extension 204 . Hereafter, fins 208 and 209 may be referred to as sidewalls 208 and 209 .
Fins/sidewalls 208 and 209 taper in height from base 202 to opposing left and right apices 212 and 213 of vee extension 204 . Sidewalls 208 and 209 may be formed with vee extension 204 , for example where baffle 200 / 250 is molded from plastic or other flowable material), or sidewalls 208 and 209 may be formed as separate parts and attached with vee extension 204 and/or base 202 . The junction of sidewall 208 or 209 with base 202 and a respective sidewall 214 of base 202 may be reinforced or stiffened with an additional joiner 217 . In one aspect, sidewall 214 and sidewall 208 or 209 form a continuous sidewall, for example where baffle 200 / 250 is formed as a unitary piece. Joiner(s) 217 may be added if stiffening or reinforcement is desired. Like spike extension 104 and fin 108 ( FIGS. 1 and 2 ), vee extension 204 and sidewalls 208 and 209 effect a gradual change in airflow from the impeller to the outlet.
Sidewall(s) 214 extend from base 202 and provide an attachment point for bolting or otherwise fastening baffle 200 / 250 in the fan outlet. Base 202 may also include a terminal lip 216 for extending over a bottom edge or end of the fan outlet, to facilitate positioning of baffle 200 with the outlet. Although not shown, base 202 , sidewall 214 , one or both of sidewalls 208 and 209 and/or lip 216 may form openings for hardware to secure baffle 200 / 250 in place.
A fan case extension 218 extends from a bottom surface 219 of base 202 , for filling a gap between the fan impeller and the fan scroll cut off/blower case, when baffle 200 / 250 is installed in a centrifugal fan. Fan case extension 218 may include a longitudinal ridge 220 for fitting with the fan scroll cut off, to facilitate positioning of baffle 100 within the blower outlet. Fan case extension 218 tapers from bottom surface 219 to an end 221 , for example forming a roughly triangular shape, although shape of fan case extension 218 may vary depending on geometry of a gap to be filled.
In one aspect, a back side 222 of fan case extension 218 continues curvature of back side 206 of vee extension 204 . In another aspect, back side 222 essentially forms an obtuse angle with back side 206 . When baffle 200 / 250 is secured with a fan outlet, fan case extension 218 fills a gap that could otherwise remain between baffle 200 / 250 and the fan scroll cut off, thus enhancing acoustic performance. A front side 223 of fan case extension 218 is curved or otherwise shaped for fitting with a blower case proximate the cut off (see, e.g., baffle 150 in housing 314 , FIG. 9 ).
It will be appreciated that geometry of back side 206 and back side 222 , as well as length and width of baffle 200 / 250 and dimensions of sidewalls 208 and 209 may vary depending upon dimensions of the fan to be outfitted with baffle 200 / 250 . It will also be appreciated that geometry of fan case extension 218 may vary depending upon dimensions of the fan to be outfitted with baffle 200 / 250 . For example, an angle between back side 206 and back side 222 may be determined based upon dimensions of an existing fan case, such that left and right apices 212 , 213 are a minimal distance from the fan scroll without interfering with the fan scroll during service or use. Base 202 may also include a cutout 224 , dimensions and placement of which may also vary to accommodate preexisting features of the fan outlet.
Vee extension 204 of baffle 200 ( FIG. 3 ) has inner, left and right sides 232 and 234 that taper from apices 212 and 213 (respectively) to a trough 236 in a linear manner Vee extension 204 may alternately feature a non-linear taper of its opposing internal sides. Baffle 250 , FIG. 4 includes inner left and right sides 236 and 238 , which taper from apices 212 and 213 to base 202 in a non-linear manner.
Baffles 100 , 150 , 200 and 250 may be made of any material or materials that are compatible with the fan to be outfitted. In one aspect, baffles 100 - 250 are made of plastic, such as a thermoformed plastic. Fan case extensions 118 , 218 may be integral to baffles 100 , 150 and 200 , 250 , respectively, or fan case extensions 118 , 218 may be formed of the same or another material and attached with their respective acoustic baffles.
FIGS. 5 and 6 show a centrifugal fan 300 with baffle 150 (with a non-linear spike extension 104 , as shown in FIG. 2 ) installed in an outlet 302 . FIGS. 5 and 6 are best viewed together with the following description.
Base 102 of baffle 150 is sized to span a width w 0 of the outlet, for example fitting over or with a cut off of fan 300 (shown in FIGS. 7-9 ) via features 118 - 120 . Extension 104 extends over and conforms to curvature of an impeller 304 of fan 300 (at least along back side 106 ). When baffle 150 is in place, extension 104 tapers over impeller 304 from opposing sides 306 and 308 of outlet 302 to a midpoint 310 of outlet 302 (i.e., a point halfway between sides 306 and 308 , shown marked as a half point of width w 0 ). Apex 112 overlies (but does not touch) impeller 304 proximate a fan tangency point 312 (see FIGS. 8 and 9 ). Fin 108 of extension 104 tapers from base 102 , proximate the fan cut off, to apex 112 proximate tangency point 312 . Thus, baffle 150 smoothes changes in both radial and tangential airflow at outlet 302 to reduce fan noise (known as the fan blade passage tone).
FIGS. 7-9 are cross-sectional views of a fan scroll/housing 314 , taken along line A-A (see FIG. 6 ). FIG. 7 shows outlet 302 without an acoustic baffle. FIG. 8 shows outlet 302 fitted with baffle 150 , with fan case extension 118 removed for purposes of viewing a gap at the fan scroll cut off. FIG. 9 shows outlet 302 fitted with baffle 150 and showing fan case extension 118 . It will be appreciated that although baffle 150 is shown and described with respect to fan 300 /housing 314 , baffles 100 , 200 or 250 may also fit with fan outlet 302 to provide noise reduction as described herein.
FIGS. 7-9 are best viewed together with the following description. Note the relatively large gap between impeller 304 and fan scroll cut off 318 in FIG. 7 , whereas, in FIG. 8 , the gap is reduced by baffle 150 . Baffle 150 extends out over impeller 304 to fan tangency point 312 and gradually varies the flow area of outlet 302 after tangency point 312 (for example, via tapering left and right sides 128 and 130 , and via tapering fin 108 ). However, in FIG. 8 , a reduced gap 316 between baffle 150 and a fan scroll cut off 318 remains unfilled.
In FIG. 9 , baffle 150 includes fan case extension 118 , which fills gap 316 . Baffle 150 and fan case extension 118 together encase impeller 304 . In laboratory tests, filling gap 316 improved acoustic performance of baffle 150 by up to about 50%. As shown, fan case extension 118 is somewhat triangular in cross section; however, shape of fan case extension 118 / 218 may vary according to a gap to be filled.
Fan blade passage tone (objectionable fan noise) is dependent upon the quantity of fan blades in the fan impeller, and the speed of the fan. The fan blade passage frequency, which generates the objectionable noise, can be calculated as follows:
Frequency Fan ( Hz ) = RPM Fan 60 Eq . 1 Frequency FanBladePassage ( Hz ) = Frequency Fan × FanBladeQuantity Eq . 2
Once the fan blade passage frequency is known, it may be isolated during acoustic surveys of the fan, and overall effectiveness of an acoustic baffle may be measured.
FIGS. 10-14 are graphs showing experimental results obtained in testing acoustic baffles 100 and 200 . Turning first to FIG. 10 , graph 1000 plots evaporator fan blade passage tone (dB) against fan blade passage frequency (Hz). Line 1002 shows baseline fan blade passage tone of a fan without an acoustic baffle, at frequencies from about 900 Hz to about 2,550 Hz. Line 1004 illustrates fan blade passage tone of a fan outfitted with baffle 200 or 250 at these same frequencies. Line 1006 illustrates fan blade passage tone of a fan outfitted with linear tapered baffle 100 , again at frequencies between about 900 Hz and about 2,550 Hz. Line 1008 shows, at these frequencies, fan blade passage tone of a fan outfitted with non-linear tapered baffle 150 .
As shown, at 1500 Hz, a non-baffled fan produced a fan blade passage tone of about 100 dB. In contrast, a fan outfitted with baffle 200 / 250 produced about 89 dB of noise. A fan outfitted with baffle 100 produced about 83 dB fan blade passage tone, and a fan outfitted with baffle 150 produced about 81 dB.
FIG. 11 features a graph 1100 showing reduction of fan blade passage frequency from baseline 1002 ( FIG. 10 ). Line 1104 shows reduction by baffle 200 / 250 , line 1106 shows reduction by baffle 100 , and line 1108 shows reduction by baffle 150 . At 1500 Hz, baffle 200 / 250 reduced fan blade passage tone by about 11 dB. Baffle 100 reduced tone by about 17 dB, and baffle 150 reduced fan blade passage tone by about 19 dB. At about 2,100 Hz, baffles 100 / 150 achieved about a 1 dB reduction in fan blade passage tone, whereas baffles 200 / 250 reduced tone by about 11 dB.
FIG. 12 shows a bar graph 1200 illustrating maximum evaporator fan blade passage tone level over a fan speed sweep of 600-5,700 RPM. Over this range, the maximum baseline (baffle-free fan) passage tone level was 100 dB. Bar 1202 represents the baseline. At this tone, baffles 100 and 150 , represented by bars 1206 and 1208 , respectively, reduced noise by about 17 dB. Baffles 200 and 250 , represented by bar 1204 achieved about an 11 dB reduction.
Experimental results suggest that overall, “spike” style acoustic baffles such as baffles 100 and 150 have better noise reduction in the 1,200-1,700 Hz fan blade passage frequency, while “vee” style baffles 200 and 250 have better noise reduction in the 2,100-2,600 Hz fan blade passage frequency.
Inclusion of baffle 100 , 150 , 200 or 250 in the blower outlet of a centrifugal fan (i.e., outlet 302 of fan 300 ) results in minimal reduction of flow into the distribution duct (e.g., a duct attached at outlet 302 ). Impact on blower flow rate was calculated by measuring the static pressure at multiple flow rates for a baseline configuration, and with the acoustic baffles installed. FIG. 13 shows a graph 1300 that plots static pressure (InH 2 O) against flow rate (ACFM). Line 1302 is a baseline depicting flow rate of a baffle free fan. Line 1304 shows flow rate of a fan outfitted with vee-style baffle 200 or 250 . Line 1308 illustrates flow rate of a fan outfitted with baffle 150 . Line 1309 illustrates flow within a distribution duct of the fan. Data collected from fans outfitted with acoustic baffles 150 or 200 / 250 (lines 1308 and 1304 ) was compared with the distribution duct performance (line 1309 ) and flow losses calculated. FIG. 14 is a graph 1400 that shows losses using baffle 150 and baffle 200 / 250 . Line 1402 represents a 5,700 RPM baseline, while line 1404 represents a fan with baffle 200 / 250 and line 1408 represents the fan with baffle 150 installed. Line 1409 shows flow within the distribution duct. With baffle 150 installed, a 4.5 cfm loss was measured at 5,700 RPM. A 6.0 cfm loss in flow at 5,700 RPM was measured with baffle 200 / 250 in place. These losses amount to a 2.27% reduction in flow with baffle 150 , and a 3.02% reduction with baffle 200 / 250 . The measured losses minimally impact performance of the centrifugal fan, and are well outweighed by gains in acoustic performance (see FIGS. 10-12 ).
Certain changes may be made in the above systems and methods without departing from the scope hereof. For example, features and use shown or described with respect to one of baffles 100 - 250 may be incorporated into or pertain to another of baffles 100 - 250 . Thus, it is intended that all matter contained in the above description or shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. It is also to be understood that the following claims are to cover generic and specific features described herein, and all statements of the scope of the invention which, as a matter of language, might be said to fall there between.
|
An acoustic baffle for reducing noise of a centrifugal fan includes a base for mounting with a fan outlet and a projection extending from the length of the base at a back side of the base and curving away from a top surface of the base. The projection continuously tapers from the base to an apex that aligns with a center line of the base. The projection extends over the fan wheel and tapers from left and right sides of the outlet to a fan tangency point at a midpoint of the outlet and aligned with the apex, when the acoustic baffle is installed in the outlet. The acoustic baffle effects a gradual variation in radial and tangential airflow at the blower outlet, to reduce fan blade passage tone.
| 5
|
BACKGROUND OF THE INVENTION
The present invention relates to the employment of molecular crystals as bactericidal, viricidal and algicidal devices, but more particularly to the molecular crystal semiconductor tetrasilver tetroxide Ag 4 O 4 which has two trivalent and two monovalent silver atoms per molecule, and which through this structural configuration enables electronic activity on a molecular scale capable of killing algae and bacteria via the same mechanism as macroscale electron generators. The concept of molecular scale semiconductor devices for the storage of information has been the subject of much activity in recent years so that the concept of a molecular scale device performing such functions as storing information or acting as resistors, capacitors or photovoltaic devices is well accepted. The molecular device of this invention is a multivalent silver diamagnetic semiconductor. The bactericidal activity of soluble divalent silver (Ag II) complex bactericides is the subject of U.S. Pat. No. 5,017,295 of the present inventor. The inventor has also been granted U.S. Pat. Nos. 5,078,902, 5,073,382, 5,089,275, and 5,098,582, which all deal with Ag II bactericides but more particularly with (respectively) halides, alkaline pH, stabilized complexes and the divalent oxide. It is U.S. Pat. No. 5,098,582, and its perfection that has led to the present invention. This patent designated AgO as divalent silver oxide, the popular name of the compound. Indeed, the Merck Index (11th Edition) designates the oxide as silver(II) oxide (AgO) (entry 8469). However, it also states that it is actually a silver(I)-silver(III) oxide with a molecular weight of 123.88. After filing my patent application, a comprehensive examination was begun of information relating to the structure of this oxide. Further investigation of the scientific literature revealed that said oxide was actually on a molecular level Ag 4 O 4 where one pair of silver ions in the molecule was trivalent and another pair was monovalent. Said oxide is actually on a molecular level Ag 4 O 4 where one pair of silver ions in the molecule is trivalent and another pair is monovalent.
While the formula AgO accurately designates the silver:oxygen ratio, the molecular weight of the compound is actually 495.52. Further elucidation of the molecule's electromagnetic properties revealed that it is a diamagnetic semiconductor. The structure is electronically active because of the trivalent sp 2 electron configuration disparity of the electrons within the crystal. The oxide as presented in my patent was actually capable of killing 100% of standardized E. coli and Strep. faecalis colonies in less than five minutes at concentratiors of 0.5 PPM. My independent evaluations of this oxide in areas unrelated to water treatment resulted in the "molecular device" concept which was substantiated by submission of the oxide for testing with a preferred embodiment of the invention (10 PPM of sodium persulfate) at an Environmental Protection Agency (EPA) certified laboratory which revealed that 0.5 PPM of oxide only yielded 0.003 PPM of silver in solution, a silver concentration entirely too low to cause this level of bactericidal activity. Indeed, the killing of the bacteria was analogous to that obtained by electron generating devices utilized in swimming pools or water towers for killing bacteria. It was therefore postulated that the oxide efficacy at low concentrations could only be attributed to regarding each oxide molecule as a device. Further testing was continued on algae and viruses. The accumulated data of efficacy at low concentrations, coupled together with a reinterpretation of silver oxide efficacy, has led to the final development of this invention, namely, a molecular device for killing algae, bacteria and viruses in utilitarian water bodies, such as swimming pools.
OBJECTS OF THE INVENTION
The main object of this invention is to provide for a molecular scale device of a single tetrasilver tetroxide semiconductor crystal capable of killing viruses, bacteria, and algae when operating in conjunction with other such devices.
Another object of the invention is to provide for a device which is so small that several thousand trillion can be added to a water supply to perform their effective functions and still be effective at concentrations of the devices in said supply not exceeding one part per million.
Still another object of the invention is to provide for a device which will perform the aforementioned anti-pathogenic functions without polluting the water supplies it is intended to purify, such as swimming pools, industrial cooling towers, hot tubs and municipal water supplies.
Still another object of the invention is to provide for a device which can be employed in swimming pools, hot tubs and other environments for these aforementioned functions in the presence of humans, without causing them respiratory and eye irritations and other nuisance effects characteristic of active sanitizers based on halogens such as chlorine, one such nuisance affect being the deterioration of bathing suits.
Other objects and features of the present invention will become apparent to those skilled in the art when the present invention is considered in view of the accompanying examples. It should, of course, be recognized that the accompanying examples illustrate preferred embodiments of the present invention and are not intended as a means of defining the limits and scope of the present invention.
SUMMARY OF THE INVENTION
This invention relates to a molecular scale device capable of destroying gram positive and gram negative bacteria as well as viruses and algae. Said molecular scale device consists of a single crystal of tetrasilver tetroxide. Several hundred thousand trillion of these devices may be employed in concert for their bactericidal, viricidal, and algicidal properties and applied to industrial cooling towers, swimming pools, hot tubs, and municipal water supplies.
The molecular crystals which are the subject of this invention are commercially available and can be prepared by reacting silver nitrate with sodium or potassium peroxydisulfate according to the following equation:
4AgNO.sub.3 +2Na.sub.2 S.sub.2 O.sub.8 +8NaOH=Ag.sub.4 O.sub.4 +4Na.sub.2 SO.sub.4 +4NaNO.sub.3 +4H.sub.2 O
The oxide lattice represented by the formula Ag 4 O 4 is depicted in the Drawing FIG. 1. It is a semiconducting electron active diamagnetic crystal containing two monovalent and two trivalent silver ions in combination with four oxygen atoms. The distance between the Ag(III)-O Ag(I)O units equals 2.1 A. Ag(III)-Ag(III)=Ag(I)-Ag(I)=3.28A and Ag(I)-Ag(III)=3.19 A. Each trivalent silver ion is coordinated via dsp 2 electron bonds to 4 oxygen atoms. The depiction of this lattice is based on several literature references relating to crystallographic studies. Exemplary of this literature are J. A. McMillan's studies appearing in Inorganic Chemistry 13,28 (1960); Nature vol. 195 No. 4841 (1962), and Chemical Reviews 1962, 62,65. Alvin J. Salkind elucidated studies involving neutron diffraction with his coworkers (J. Ricerca Sci. 30, 1034 1960) proving the Ag(III)/Ag(I) nature of this molecule and states in his classic entitled Alkaline Storage Batteries (Wiley 1969), coauthored with S. Uno Falk, that the formula is depicted by Ag 4 O 4 (page 156).
That same year a scientific communication appeared in Inorganic Nuclear Chemistry Letters (5,337) authored by J. Servian and H. Buenafama which maintained that their neutron diffraction studies also confirmed the tetroxide lattice and the presence cf Ag(III) and Ag(I) bonds in the lattice, a conclusion also reported previously by Naray-Szahn and Argay as a result of their x-ray diffraction studies (Acta Cryst. 1965, 19,180). Thus the effects of this invention can be explained in terms of these structural elucidations, namely, that the single molecular semiconductor crystal which inevitably must be electronically active exchanging two electrons per crystals between its mono and trivalent bonds is in reality a device which kills pathogens in the same manner as electrically active large-scale devices utilized in water supplies.
When the tetroxide crystals are utilized to destroy pathogens, they will not do so unless activated by an oxidizing agent. This is analogous to the behavior of single semiconducting photovoltaic molecular devices such as copper indium selenide whose surfaces must be "etched" in order to activate the photovoltaic activity, i.e., for light to facilitate the release of electrons from the molecule. The tetroxide was activated by persulfates. It was found that when the persulfates were tested as a control by themselves, they failed to exhibit any unilateral antipathogenic activity at the optimum level selected of 10 PPM. The persulfates evaluated varied from OXONE (Registered Trademark Du Pont Company) brand potassium monopersulfate to alkali peroxydisulfates.
DESCRIPTION OF THE DRAWING
In the drawing which illustrates the best mode presently contemplated for carrying out the present invention:
FIG. 1 is a diagrammatic view showing the molecular crystal Ag 4 O 4 attacking a pathogenic bacillus.
DESCRIPTION OF THE INVENTION
Turning now to Drawing FIG. 1 depicting the crystal lattice of Ag 4 O 4 , the device operates by transferring electrons from the monovalent silver ions 10 to the trivalent silver ions 11 in the crystal 20 through the aqueous media in which it is immersed and which conducts electrons depicted by the path 12, contributing to the death of pathogen 13 with electrons 14, traversing the cell membrane surface 15, said pathogen being "electrocuted" by not only these electrons but by others: 16 and 17 following paths 18, and 19 emanating from other molecular devices in the vicinity of the pathogen. Drawing FIG. 1 exaggerates the size of the silver oxide molecular device with respect to that of a microorganism for depiction purposes only. The device is attracted to the cell membrane surface 15 by powerful covalent bonding forces 21 caused by the well-known affinity of silver to certain elements present in the membrane, such as sulfur and nitrogen.
The electron transfer can be depicted by the following half reactions in which the monovalent silver ion loses an electron and the trivalent silver gains one as follows:
Ag.sup.+ -e=Ag.sup.+2
Ag.sup.+3 +e=Ag.sup.+2
The molecular crystal then will become stabilized with each silver ion having a divalent charge.
The molecular device was evaluated in concentrations ranging from 0.5 to 5.0 PPM on mixed gram positive and gram negative cultures and mixed coliforms for evaluation in conjunction with EPA protocols for swimming pools in the presence of 10 PPM sodium persulfate. It killed 100% of colonies of Streptococcus faecalis and E. coli within three minutes at 0.5 PPM. The EPA requirement is within ten minutes. The colony concentrations were 100,000/cc.
In order to consider the possibility that silver ions escaping the crystal device may have had an influence on the bactericidal properties of the device especially if those silver ions were of a higher valence state facilitated by the persulfate according to the reaction:
AgO+H.sub.2 O=Ag.sup.+2 +2OH.sup.-
Ag 4 O 4 crystals were sent to an independent EPA certified testing laboratory together with sodium persulfate with specific instructions to prepare Ag 4 O 4 suspensions in 10 PPM persulfate at various concentrations. The preparations were made in one-liter volumetric flasks utilizing 0.5 mg and other concentrations /L of Ag 4 O 4 , where the concentration of mg. per liter equals parts per million of the oxide. After vigorous mixing of the oxide crystals in the flasks, the solutions were allowed to remain undisturbed for 24 hours. After that time period the supernatant liquid was analyzed for silver utilizing atomic absorption spectroscopy with inductively coupled plasma. At 0.5 PPM Ag 4 O 4 there was only silver found equivalent to 0.003 PPM. This concentration is so low that even if it were speculated that the ions were in a higher valence state, they could never even then be considered bactericidal. Indeed, the inventor's U.S. Pat. No. 5,017,295 involving divalent silver bactericides claims these compounds at the lowest silver ion concentration of 0.5 PPM.
If we are to consider one molecular device in operation, then each molecule would release two electrons having each a charge of 4.8×10 -10 e.s.u. equivalent to approximately 1.6×10 -19 coulombs. The EMF given in my Encyclopedia of Chemical Electrode Potentials (Plenum 1982), page 88, for the oxidation of Ag(I) to Ag(II) is 1.98 volts which approximates 2.0 V. The total power output per device can be calculated in watts by multiplying the power output for each electron by 2. Since power is the product of the potential times the charge, P=EI; for each electron it would be
2.0×1.6×10.sup.-19 =3.2×10.sup.-19 watts
From this, and using Avogadro's number, we can calculate that the power flux of one liter of solution containing 0.5 PPM of devices would be 0.064 watts. Since the electronic charges of the devices are directly proportional to the number of devices in solution, i.e., the concentration of the oxide in the solution, we can arbitrarily assign our own device power flux constant which can be used to gauge the concentrations of the devices required in order to kill particular organisms in specific environments. I have found the following formula useful for this purpose:
Power Flux=EMF generated per molecule×Concentration×5
(the EMF being 4.0 volts per molecular device times the concentration in PPM). Utilizing this formula, the power flux to effectuate 100% kills for E. coli and Streptococcus faecalis is equal to 6.0.
Tests were conducted to see whether the molecular crystals posed any harm to the human body. Accordingly, a 3% concentrate of the crystals was prepared for a series of evaluations.
The first evaluation met the requirements of Code of Federal Regulations (CFR) 40 part 160 which consisted of determining the single dose toxicity in rats or LD 50 . All the animals survived so that the LD 50 was greater than 5.0 g./Kg. This was true for concentrations of crystals of a magnitude of 6-60,000 times the actual concentrations that would be used in its utilization. This test classified the device as a category IV substance according to EPA protocols.
The second evaluation was for acute dermal toxicity in rabbits. The protocol, 40 CFR 158.135, 81-2, was to determine the LD 50 for dermal application. All animals survived the maximum dose 2.0 g/Kg., classifying the
crystals as category III with a dermal LD 50 greater than 2000 mg/Kg.
The third evaluation, entitled "Primary Dermal Irritation in Albino Rabbits", conformed to 40 CFR 160. It consisted of exposing the rabbits for prolonged periods of time and observing edema, erythema, ulceration, necrosis and any other evidence of dermal reactions or tissue destruction. There were none, classifying the crystal concentrate as a category IV dermal agent by EPA criteria.
The fourth evaluation dealt with primary eye irritation. This also was in conformity with 40 CFR part 160. There was absolutely no eye irritation when the crystal concentrate was applied, classifying it as a category IV substance with regard to eye effects according to EPA criteria.
The concentrate submitted for these evaluations, i.e., the 3% suspension of crystals, represented a concentration 1.50% times as great as the end product intended for commercialization, namely, a 2% suspersion of silver oxide crystals.
The crystals were also evaluated by monitoring their performance over a period cf time at various concentrations. Periodically, water samples were taken and shipped in a refrigerated state for bacterial counts. Accordingly, the device performed in concert with its attendant devices in full conformity with the ultimate objects of this invention.
Other objects and features of the present invention will become apparent to those skilled in the art when the present invention is considered in view of the accompanying examples. It should, of course, be recognized that the accompanying examples illustrate preferred embodiments of the present invention and are not intended as a means of defining the limits and scope of the present invention.
EXAMPLE 1
Tetrasilver tetroxide (Ag 4 O 4 ) crystals were prepared by modifying the procedure described by Hammer and Kleinberg in Inorganic Syntheses (IV,12). A stock solution was prepared by dissolving 24.0 grams of potassium peroxydisulfate in distilled water and subsequently adding to this 24.0 of sodium hydroxide and then diluting the entire solution with said water to a final volume of 500 ml. Into 20 ml. vials were weighed aliquots of silver nitrate containing 1.0 g. of silver. Now 50 ml. of the aforementioned stock solution were heated in a 100 ml. beaker, and the contents of one of the vials was added to the solution upon attaining a temperature of 85° C. The beaker was then maintained at 90° C. for 15 minutes. The resulting deep black oxide obtained consisting of molecular crystal devices was washed and decanted four times with distilled water in order to remove impurities. The purified material was collected for further evaluation and comparison with commercial material. The commercial material was purchased from Johnson Matthey's Catalog Chemicals Division of the Aesar Group of Ward Hill, Massachusetts, under product code 11607 and generically listed in its materials Safety Data Sheet as both silver peroxide and silver suboxide, having a purity of 99.9%.
Both the prepared and commercial device crystals were submitted for bactericidal evaluation following "good laboratory practice" regulations as set forth in Federal Regulations (FIFRA and ffdca/40 CFR 160, May 2, 1984). The protocols consisted of exposures to Streptococcus faecalis, a gram positive pathogenic bacillus utilizing AOAC (15th) 1990:965:13: at colony densities of 100 000 colonies/cc. and two exposure times of five and ten minutes. The devices were tested at concentrations of 0.3, 0.5 and 1.0 PPM in distilled water adjusted to pH=7.5 and containing Oxone (Registered Trademark Du Pont Company), which is potassium monopersulfate at a level of 10 PPM. The evaluations were repeated at the same persulfate concentration utilizing commercial grade sodium persulfate manufactured by FMC. 100% kills were actually obtained after three minutes at all the aforementioned device concentrations, there being actually zero colonies at the 0.5 and 1.0 PPM levels after five minutes and at the 0.3 PPM level after ten minutes. Analogous testing employing the same colony density of the gram negative bacillus E. coli were carried out. The same results were obtained. EPA criteria require that 100% kills be obtained within ten minutes for a substance to meet EPA criteria for swimming pool utilizatior. In this case, the devices at 0.3 PPM, equivalent to approximately 360,000 trillion devices, were able to far exceed EPA criteria for sanitizing a swimming pool.
EXAMPLE 2
Commercial grade silver oxide prepared according to the method of Example 1, but which is actually the tetrasilver tetroxide molecular devices were tested in a swimming pool under actual-use conditions. The swimming pool contained approximately 27,000 gallons of water. The level of the device crystal concentration was maintained at 1.0-1.5 PPM. The swimming pool was periodically monitored by removing water samples for pH, silver calcium, algae and bacteria. The swimming pool was utilized on a daily basis over a period of six weeks by an average number of four people per day. The pool was made up fresh with a fresh coating of plaster. The initial pH was 9.7. By the end of the first week, the pH dropped to 8.2. Thereafter the average daily pH of the pool was 7.8. The calcium level of the pool was allowed to rise slowly from an initial 100 PPM to 220-240 PPM. Without any new additions of silver to the solution of the initial 1.5 PPM molecular crystal concentration, the pool had zero bacteria and zero algae. Other extraneous factors were also monitored, such as copper (0.1-0.2 PPM) and iron (initial .0 average .05 PPM), which did not affect the results.
EXAMPLE 3
Tests were performed on residual silver concentration of device crystals in water to see whether the devices could be used to treat municipal drinking water supplies since the devices had proven to be antipathogenic at 0.3 PPM according to Example 1. Now there is no adverse health effect for silver at the present time according to the EPA, and it has been dropped from the 1991 pollutants list according to 56 FR 1470 p.7. A secondary maximum contaminant level for drinking water involving silver was proposed in 1989 (54 FR 22062), May 22, 1989) of 0.1 PPM. The oxidizing agent to activate the crystals for water supplies would be OXONE (Registered Trademark Du Pont Company) or hydrogen peroxide. Accordingly, brand potassium monopersulfate samples of commercial oxide devices of Aesar origin as heretofore described were sent to an EPA certified laboratory for evaluation. The laboratory prepared samples of the devices at concentrations of 0.5, 1.0, 2.0, 5.0 and 10.0 PPM in 10 PPM sodium persulfate solution. The solutions were allowed to stand for 24 hours, after which the supernatant liquid was tested for residual silver content by atomic absorption spectroscopy using inductively coupled plasma as the excitation source. The respective amounts of silver found in the supernatant liquid were respectively 0.003, 0.13, 0.52 and 0.94 PPM. This means that at a concentration of nearly double the pathogenic inhibition requirement level that the secondary silver allowance of 0.1 PPM was hardly reached, which qualifies the devices for drinking water.
EXAMPLE 4
The devices were tested against AIDS virus. The protocol used was that of the Ministry of Health of the State of Israel at their Virology Laboratory located at Tel HaShomer, Israel. AIDS viruses which had been grown in vitro in a tissue culture were isolated and exposed to the devices at device concentrations of 0.05, 1.0, 2.0, 3.0, 5.0 and 10.0 PPM. There was no evidence of AIDS suppression at all until the concentrations reached 5.0 and 10.0 PPM. At 5.0 PPM, 60% of the viruses were killed. AT 10.0 PPM, 75% of the viruses were killed. Extrapolation of this data reveals that at 18.0 PPM there would be total suppression of the virus. These test results indicate that the devices are capable of being used to destroy viruses in applications involving the proliferation and transmittal of the AIDS virus outside of the human body as in cold sterilization.
EXAMPLE 5
An ATTC strain of Chorella was grown in nutrient Medium 866 broth under the required lighting. When optimal growth was reached, the number of organisms per ml. were determined by microscopic count and then subcultured. The molecular crystal devices were applied to the algae at concentrations of 1 and 2 PPM. The algae were left in contact for one hour, one day and ten days. The protocol for these tests involved procedures described in the Water and Waste Water Manual of the United States Public Health Service. The exposure tests involved post inoculation in order to determine whether the devices were algicidal or algistatic. The oxidizing agent for activation was sodium persulfate at a concentration of 10 PPM. The devices were found to be algistatic at 1 PPM and algicidal at 2 PPM after one hour's exposure. After one day and ten days, there were no positive flasks at all. Ten flasks of subculture were utilized for each test, and only one flask was positive out of ten after one hour at 1 PPM.
While there is shown and described herein certain specific examples embodying the invention, it will be manifest to those skilled in the art that various modifications and rearrangements of &he invention may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.
|
A novel molecular scale device is described which is bactericidal, fungicidal and algicidal. The antipathogenic properties of the device are attributed to electron activity indigenous to diamagnetic semiconducting crystals of tetrasilver tetroxide (Ag 4 O 4 ) which contains two monovalent and two trivalent silver ions in each molecular crystal. When the crystals are activated with an oxidizing agent, they release electrons equivalent to 6.4×10 -19 watts per molecule which in effect electrocute pathogens. A multitude of these devices are effective at such low concentrations as 0.3 PPM where they can kill 100% of 100 K/cc Streptococcus faecalis, and E. coli colonies in three minutes meeting the ten-minute EPA criteria of 100% kills within ten minutes for swimming pool and hot-tub applications. The devices can be used in utilitarian bodies of water, such as municipal and industrial water reservoirs.
| 2
|
FIELD OF THE INVENTION
[0001] The invention relates to heat exchangers, especially for motor vehicles, and more particularly to a manifold for a heat exchanger, comprising a manifold plate closed by a wall in such a way as to delimit a chamber into which at least one pipe opens out.
BACKGROUND OF THE INVENTION
[0002] In a manifold of this sort, the manifold plate, which is also called hole plate, possesses a multiplicity of holes in which are accommodated the extremities of tubes which constitute the core of the heat exchanger. Fins contributing to increasing the heat-exchange surface area are associated with these tubes.
[0003] The manifold plate is closed by a wall so as to delimit a chamber which communicates with the tubes in order to allow a fluid to circulate in the core.
[0004] The abovementioned wall is usually equipped with at least one pipe to allow the abovementioned fluid to enter or leave.
[0005] The design of these pipes poses many problems in practice, given that they have to be placed at precise places on the wall depending on the conditions dictated by the placing of the heat exchanger in the vehicle in question.
[0006] Moreover, the pipe has to be shaped in a particular way, for example bent, in order to present an end part extending in a given direction in order for a flexible hose to be fitted over it.
[0007] Manifolds of this sort are already known, in which the manifold plate is of metal, while the wall is molded from plastic with the pipe or pipes which are associated with it.
[0008] In this case, leaktightness between the manifold plate and the wall is ensured by means of a gasket, the manifold plate being equipped with claws which are folded down or crimped against a peripheral rim of the wall.
[0009] The production of such a wall with at least one associated pipe requires molds of complex shapes.
[0010] Manifolds of this sort are also known in which the various elements are metal pieces assembled together by brazing.
[0011] Here again, that poses difficulties in producing and installing the pipe at an appropriate place, especially when this pipe is bent.
[0012] The object of the invention is especially to overcome the abovementioned drawbacks.
SUMMARY OF THE INVENTION
[0013] According to the present invention there is provided a manifold for a heat exchanger, having a manifold plate closed by a wall in such a way as to delimit a chamber into which at least one pipe opens out, and further comprising
[0014] a first part formed from a shaped metal sheet featuring a bottom and two lateral walls folded face-to-face, at least one of which is provided with an aperture in order for a pipe to be affixed there and a second part formed from a shaped metal sheet able to be fitted onto the lateral walls of the first part in order to form a cover opposite the bottom of this first part, wherein one of the first part and the second part comprises the manifold plate, and wherein the first part, the second part and the pipe are assembled by brazing
[0015] It is thus possible to produce all the elements of the manifold, including the pipe, from metal pieces, shaped especially by stamping, which are then assembled by brazing.
[0016] Thus, the constituent elements of the manifold can be brazed in an oven, at the same time as the rest of the heat exchanger, which markedly simplifies the manufacturing operations.
[0017] Advantageously, the two lateral walls of the first part are generally flat and parallel to each other and are connected perpendicularly to the bottom.
[0018] It is advantageous for the two lateral walls of the first part each to include a peripheral groove for accommodating a longitudinal edge of the second part. This contributes to correct temporary holding of the first part and of the second part together.
[0019] In a variant, this temporary holding can be obtained by the fact that the two lateral walls of the first part each include a series of cut-outs delimiting support regions formed in projection from the inner side for accommodating a longitudinal edge of the second part.
[0020] These support regions are preferably each formed by stamping of the lateral walls of the inner side.
[0021] In order to contribute to the holding, it is preferable for each longitudinal edge of the second part to be equipped with projecting studs able to be engaged respectively in the cut-outs of the lateral walls.
[0022] According to yet another characteristic of the invention, the second, cover-forming part is defined by a sheet which is shaped so as to have generatrices generally parallel to each other.
[0023] In a first embodiment of the invention, the manifold plate is included in the bottom of the first part and is connected to the lateral walls, while the second part constitutes a closed cover.
[0024] In this case, the two lateral walls advantageously possess respective face-to-face extensions, at least one of which is provided with an aperture for the pipe.
[0025] In a second embodiment of the invention, the manifold plate is included in the second part, while the bottom of the first part is closed and is connected to the lateral walls.
[0026] In the invention, the first part and the second part are each obtained by stamping and cutting out from a metal sheet. The latter is advantageously a sheet of a material comprising aluminum.
[0027] According to another aspect, the invention relates to a heat exchanger comprising at least one manifold as defined above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] In the description which follows, given solely by way of example, reference is made to the attached drawings, in which:
[0029] [0029]FIG. 1 is an exploded view in perspective of a manifold according to a first embodiment of the invention;
[0030] [0030]FIG. 2 is a view in perspective analogous to FIG. 1 after assembly of the manifold;
[0031] [0031]FIG. 3 is a side view corresponding to FIG. 2;
[0032] [0032]FIG. 4 is a sectional view along the line IV-IV of FIG. 3;
[0033] [0033]FIG. 5 is a top view of the manifold of FIG. 2;
[0034] [0034]FIG. 6 is a sectional view along the line VI-VI of FIG. 5;
[0035] [0035]FIG. 7 is a side view of a manifold, in the assembled state, according to a second embodiment of the invention;
[0036] [0036]FIG. 8 is a sectional view along the line VIII-VIII of FIG. 7;
[0037] [0037]FIG. 9 is a top view corresponding to FIG. 7;
[0038] [0038]FIG. 10 is a sectional view along the line XI-XI of FIG. 9;
[0039] [0039]FIG. 11 is a side view of a manifold, in the assembled state, according to a third embodiment of the invention;
[0040] [0040]FIG. 12 is a top view corresponding to FIG. 11;
[0041] [0041]FIG. 13 is a sectional view along the line XIII-XIII of FIG. 11;
[0042] [0042]FIG. 14 is a sectional view along the line XIV-XIV of FIG. 11;
[0043] [0043]FIG. 15 is a partial view in perspective of the manifold of FIG. 11 before assembly;
[0044] [0044]FIG. 16 represents the detail XVI, on an enlarged scale, of FIG. 15; and
[0045] [0045]FIG. 17 represents the detail of FIG. 16, after assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] In the various figures, like reference numerals refer to like parts, unless otherwise specified.
[0047] The embodiment of FIGS. 1 to 7 will be referred to first of all, in which the manifold comprises a first part 10 and a second part 12 each formed from a metal sheet, advantageously of aluminum, which is shaped by conventional cutting-out and stamping operations.
[0048] The first part 10 includes a bottom 14 which is generally flat and of elongate rectangular shape. This bottom 14 is intended to constitute the manifold plate, also called “hole plate”, of the manifold. This bottom, to that end, includes a plurality of spaced holes 16 of elongate shape intended to accommodate tubes 18 forming part of a heat-exchanger core (FIGS. 1 and 2). In the example, these are flat tubes between which are arranged fins 20 produced in the form of corrugated spacers.
[0049] The sheet 10 further comprises two lateral walls 22 folded face-to-face, which are generally flat and parallel to each other. These walls are connected substantially perpendicularly to the bottom 14 by two fold lines 24 which are parallel to each other.
[0050] The lateral walls 22 are of elongate shape and include, in their central part, respective extensions 26 and 28 arranged face-to-face and each being in a “paper hat” shape. In the example, the extension 26 includes an aperture 30 , while the extension 28 is completely closed. The aperture 30 is of circular shape and is intended to allow fitting of a pipe 32 of circular cross section.
[0051] Each of the lateral walls 22 includes a peripheral groove 34 , which is continuous and ends in two end slots 36 which extend over the width of the bottom 14 .
[0052] These grooves are intended to allow nested fitting of two longitudinal edges 38 of matching shape which the second part 12 includes. This second part is intended to form a cover so as to fit over the lateral walls 22 in such a way that, after nested fitting, these two parts jointly delimit a closed volume which communicates with the tubes of the core.
[0053] The second part 12 is obtained from a metal sheet of given width which possesses parallel generatrices. As can be seen more particularly in FIGS. 1, 3 and 7 , this sheet includes a paper-hat-shaped central part 40 framed by two coplanar parts 42 , which have respective extremities 44 folded at a right angle and able to come to engage in the grooves 36 .
[0054] This second part 12 can thus be nested into the corresponding grooves 34 and 36 of the first part 10 in order to form an assembly (FIG. 2) ready to be brazed at the same time as the pipe 32 .
[0055] It will be understood that it is thus possible, in a single operation, to produce a heat exchanger comprising a core formed by a multiplicity of tubes 18 and of fins 20 , at the same time as one or two manifolds as defined above.
[0056] Referring now to the embodiment of FIGS. 7 to 10 , in this second embodiment the manifold comprises a first part 50 and a second part 52 each formed from a shaped metal sheet, for example of aluminum. The first part 50 features a closed bottom 54 and two lateral walls 56 folded face-to-face. These two lateral walls 56 have a substantially trapezoidal oblong shape and are each delimited by a longitudinal edge 58 , a non-parallel longitudinal edge 60 forming a fold line with the bottom 54 , an end edge 62 and another end edge 64 which is partly rounded. This end edge 64 corresponds to a wider region of the wall 56 in which an aperture 66 is formed for receiving a pipe 68 (FIGS. 9 and 10). The other lateral wall 56 has a matching shape, but does not include an aperture.
[0057] It will be understood that the first part 50 can thus be produced by stamping in order to form a cup-shaped element which comprises the bottom 54 and the two lateral walls 56 . The bottom 54 is defined by mutually parallel generatrices.
[0058] The first part 50 is stamped and thus defines a flat aperture of generally rectangular shape for accommodating the second part 52 . This second part 52 is a metal piece of generally flat shape which here constitutes the manifold plate, also called hole plate, of the manifold. This part 52 thus forms a cover fitting over the first part, but this cover is equipped with a plurality of holes 70 for receiving tubes similar to the tubes 18 represented in FIG. 2.
[0059] Hence, in the embodiment of FIGS. 7 to 10 , the manifold plate is included in the second cover-forming part, whereas in the embodiment of FIGS. 1 to 6 the manifold plate is included in the first part.
[0060] As in the case of the preceding embodiment, the two parts can be produced by conventional operations of cutting out and of stamping.
[0061] In the embodiment of FIGS. 11 to 17 , the manifold comprises a first part 72 and a second part 74 each formed from a shaped metal sheet, for example of aluminum. The first part 72 features a closed bottom 76 and two lateral walls 78 folded face-to-face and connected substantially perpendicularly to the bottom 76 . This bottom 76 forms a manifold plate and is provided with holes 80 (FIG. 15) for receiving tubes similar to those described previously.
[0062] The two lateral walls 78 have an oblong shape and are especially each delimited by a longitudinal edge 82 . The two lateral walls have wider face-to-face regions, which form extensions, and one of which includes an aperture receiving a pipe 84 (FIGS. 11 and 12).
[0063] It will be understood that the first part 72 can thus be produced by stamping in order to form a cup-shaped element which is intended to receive the second part 74 which forms a cover. This second part 74 is formed from a metal sheet with parallel generatrices, which is shaped so as to fit onto the edges of the first part and, in particular, onto the longitudinal edges 82 of the lateral walls 78 .
[0064] The two lateral walls 78 each include a series of cut-outs 86 , of generally rectangular shape, which delimit support regions 88 formed in projection from the inner side for accommodating a longitudinal edge 90 of the second part. These support regions 88 are of generally rectangular shape and are each formed by stamping of the lateral walls 78 of the inner side.
[0065] Each longitudinal edge 90 of the second part 74 is equipped with studs 92 formed in projection and able to engage respectively into the cut-outs 86 of the lateral walls 78 (FIGS. 15 to 17 ). These studs form folded lugs of short length which are lodged partly in the recesses formed on the outer side of the lateral walls because of the stamped support regions (FIG. 13).
[0066] Thus the two parts 74 and 76 are held temporarily in a correct position before brazing.
[0067] As in the case of the two preceding embodiments, the two parts can be produced by conventional operations of cutting out and of stamping.
[0068] After assembling of the two parts and of the pipe, the assembly can be brazed in an oven, at the same time as the rest of the heat exchanger to be manufactured.
[0069] Thus a brazing operation is carried out, during which all the elements of the heat exchanger are brazed, which simplifies the manufacturing operations.
[0070] The invention finds a particular application to the heat exchangers for motor vehicles in order to constitute, for example, a radiator for cooling the engine, or else a radiator for heating the passenger compartment.
[0071] Needless to say, the invention is not limited to the embodiments described above by way of example and extends to other variants.
[0072] In particular, the shaping of the first and second parts is capable of many variations, as is the shape of the lateral walls and the site at which the pipe or pipes is or are installed.
|
Manifold with integrated pipe for a heat exchanger A manifold for, e.g. a motor vehicle heat exchanger, has a first part formed from a shaped metal sheet and featuring a bottom and two lateral walls folded face-to-face, at least one of which is provided with an aperture for fixing a pipe there. A second part is formed from a shaped metal sheet and able to be fitted onto the lateral walls of the first part to form a cover opposite the bottom of this first part. Either the first part or the second part has a manifold plate. The first part, the second part and the pipe are assembled by brazing.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is entitled to the benefit of and incorporates by reference essential subject matter disclosed in International Application No. PCT/EP02/00866 filed on Jan. 28, 2002 and German Patent Application No. 101 05 082.8 filed on Feb. 5, 2001.
FIELD OF THE INVENTION
The invention concerns an apparatus for accepting banknotes, especially an automatic money machine, with a compartment for receiving a banknote bundle and a separating mechanism for withdrawing individual banknotes from the bundle.
BACKGROUND OF THE INVENTION
The mechanical mechanisms inside an automatic money machine are highly developed complex components, which are carefully made and adjusted in order to be able to inspect individual banknotes with high clock frequency and to sort, count and transport them. These mechanisms react with corresponding sensitivity to foreign bodies, especially metal objects, such as office clips, stick pins, coins or the like. It must therefore be avoided that such foreign bodies do not move into the apparatus with the banknotes.
The invention has as its object the provision of a mechanism of the previously mentioned kind, which avoids a damaging of the mechanical components of the device by metallic foreign bodies.
This object is solved in accordance with the invention in that along at least one of the walls which bound the compartment a sensor arrangement is arranged for detecting metallic foreign bodies connected with the banknotes.
SUMMARY OF THE INVENTION
When the sensor arrangement discovers metallic objects at the inserted banknote bundles, the taking in of the banknotes is interrupted or is in deed not started. The customer can be required to again inspect the banknotes for foreign objects.
One possibility for non-contactingly detecting metal objects exists in that the sensor arrangement is formed as an eddy current sensor. One such eddy current sensor includes an oscillator, whose oscillations are damped and shifted in phase by the eddy currents induced in metal objects located in the vicinity of the sensor. These changes of the oscillation characteristic values can be evaluated as disturbance signals.
The employed eddy current sensor consists of a current carrying coil which is arranged on a metallic carrier sheet. With suitable design, by way of the inductive interaction of the two components the desired properties of the sensor are obtained. The effect of a flat elongated conductor on the magnetic field distribution of a current carrying coil located over the conductor is dependent on its electric and magnetic properties. From the mirroring method it is established that the field distribution of this arrangement is identical with that of the same coil and a mirroring coil on the boundary surface of the conductor. The arrangement of a coil at a spacing Δ above a flat conductor is replaced by the arrangement of two coils at a spacing 2 Δ with similar geometries, similar current amplitudes and a current phase which depends on the electric and magnetic properties of the flat conductor. In order that the boundary conditions which follow from the Maxwell equations are satisfied for the tangential component of the electric field strength at the boundary surface in the boundary case of an ideal conductor (conductivity σ→∞) the current direction must in the mirroring coil be oppositely directed to the direction in the original coil. The magnetic field linked with the current weaken at the same time. The entire field vanishes with decreasing spacing Δ→0. In the boundary cases of an ideal magnetic conductor (magnetic permeability μ r →∞), the current direction in the mirroring coil must agree with that of the original coil so that the boundary conditions for the tangential component of the magnetic field strength at the boundary surface of the conductor are satisfied. The magnetic fields linked with the current increase in the forward direction. The entire field doubles with decreasing spacing Δ→0 and dissolves in the rearward direction.
An arrangement suitable as a eddy current sensor of the illustrated kind requires therefore a mirroring material with high permeability and low conductivity. Sintered ferrites are good for use in this respect. However, these are mostly only available in cylinder or ring shapes and are seldom available in flat form. Moreover, they are brittle, slightly robust and mechanically poor to process. Mu-metals or weak magnetic ferrite steel offer a good compromise in respect to measuring sensitivity, workability, availability and costs. In this case, the reciprocal phase condition of the alternating current in the coil and its mirror image is not exactly filled. With suitable choice of the frequency of the coil current the relationship of the effect of conductivity and permeability is nevertheless clearly on the side of permeability so that a constructive overlapping of the two magnetic field components and therewith an amplification of the measuring sensitivity in the forward direction is achieved.
In an especially preferred embodiment, the sensor arrangement has at least one measuring coil and at least one compensation coil which is identical with the measuring coil in regard to its electric properties, which coils are arranged flatly in a spacing from one another on a metallic carrier plate bordering the compartment and which coils are connected with an oscillator as well as with an evaluation circuit. This arrangement is suited especially to the high sensitivity testing of flat objects such as banknotes. The measuring coil and the compensation coil should lie far enough from one another that they are not influenced in the same way by foreign objects such as office clips and the like, so that one can evaluate the presence of a metal object by way of a clear differential signal between the measuring coil and the compensation coil, which differential signal can be evaluated.
Preferably, the sensor arrangement has a plurality of measuring coils and compensation coils respectively associated with the measuring coils, which coils are arranged in distributed fashion over the carrier plate, with one measuring coil and an identical compensation coil being connected in sequence with the oscillator and the evaluation circle by means of a multiplexing circuit. Thereby, one achieves a large surface sensing arrangement which makes possible a monitoring of the entire compartment wall.
The carrier plate consists, at least on its outer side facing the coils, of a material of high permeability, for example a mu-metal or a weak magnetic ferrite steel. The carrier plate can consist entirely of this material. In so far as this may not be possible, it is however sufficient if on another metallic material a thin foil of the material of high permeability is applied.
The coils should be as flat as possible and are therefore advantageously each made as one layer of wire winding, or made by a lithographic etching technique and are for example adhesively attached to the carrier plate or are printed onto a foil which then is adhesively attached to the carrier plate.
The carrier plate with the coils is advantageously parallel to the outer surface of a banknote bundle lying in the compartment. For example, the carrier plate can itself be made from the banknote holdback plate, through which the drawing-off elements of the separating mechanism extend. The metallic carrier plate screens thereby the coil arrangement against electromagnetic disturbance signals from the interior of the device.
The arrangement can, however, also be so accomplished that the or a further carrier plate carrying the measuring and compensation coils is directed perpendicularly to the outer surface of the banknote bundle. If one has two nearly perpendicular to one another carrier plates the signals obtained from the coils on these carrier plates can be evaluated in common in order to increase the sensitivity of the sensor arrangement with respect to metal objects in the receiving compartment.
Advantageously, the clock speed of the sensor interrogation is coordinated with the withdrawing speed of the separating mechanism so that for each withdrawn banknote all of the coil pairs of the sensor arrangement are interrogated. In this way, it is assured that the entirety of the space detectable by the sensor arrangement is monitored.
In a further embodiment of the inventive solution, the eddy current sensor includes two arrangements of coils which are arranged on two walls which are parallel to one another of the compartment for the receiving of a banknote bundle, which walls border the compartment, with the coils of the one arrangement being switched as sending coils and with the coils of the other arrangement being switched as receiving coils. With this arrangement a high sensitivity of the eddy current sensor can be achieved so that also small metal parts such as, for example, paper clips in a note bundle can be detected.
The coils of each arrangement are preferably arranged next to one another over the entire width of the compartment so that the compartment can be monitored without gap.
In an especially preferred embodiment, the coils of a coil arrangement arranged on the one wall are arranged with respect to the coils of the coil arrangement on the other wall so as to be displaced by half a coil diameter. This obtains, for example, a receiving coil signal from two next to one another lying sender coils. Thereby, the width of the compartment is gaplessly monitored and it is avoided that a small metal object, which lies between two coils, can be missed, that is not detected. As has already been described above, the coils of the coil pairs are connected by way of a multiplexing circuit so as to be sequentially connected with a sending oscillator and a receiving and evaluation circuit, with a plurality of coils spaced from one another being simultaneously activated in order for the sensor arrangement to sensed with a high speed. This delivers the possibility, upon the insertion of the note bundle, that is during the movement of the same, to monitor the entire width of the compartment.
To avoid an influencing and disturbance of the sensor by metal parts of the device in which it is built the coils of both coil arrangements preferably are arranged on the side of a metallic carrier plate facing the compartment, which plate screens the coils against disturbances from the device.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the invention will be apparent from the following description, which in combination with the accompanying drawings explain the invention by way of an exemplary embodiment. The drawings are:
FIG. 1 a schematic side view of a banknote receiving compartment of an automatic money machine,
FIG. 2 a schematic plan view of a carrier plate with a measuring coil and a compensation coil of the sensor arrangement according to the invention,
FIG. 3 a principal circuit diagram of the sensor arrangement with oscillator and evaluation circuit,
FIG. 4 a schematic partial section through the input compartment of a bank automatic machine,
FIG. 5 a partial schematic plan view of a carrier plate with an assembly of coils, and
FIG. 6 a schematic plan view of two coil assemblies displaced with respect to one another.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 , the reference numeral 10 indicates the housing of an automatic money machine which is designed for the accepting of banknotes. The automatic money machine can moreover be made in various known ways and need not be described here in more detail. Inside of the operating field 12 of the automatic money machine is formed a receiving compartment 14 for the insertion of a banknote bundle 16 . The receiving compartment 14 has a rear wall 18 , a bottom 20 , a cover surface 22 and two side walls 24 , of which only one is illustrated here. The banknote bundle 16 is so inserted that it stands on edge on the bottom 20 and lies flatly against the rear wall 18 . The rear wall 18 has gaps 26 through which the draw-off rolls 28 extend, which in cooperation with separating rolls 30 of a separating mechanism individually draws off the individual banknotes 32 of the banknote bundle 16 and delivers them for processing in the automatic money machine.
Practice has shown that office dips or stick pins are often found on the banknotes by means of which the banknotes are held to one another and which can lead to damage in the examination and processing mechanisms inside of the automatic money machine. Therefore, it must be avoided that these objects reach the interior of the automatic money machine. For this, flat sensor arrangements 34 and 36 are arranged respectively on the rear wall 18 and also on the bottom 20 parallel respectively to the rear wall 18 and to the bottom 20 , which sensor arrangements will now be explained in more detail in connection with FIGS. 2 and 3 .
A sensor arrangement includes a carrier plate 38 which consists of a metal of high permeability such as, for example, mu-metal or weakly magnetic ferrite steel or which is at least covered with a thin layer of such metal. For the sensitivity of the sensor arrangement a carrier plate of ferrite would be the best. However, this material in general is not processed in plate form or usable in devices such as an automatic money machine. On the carrier plate are at least two, preferably two pair wise similar, flat coils, so called pancake coils, which are arranged on the carrier plate upper surface in the form of single wire windings or as printed coils. The coils can, for example, be applied by adhesive or can be printed onto a foil which is then in turn fastened to the carrier plate. Each two coils which are spaced from one another should be formed identically. One of the coils forms a measuring coil while the other is designated as a compensation coil, with the measuring coil and the compensation coil being physically identical.
As is shown in FIG. 3 , the group of measuring coils 40 is connected with a first switch 44 and the group of compensation coils 42 is connected with a second switch 46 of a multiplexer 48 . By way of the switches 44 and 46 , the measuring coils 40 and 42 can be connected pair wise with a current source 50 and an oscillator 52 as well as with the non-inverting and inverting inputs of a differential amplifier 54 . The output of the differential amplifier 54 is connected with two rectifier circuits 56 and 58 for a phase selective rectification, to which further the oscillator signal and the 90° phase shifted oscillator signal are delivered. The outputs of the rectifier circuits 56 and 58 are connected with a microcontroller 64 respectively through an AD-Converter 60 or 62 , which microcontroller in turn controls the differential amplifier 54 and on the other hand the multiplexer 48 , and which microcontroller stands in connection with a PC 68 through an interface 66 . Further, the microcontroller is connected with the oscillator 52 so that it can adjust its frequency.
If the sensor arrangement is activated by the coils 40 , 42 the switches 44 , 46 of the multiplexer 48 in sequence switch a single measuring coil 40 and a single compensation coil 42 to form an active coil pair. If a metallic object is located in the compartment, that is on the banknotes 32 of the banknote bundle 16 , the amplitude and phase of the oscillations in the coils 40 , 42 are changed by the eddy current induced in the metallic object. The measuring signal carries both amplitude and phase information which by means of phase selection can be used to distinguish the signal contributions of the different metallic parts (ground, material) from those which arise from temperature influences on the sensor arrangement and on the investigation electronics.
Electromagnetic disturbance coupling into the sensor arrangement as a result of electric switching processes inside of the automatic money machine can be suppressed by small band filtering of the eddy current signal and by the differential switching of the coils 40 and 42 .
If the evaluation of the difference signals appearing in the coils 40 and 42 indicates that a metal object is located in the receiving compartment, the running intake is interrupted or the intake is not begun at all. The customer is then advised that he should again remove the banknotes and inspect them for the presence of metallic parts.
The sensitivity of the sensor arrangement can be further increased in that along with the sensor arrangement 34 on the rear wall 18 , a sensor arrangement 36 on the bottom 20 of the receiving compartment is also provided. The signals of a sensor arrangement 36 can themselves be evaluated or can be compared with the signals of the sensor arrangement 34 in order to provide a further criteria for the presence of metallic objects in the receiving compartment 14 .
The clock speed at which the multiplexer 48 senses the measuring and compensation coils is advantageously suited to the intake speed of the banknotes 32 so that it is assured that each banknote is interrogated by the entire sensing arrangement.
In FIG. 4 is seen the input compartment, indicated generally at 70 , of an automatic bank machine which is designed for the receiving of bundles of banknotes, check forms or the like. The compartment 70 is closed on its input side by an arcuately curved flap 72 which can be moved by means of a motor 74 between the illustrated closed position and an open position, in which the compartment 70 is made free. Adjacent the side opposite the flap 72 is an intake and transport mechanism 76 , which will not be explained here in more detail and which delivers the inserted note bundle to further processing.
The input chute or input compartment 70 is bounded by two walls 78 and 80 of plastic material, which in the vicinity of the flap 72 define a funnel shaped insertion region and which thereafter are arranged parallel to one another. On each of these parallel sections of the walls 78 and 80 which face away from one another is arranged a metallic carrier plate 82 which on its side facing the compartment 70 carries an arrangement of coils 84 , as is illustrated in FIG. 5 . The coils 84 of each coil arrangement are adhesively attached to a carrier foil 86 which has a projection 88 over which the non-illustrated connecting conductors for the individual coils 84 run. The arrangement of the coils 84 of the two coil arrangements in the viewing direction of the observer in FIG. 4 are displaced from one another by a half coil diameter, as is schematically shown in FIG. 6 wherein the line 90 illustrates the width of the compartment 70 in the viewing direction of the observer of FIG. 4 .
An emitted oscillating signal from the coils S 1 to S 6 is disturbed in respect to amplitude and phase by metal objects inserted into the compartment 70 so that by the change of the signals of the associated receiving coils E 1 to E 6 the presence of a metallic object in the compartment can be recognized. For this, the coils S 1 to S 6 and E 1 to E 6 by means of a multiplexer switch are sequentially connected with a sending oscillator and a receiving and evaluation circuit. With the arrangement according to FIG. 6 the receiving coil E 1 is combined both with the sending coil S 1 and the sending coil S 2 . The receiving coil E 2 is combined with the sending coil S 2 and the sending coil S 3 , and so forth. By this overlapping interrogation a gapless monitoring of the compartment width is possible. Further, to save time, simultaneously for example, the sending-receiving pairs S 1 , E 1 and S 4 , E 4 , the sending-receiving pairs S 2 , E 2 and S 5 , E 5 and so forth can be interrogated so that the width of the compartment 70 can also be monitored if the bundle is relatively rapidly moved through the compartment 70 .
It has been shown that the sensitivity of this arrangement is so large that, for example, it can be distinguished whether a disturbance arises from a paper clip or from the magnetic ink of a check form. In this way, it can be reliably avoided that metallic parts reach the apparatus and damage or disturb the separating mechanism used for separating the banknotes or check forms.
|
A device for accepting banknotes comprises a compartment for receiving a bundle of banknotes and a separating mechanism for extracting individual banknotes from the bundle. A sensor system for detecting metallic foreign bodies connected to the banknotes is arranged along at least one of the walls defining the compartment.
| 6
|
BACKGROUND OF THE INVENTION
A very common problem encountered in many industries, such as the petrochemical industry, is compensating for disturbances in the flow rate of liquid materials coming into a particular processing unit. Such disturbances are usually common and ordinary events in the routine operation of the process, for example in an olefin plant.
One of the most common and important disturbances which occurs in an olefin plant is a change in the plant feed rate. For instance, furnaces are frequently brought off-line for decoking and then brought on-line again. The plant feed disturbance caused by bringing down or starting up a furnace enters the pyrofractionator whose top products go through compression and fractionation (demethanizer, deethanizer, ethylene splitter, depropranizer, and debutanizer), creating temperature and composition control problems for the cold side fractionation of the olefin plant. Ultimately, smooth operation of a plant may be hindered. Disturbances are commonly transmitted from the point of origin through the plant by means of changes in the forward flow. The less sudden these changes, and the more the magnitude of these disturbances can be minimized, the better will be the plant controllability. Most of these processes can be adjusted to accommodate these variations with little loss in efficiency, providing the surge is not too great and sufficient time is available to adjust the process.
One strategy has been to include one or more surge tanks in the liquid flow lines or to utilize certain volume capacity ranges within existing vessels to provide temporary capacity for smoothing out the surges. The liquid levels in these vessels, e.g., surge tanks, bottoms of fractionation columns and accumulators, and so forth, may then be allowed to vary within limits so that the outlet flow changes from these vessels are significantly smaller than the instantaneous inlet flow changes. Each liquid level thus acts as a buffer for the downstream units. Thus, this surge capacity, which may be receiving flow from a number of different units, by allowing the level in the surge tank to deviate from its setpoint while staying within allowable limits, attenuates the effects of any feed flow disturbance so that the disturbances do not propagate quite as strongly and the operation of the process is much steadier.
A good surge volume control algorithm should have several important characteristics. The level in the vessel should not exceed the high and low limits to ensure that the vessel will not overflow or empty. In the absence of any disturbance over a long period of time, the level should line out at the target level. The available surge volume should be utilized effectively to minimize the effect of a feed rate change on the downstream process. The method should be relatively simple so that it can be easily maintained. Also, tuning the controller should not be difficult and should not require much effort.
This is not a new problem, and sophisticated and complicated control programs for entire refining plants exist, usually requiring a very large computer installation for implementation. Rigorous solutions of this problem, for example, typically require a quadratic programming technique. What is needed is a less complicated but robust and equally effective method and apparatus for surge volume control which can be readily and economically utilized and implemented in smaller surge control applications. Ideally, the method and apparatus could be implemented in a portable, microprocessor-based controller, thereby affording the greatest economy and versatility.
SUMMARY OF THE INVENTION
Briefly, the present invention meets the above needs and purposes with a surge control system and method which simultaneously accomplish four objectives. Firstly, when an inlet flow disturbance occurs, the outlet flow is manipulated smoothly to dissipate the mass imbalance over a period of time whose length depends on the surge capacity of the vessel. Secondly, the level is permitted to deviate from its setpoint during this period but it is kept within limits. Thirdly, the level, over a period of time, is returned to its setpoint. Fourthly, the level, in the absence of further large inlet flow disturbances, remains close to the setpoint.
To understand the implementation, level control operations can be divided into essentially three distinct modes. During periods in which very small upsets in the feed flow rate may enter a unit, the level in a surge vessel is allowed to drift somewhat but ultimately should line out at the setpoint. Very small outlet flow changes are therefore made during this normal period. During periods in which a large upset occurs in the unit, however, for example when the plant feed changes due to a furnace tripping in an olefins plant, the surge volume in the vessel is used to filter this large disturbance and slow down its movement from the upstream section of the unit to the downstream section. In this mode of operation, the surge or reservoir capacity of the vessel is exploited by the volume control system to make the smallest possible outlet flow changes during each time interval such that the outlet flow rate will match the new inlet flow by the time the surge capacity of the vessel is exhausted. This dissipates the mass imbalance introduced by the upset as smoothly as possible. Finally, instances may arise when the level in the surge vessel has exceeded a high or low limit. In that case, the priority is to turn the level around and bring it back quickly within the limits, even though this may create an undesirably large excursion in the outlet flow rate.
The present invention readily handles all three modes, and moves easily between the modes as needed. Furthermore, the present invention is implemented in an uncomplicated, microprocessor-based portable configuration which can easily be implemented even on smaller process units having only a few loops which require this type of advanced control. In the present invention, the level of the fluid in the surge vessel is determined continuously using a neutron backscatter level detector which is easily attachable to the vessel for detecting the fluid level therein. The detector has a plurality of spaced neutron sources and suitable means for converting the detected count rates to a substantially continuous indication of the detected fluid level. This information is then passed to an appropriately programmed microprocessor which calculates three different outlet flow changes depending upon the current state of the level and the rate of change of level in the vessel. The microprocessor then implements the flow change via a proportional-integral flow controller which sends an appropriate output signal to a flow valve.
During the normal state, the move is given by a discrete optimal proportional-integral controller. The only tuning constant is the time period over which it is preferred that the level returns to the setpoint if there has been an offset or a slight mass imbalance. During the upset state, a set of equal moves or flow rate changes over a period of time is calculated and specified so that the level in the vessel arrives at its maximum or minimum limit when the mass imbalance (i.e., the differential in mass flow rate between the inlet and the outlet of the surge vessel) is dissipated, the outlet flow thereby following a ramp response from initial to final states. In the most extreme case, where the level has exceeded one of those limits, the microprocessor determines and specifies a move which is also based on a discrete optimal proportional-integral algorithm, but this time with the limit as the target level, with the tuning being such that the level can be turned around if it has stayed out of limit for two or more consecutive control executions. These three moves are derived based on least squares minimization theory and are optimal in the least squares sense. The logic which selects the move which is to be implemented is based on the current state of the level and the relative signs and sizes of the three moves.
It is therefore an object of the present invention to provide a new and improved portable surge level control method and apparatus; such a method and apparatus which can be used for controlling the inlet or outlet flow of a fluid-containing in-line vessel having a surge or reservoir capacity; which includes a neutron backscatter level detector attachable to the vessel for detecting the fluid level therein; in which the neutron backscatter level detector includes a plurality of spaced neutron sources (which could also be a continuously distributed source) and means for converting the detected count rates to a substantially continuous indication of the detected fluid level; which also includes computational means such as a microprocessor which is connected to the level detector and also connectable to regulate the flow to and/or from the vessel in response to the detected fluid level; in which the computational means regulates the flow by estimating the instantaneous mass imbalance and predicting the resultant volume in the vessel, calculates a normal control move in response to the estimated instantaneous mass imbalance and predicted resultant volume, calculates an out-of-limit control move with the volume high limit or low limit as a target when it has been determined that the predicted resultant volume exceeds that limit, calculates an upset move based upon the vessel's surge capacity and the estimated mass imbalance when it is predicted that the resultant volume will not exceed the vessel limits but that there is an instantaneous mass imbalance greater than a threshold amount, and compares the signs and magnitudes of the calculated moves to select the move to be implemented; which thereby generates control moves which regulate the vessel's fluid flow to smoothly converge the fluid level in the vessel toward a predetermined volume target or setpoint and protect against exceeding the capacity of the vessel; and to accomplish the above objects and purposes in an inexpensive, uncomplicated, durable, versatile, and reliable method and apparatus, inexpensive to manufacture and implement, and readily suited to the widest possible utilization in portable surge or reservoir capacity and surge level control systems.
These and other objects and advantages of the invention will be apparent from the following description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a highly figurative, schematic illustration showing a surge tank under the control of a surge level control system according to the present invention;
FIGS. 2A and 2B are a flow chart showing the procedure for determining the moves or outlet flow adjustments which are made for the surge or in-line vessel illustrated in FIG. 1, FIG. 2B being a continuation of the procedure illustrated in FIG. 2A;
FIG. 3 is a graphical illustration showing the efficient utilization of the surge capacity of a vessel by the present invention in the upset level control mode;
FIG. 4 is an illustration similar to FIG. 3 showing the response when the upset in the inlet flow rate is twice that shown in FIG. 3;
FIG. 5 is an illustration similar to FIGS. 3 and 4 showing the response of two surge vessels of equal capacity connected in series as they attenuate the effects of a large surge of the magnitude illustrated in FIG. 4; and
FIG. 6 illustrates the operation of the present invention in several modes, showing the response to a severe surge in which the initial control moves are determined by the upset control mode, and a smooth transition is then effected to the normal control mode, eventually returning the vessel to its setpoint.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the drawings, the new and improved surge level control system for controlling the flow in a fluid-containing in-line vessel having a surge or reservoir capacity, and the method therefor according to the present invention, will be described. FIG. 1 shows a vessel 10 in which a liquid 14 is being received through an inlet pipe 16 and discharged through an outlet pipe 17. A neutron backscatter level detector system 19, which is attachable to vessel 10 for detecting the level of the liquid or fluid 14 therein, provides a substantially continuous indication of the detected fluid level to a microprocessor 20. The neutron backscatter level detector system 19, which contains at least two spaced neutron sources (or a continuously distributed source) 22, is described in greater detail in copending U.S. patent application Ser. No. 203,977, filed 6/8/88 entitled "Wide-Range Fluid Level Detector" (Leonardi-Cattolica, McMillan and Telfer), the entire subject matter of which is expressly incorporated herein by reference. Using the data from the level detector system 19, the microprocessor 20 then generates control commands or moves, according to the preferred embodiment of the present invention, for the outlet flow controller 25 in the outlet pipe 17. (Of course, components shown separately for clarity of illustration may be combined as desired, such as, for example, the microprocessor 20 and the flow controller 25.)
Referring to FIGS. 2A and 2B, the microprocessor 20 determines the changes or moves which the outlet flow controller or valve system 25 should make by determining the conditions at hand and then operating in one of three corresponding modes, referred to herein as a Normal Move, an Upset Move, and an Out-of-Limit Move.
NORMAL MOVE
During normal operation, the surge volume controller should keep the level in the buffer vessel 10 near the desired steady-state level, or "setpoint". However, the level in the tank should be permitted drift somewhat before ultimately lining out at the setpoint target level, allowing any outlet flow changes to be as small as possible. These technical requirements can be stated mathematically as: ##EQU1## Δf i =outlet flow change at the ith time interval based on the current mass imbalance and level
V o =volume at current time interval
V prev =volume at previous time interval
V sp =volume at setpoint level
V N =volume at the end of Nth time interval
Δt=time interval between control executions
f o =estimated current mass imbalance
N=tuning parameter specifying a time horizon at which the volume is at setpoint and the mass imbalance is zero. N≧2.
The analytical solution to this minimization problem is: ##EQU2##
In an on-line application, only the move at the first time interval is implemented and the mass imbalance f o and volume difference ΔV sp are recalculated at each control execution. For i=N ##EQU3## From the definition of f o and ΔV sp one can then define the Normal Move as: ##EQU4## This is the discrete velocity form of the proportional-integral controller. Given a time horizon N, this is the optimal controller in the least squares sense. If N is large, surge volume control results. The level is allowed to drift before returning to the setpoint and the outlet flow changes gradually. If N is small, tight level control results and the outlet flow changes quickly in response to a mass imbalance and offset.
The mode described above does not handle constraints. To ensure that the tank does not overlow or empty, the volume must be kept within limits. The upset move does that.
UPSET MOVE
When a large mass imbalance occurs the surge volume control system must keep the volume within the allowable limits (between V Max and V Min ) as well as dissipate the mass imbalance. The normal move does not consider the constraints on the volume of the vessel. Consequently, it does not try to keep the level within limits. The upset move uses the surge capacity optimally to dissipate any mass imbalance in the vessel. The upset move is given by the solution to the following minimization problem: ##EQU5## Solving this minimization problem by assuming NLIM to be some constant yields a "ramp" change in the outlet flow, ##EQU6## Combining equations (8) and (9) allows the Upset Move to be defined as: ##EQU7##
A comparison of the normal and upset moves is made (see FIG. 2B) to decide which move should be implemented. If the signs of the two moves are opposite the normal move is selected because it always drives the level in the proper direction. Without this comparison of signs an upset move might be implemented when it was not necessary. When the signs are the same the move which has the larger magnitude is implemented because, if the upset move is larger, the normal move cannot keep the level within limits.
OUT-OF-LIMIT MOVE
The upset move from equation (10) does not deal with the situation where the level has already exceeded the high or low limit. In such a situation, the first priority is to turn the level around quickly and bring it within the limit in a few control moves. The least squares normal move with two minor modifications can do this. In the integral term of equation (6) the V sp is replaced by V LIM . In addition, the tuning needs to be very tight to obtain fast response. Consequently, the Out-of-Limit move is defined as: ##EQU8##
When a large mass imbalance occurs which may move the level further from the violated limit, it is desirable to return the level quickly inside the limit without introducing a large mass imbalance in the opposite direction. It can be shown that with N oL equal to four the level will turn toward the limit in two control executions. N oL can be greater than four, but should not be less. With N oL less than four too large a mass imbalance may be introduced which may cause the level to go to the opposite limit. A good analogy to the way the constraints are handled is that it provides least squares satisfaction of limits weighted appropriately.
The calculations of all three types of moves require volume as an input. The advantage to using volume in place of level is that the control system becomes independent of vessel geometry. This is particularly important in the case of a horizontal cylindrical vessel. The level control problem for a horizontal cylindrical vessel is nonlinear whereas the equivalent volume control problem is linear. It is therefore preferred to include a routine in microprocessor 20 which converts a level reading from the level detector 19 to a volume, given the vessel geometry. Preferably, for a portable system, this routine will support two types of tank geometry: vertical cylindrical and horizontal cylindrical vessels.
Advantageously, the present invention can be extended to handle vessels in series. In that case, the future projections of the outlet flow moves from the upstream vessel are simply included in the calculations of the moves of the downstream vessel. This method may be useful for a series of vessels which experience large upset but have small capacities.
Referring again to the flowchart in FIGS. 2A and 2B, the first step is to estimate the current mass imbalance using equation (3). The next step is to calculate the normal move by equation (5). If the projected fluid level is within the maximum (V MAX ) and minimum (V MIN ) limits and the mass imbalance f o is less than a given amount (e.g., <10 -10 ), the microprocessor 20 returns the normal move as the move to be implemented. If a limit has been exceeded, the out-of-limit move is calculated. Otherwise, the upset move is calculated. After these moves are calculated, the sign of either the out-of-limit or upset move is compared to the sign of the normal move. If the signs are opposite, the normal move is implemented. If the signs are the same, then the magnitudes of the moves are compared and the move with the larger magnitude is implemented.
The calculations of the upset and normal moves require the estimation of a mass imbalance. In some vessels the level signals may be very noisy. The noise can be of such a frequency that the instantaneous estimated mass imbalance changes significantly over one time period while the longer time trend of the level remains relatively unperturbed. This phenomenon can cause larger than necessary moves to be made. To reduce this effect a nonlinear filter whose tuning is based on statistical properties of the level may be used. This filter is given by ##EQU9## where f t =filtered estimate of mass imbalance at time t
f t =(v t -v t-1 )/Δt
v t =volume in the vessel at time t
Δt=time period between control actions, in units of t
α=standard deviation of the noise in f t which is estimated a priori.
This nonlinear filter will reduce the magnitude of those mass imbalances which arise due to noise and pass through the larger mass imbalances which should not be filtered. Consequently, unnecessary outlet flow changes are not made.
Referring now to FIGS. 3 and 4, operation in the upset mode will be described. The objective of upset level control is to use the surge capacity of the vessel 10 to dampen severe feed rate changes. This is accomplished by changing the flow leaving the vessel along a straight line over time in order to balance the level at the high or low limit. That is, the flow in the outlet pipe 17 is targeted to match (catch up with) that in the inlet pipe 16 just as the vessel level reaches its high or low limit. This objective is shown graphically in FIGS. 3 and 4. The surge in FIG. 4 is twice that of FIG. 3, requiring the outlet flow rate to be adjusted twice as fast.
More specifically, for these examples it is assumed that the flow of liquid entering the vessel 10 goes through an uncontrollable step change (e.g., furnace trip), and that the microprocessor 20 controls the flow leaving vessel 10 along some straight line whose slope must be calculated. The area of the shaded triangle represents the amount of material which accumulates in the vessel following the change in feed rate. For the practical level control problem, the area of this triangle is known to be the difference in volume between the high/low limit and the present level.
The base of the triangle represents the length of time taken to balance the flow rates (i.e., stabilize the fluid level in the vessel 10). Since the height and area of the triangle are known, the base (time) can be calculated, along with the corresponding slope of the flow change line. This calculated slope represents the slowest rate of change of flow which keeps the fluid level within its limits. If the rate of change of flow is slower, the limit is exceeded. If the rate of change of flow is faster, then the feed change is not being dampened as much as it could be. Analytically, it can be shown that the calculated minimum slope is proportional to the square of the current material imbalance. This shows that immediate action toward reduction of material imbalance is very important in order to effectively use the available surge volume.
The upset level control described above with respect to FIGS. 3 and 4 is best suited for situations in which feed flow changes are unpredictable. In some cases, however, the projected future flow from each of the feed sources may be known. This information then enables the microprocessor to predict the material balance into the future and to make flow moves accordingly.
FIG. 5 shows a graphical representation of upset control for two vessels in series. It is very similar to FIGS. 3 and 4. For illustrative purposes, all liquid from the first vessel is assumed to be recovered as liquid in the second. The initial and final flows leaving the second vessel are the same as those for the first. However, the rate of accumulation of material in the second is less than that of the first because the feed rate to the second changes along a straight line over time, rather than in a single step. The difference between accumulation in the first and second vessels is represented by the area of the shaded triangle. The height and base of this triangle are the first vessel's material imbalance and time to balance its level, respectively. These values for the first vessel are both known.
Once the upset and/or out-of-limit modes have brought the fluid flows into material balance, the levels, which had been allowed to change, must be brought back to their targets within a reasonable period of time. This protects the unit from a second upset which may occur at any time. While the basic theory for "normal" level control is the same as that for "upset" level control, in practice there are some differences. In the "normal" case, the objective is to balance the vessel 10 at the target level at some time in the future. It does not matter if the target level is exceeded enroute to this final destination; the only constraint is that neither limit be exceeded. (See FIG. 6.) Thus, in the "normal" case, the user can select a length of time for the target conditions to be met. In the "upset" case, the time taken to balance the flow is fixed by the severity of the feed rate change and surge capacity of the vessel. The selected time frame depends upon the individual system. As the selected time decreases, the fluctuation of flow increases, with the level being held closer to target. As the time increases, the level is allowed to float more in order to reduce the fluctuation of flow moves.
As may be seen, therefore, the present invention has numerous advantages and provides a straightforward, economical, reliable, and highly versatile surge level control apparatus and method. Principally, it provides a robust and powerful, but uncomplicated, compact, and easily portable, surge level control system which can be readily utilized on an extremely wide range of level control applications. The traditionally complex methods for advanced process control, which have previously, due to their complexity, required implementation on large computers, have been overcome by the present invention. It is therefore not necessary to spread the cost of a major computational facility over many control loops and other functions. Instead, the present invention makes it possible to apply powerful control hardware even to process units having only a few loops which nevertheless require advanced control. Not only does the present invention operate quickly and reliably, making smooth transitions from one mode to the other as required, but it is also very easy for the user to adapt it to the particular application at hand. It is particularly easy to tune with only one tuning parameter: the time period over which the level should return to its setpoint whenever an offset or a mass imbalance occurs. N oL can also be a tuning parameter, as may be appropriate.
While discussed illustratively in connection with controlling the outlet flow of the vessel, it will be appreciated that the inlet flow could be controlled as well, depending upon the needs and conditions at hand. Therefore, when reference is made to controlling the flow in such a vessel, the meaning is that the inlet or outlet flow is controlled, as desired.
While the methods and forms of apparatus herein described constitute preferred embodiments of this invention, it is to be understood that the invention is not limited to these precise methods and forms of apparatus, and that changes may be made therein without departing from the scope of the invention.
|
A portable self-contained surge level controller detects the liquid level in a vessel, such as by neutron backscatter, and adjusts inlet or outlet flow to compensate for incoming surges while minimizing outgoing flow disturbances.
| 8
|
FIELD
[0001] This invention relates to fluid compositions and their use in controlling proppant flowback after a hydraulic fracturing treatment and in reducing formation sand production along with fluids in poorly consolidated formations.
BACKGROUND
[0002] Hydraulic fracturing operations are used extensively in the petroleum industry to enhance oil and gas production. In a hydraulic fracturing operation, a fracturing fluid is injected through a wellbore into a subterranean formation at a pressure sufficient to initiate fractures to increase oil and gas production.
[0003] Frequently, particulates, called proppants, are suspended in the fracturing fluid and transported into the fractures as a slurry. Proppants include sand, ceramic particles, glass spheres, bauxite (aluminum oxide), resin coated proppants, synthetic polymeric beads, and the like. Among them, sand is by far the most commonly used proppant.
[0004] Fracturing fluids in common use include aqueous and non-aqueous ones including hydrocarbon, methanol and liquid carbon dioxide fluids. The most commonly used fracturing fluids are aqueous fluids including water, brines, water containing polymers or viscoelastic surfactants and foam fluids.
[0005] At the last stage of a fracturing treatment, fracturing fluid is flowed back to the surface and proppants are left in the fractures to prevent them from closing back after the hydraulic fracturing pressure is released. The proppant-filled fractures provide high conductive channels that allow oil and/or gas to seep through to the wellbore more efficiently. The conductivity of the proppant packs formed after proppant settles in the fractures plays a dominant role in increasing oil and gas production.
[0006] However, it is not unusual for a significant amount of proppant to be carried out of the fractures and into the well bore along with the fluids being flowed back out the well. This process is known as proppant flowback. Proppant flowback is highly undesirable since it not only reduces the amount of proppants remaining in the fractures resulting in less conductive channels, but also causes significant operational difficulties. It has long plagued the petroleum industry because of its adverse effect on well productivity and equipment.
[0007] Numerous methods have been attempted in an effort to find a solution to the problem of proppant flowback. The commonly used method is the use of so-called “resin-coated proppants”. The outer surfaces of the resin-coated proppants have an adherent resin coating so that the proppant grains are bonded to each other under suitable conditions forming a permeable barrier and reducing the proppant flowback.
[0008] The substrate materials for the resin-coated proppants include sand, glass beads and organic materials such as shells or seeds. The resins used include epoxy, urea aldehyde, phenol-aldehyde, furfural alcohol and furfural. The resin-coated proppants can be either pre-cured or can be cured by an overflush of a chemical binding agent, commonly known as activator, once the proppants are in place.
[0009] Different binding agents have been used. U.S. Pat. Nos. 3,492,147 and 3,935,339 disclose compositions and methods of coating solid particulates with different resins. The particulates to be coated include sand, nut shells, glass beads, and aluminum pellets. The resins used include urea-aldehyde resins, phenol-aldehyde resins, epoxy resins, furfuryl alcohol resins, and polyester or alkyl resins. The resins can be in pure form or mixtures containing curing agents, coupling agents or other additives. Other examples of resins and resin mixtures for proppants are described, for example, in U.S. Pat. Nos. 5,643,669; 5,916,933; 6,059,034 and 6,328,105.
[0010] However, there are significant limitations to the use of resin-coated proppants. For example, resin-coated proppants are much more expensive than normal sands, especially considering that a fracturing treatment usually employs tons of proppants in a single well. Normally, when the formation temperature is below 60° C., activators are required to make the resin-coated proppants bind together. This increases the cost.
[0011] Thus, the use of resin-coated proppants is limited by their high cost to only certain types of wells, or to use in only the final stages of a fracturing treatment, also known as the “tail-in” of proppants, where the last few tons of proppants are pumped into the fracture. For less economically viable wells, application of resin-coated proppants often becomes cost prohibitive.
[0012] During hydrocarbon production, especially from poorly consolidated formations, small particulates, typically of sand, often flow into the wellbore along with produced fluids. This is because the formation sands in poorly consolidated formations, are bonded together with insufficient bond strength to withstand the forces exerted by the fluids flowing through, and are readily entrained by the produced fluids flowing out of the well.
[0013] The produced sand erodes surface and subterranean equipment, and requires a removal process before the hydrocarbon can be processed. Different methods have been tried in an effort to reduce formation sand production. One approach employed is to filter the produced fluids through a gravel pack retained by a screen in the wellbore, where the particulates are trapped by the gravel pack. This technique is known as gravel packing. However, this technique is relatively time consuming and expensive. The gravel and the screen can be plugged and eroded by the sand within a relatively short period of time.
[0014] Another method that has been employed in some instances is to inject various resins into a formation to strengthen the binding of formation sands. Such an approach, however, results in uncertainty and sometimes creates undesirable results. For example, due to the uncertainty in controlling the chemical reaction, the resin may set in the wellbore itself rather than in the poorly consolidated producing zone. Another problem encountered in the use of resin compositions is that the resins normally have short shelf lives. For example, it can lead to costly waste if the operation using the resin is postponed after the resin is mixed.
[0015] Thus, it is highly desirable to have a cost effective composition and a method that can control proppant flowback after fracturing treatment. It is also highly desirable to have a composition and a method of reducing formation sand production from the poorly consolidated formation.
SUMMARY
[0016] The present invention in one embodiment relates to An aqueous slurry composition having water, particulates, a chemical compound for rendering the surface of the particulates hydrophobic and an oil.
[0017] The present invention in another embodiment relates to a method of controlling sand in a hydrocarbon producing formation comprising the steps of mixing water, particulates and a chemical compound for rendering the surface of the particulates hydrophobic, pumping the mixture into the formation.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Aggregation phenomena induced by hydrophobic interaction in water are observed everywhere, in nature, industrial practice, as well as in daily life. In general, and without being bound by theory, the hydrophobic interaction refers to the attractive forces between two or more apolar particles in water. When the hydrophobic interaction becomes sufficiently strong, the hydrophobic particles come together to further reduce the surface energy, essentially bridging the particles together and resulting in the formation of particle aggregations, known as hydrophobic aggregations. It is also known that micro-bubbles attached to hydrophobic particle surfaces also tend to bridge the particles together.
[0019] In this invention the concept of hydrophobic aggregation is applied to develop compositions and methods to control proppant flowback as well as to reduce formation sand production during well production. Unlike in conventional approaches, where attention is focused on making proppants or sand particles sticky through formation of chemical bonds between resins coated on the particle surfaces, in the present invention the attention is focused on making particle aggregations by bridging the particles through strong hydrophobic force or micro-bubbles. Moreover, the hydrophobic surfaces of the particles induced by the present compositions reduce the friction between the particles and water making them harder to be entrained by fluids flowing out of the well.
[0020] In general, only a limited amount of agents is required in the present invention, and the field operational is simple.
[0021] There are different ways of carrying out the invention. For example, during a fracturing operation, a proppant, for example, sand, which is naturally hydrophilic and can be easily water wetted, is mixed with a fluid containing a chemical agent, referred as hydrophobizing agent, which makes the sand surface hydrophobic. The hydrophobizing agent can be simply added into a sand slurry comprising sand and fracturing fluid which is pumped down the well. Depending on the hydrophobizing agent used and the application conditions, different fracturing fluids (aqueous or non-aqueous fluids) can be used. Aqueous fluid is normally preferred. Of particular interest as a fracturing fluid, is water, or brine or water containing a small amount of a friction reducing agent, also known as slick-water.
[0022] The hydrophobizing agent can be applied throughout the proppant stage or during a portion of the proppant stage such as the last portion of the proppant stage, i.e., tail-in. Alternatively, sand can be hydrophobized first and dried and then used to make a slurry and pumped into fracture.
[0023] It has been discovered that when a small amount of an oil, including hydrocarbon oil and silicone oil, is mixed into the aqueous slurry containing the hydrophobized sands, the hydrophobic aggregation is enhanced significantly. The possible explanation for this is that the concentration of oil among the hydrophobic sands may further enhance the bridge between sand grains.
[0024] The present invention can be used in a number of ways. For example, in a fracture operation, proppant such as sand is mixed with a hydrophobizing agent in water based slurry and pumped into the fractures, and then followed by over flush with oil or water containing a small amount of oil to strengthen the bridge between the sand grains. Similarly, the same operation can be applied in the tail-in stage. Alternatively the slurry containing a hydrophobizing agent can be pumped into the fracture forming the proppant pack, which can be further consolidated by oil or condensate contained in the formation. Or the pre-hydrophobized sand is used as proppant and then followed by flushing with water, containing small amount of oil. Or the pre-hydrophobized sand is used as proppant which can be further consolidated by oil or condensate contained in the formation. Or the pre-hydrophobized sand is tailed in and followed by flushing with water containing small amount of oil. In all such operations, a gas such as nitrogen, carbon dioxide or air can be mixed into the fluid.
[0025] There are different ways of pre-treating the solid surface hydrophobic. For example, one may thoroughly mix the proppants, preferable sands, with a fluid containing the approperate hydrophobizing agent for certain period of time. After the proppant grains are dried, they can be used in fracturing operations. Different fluids can be used. Different hydrophobizing agents may need different conditions to interact with the solid surface. When an aqueous fluid is used, the pH of the fluid may also play a role.
[0026] Besides controlling proppant flowback in hydraulic fracturing treatments, the present invention is also useful in reducing formation sand production during well production. In the majority of cases, sand production increases substantially when wells begin to produce water. The formation sand is normally hydrophilic, or water-wet, and therefore is easily entrained by a flowing water phase. Depending on the hydrophobizing agent used and the operational conditions, different carrying fluids, aqueous or non-aqueous, can be used. There are different methods, according to the present invention, to treat a formation to reduce formation sand production. For example, a fluid, preferably an aqueous fluid, containing an appropriate amount of hydrophobizing agent can be injected into the poorly consolidated formation. After the sand grains become hydrophobic they tend to aggregate together. The hydrophobic surfaces also reduce the dragging force exerted by the aqueous fluid making them more difficult to be entrained by the formation fluid. If the water phase contains certain amount of oil, the hydrophobic aggregation between sand grains can be further enhanced. Alternatively, the fluid contain the hydrophobizing agent can be first injected into the poorly consolidated formation, and then followed by injecting small volume of oil or a fluid containing oil. In all these applications, a gas such as nitrogen, carbon dioxide or air can be mixed into the fluid.
[0027] Also, the compositions and methods of the present invention can be used in gravel pack operations, where the slurry containing hydrophobised sands are added in the well bore to remediate sand production.
[0028] There are various types of hydrophobizing agents for sand, which can be used in the present invention. For example, it is known that many organosilicon compounds including organosiloxane, organosilane, fluoro-organosiloxane and fluoro-organosilane compounds are commonly used to render various surfaces hydrophobic. For example, see U.S. Pat. Nos. 4,537,595; 5,240,760; 5,798,144; 6,323,268; 6,403,163; 6,524,597 and 6,830,811 which are incorporated herein by reference.
[0029] Organosilanes are compounds containing silicon to carbon bonds. Organosiloxanes are compounds containing Si—O—Si bonds. Polysiloxanes are compounds in which the elements silicon and oxygen alternate in the molecular skeleton, i.e., Si—O—Si bonds are repeated. The simplest polysiloxanes are polydimethylsiloxanes.
[0030] Polysiloxane compounds can be modified by various organic substitutes having different numbers of carbons, which may contain N, S, or P moieties that impart desired characteristics. For example, cationic polysiloxanes are compounds in which one or two organic cationic groups are attached to the polysiloxane chain, either at the middle or the end. Normally the organic cationic group may contain a hydroxyl group or other functional groups containing N or O. The most common organic cationic groups are alkyl amine derivatives including secondary, tertiary and quaternary amines (for example, quaternary polysiloxanes including, quaternary polysiloxanes including mono- as well as, di-quaternary polysiloxanes, amido quaternary polysiloxanes, imidazoline quaternary polysiloxanes and carboxy quaternary polysiloxanes.
[0031] Similarly, the polysiloxane can be modified by organic amphoteric groups, where one or more organic amphoteric groups are attached to the polysiloxane chain, either at the middle or the end, and include betaine polysiloxanes and phosphobetaine polysiloxanes.
[0032] Similarly, the polysiloxane can be modified by organic anionic groups, where one or more organic anionic groups are attached to the polysiloxane chain, either at the middle or the end, including sulfate polysiloxanes, phosphate polysiloxanes, carboxylate polysiloxanes, sulfonate polysiloxanes, thiosulfate polysiloxanes. The organosiloxane compounds also include alkylsiloxanes including hexamethykyclotrisiloxane, octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane, hexamethyldisiloxane, hexaethyldisiloxane, 1,3-divinyl-1,1,3,3-teframethyldisiloxane, octamethyltrisiloxane, decamethyltetrasiloxane.
[0033] The organosilane compounds include alkylchlorosilane, for example methyltrichlorosilane, dimethyldichlorosilane, trimethylchlorosilane, octadecyltrichlorosilane; alkyl-alkoxysilane compounds, for example methyl-, propyl-, isobutyl- and octyltrialkoxysilanes, and fluoro-organosilane compounds, for example, 2-(n-perfluoro-octyl)-ethyltriethoxysilane, and perfluoro-octyldimethyl chlorosilane.
[0034] Other types of chemical compounds, which are not organosilicon compounds, which can be used to render particulate surface hydrophobic are certain fluoro-substituted compounds, for example certain fluoro-organic compounds including cationic fluoro-organic compounds.
[0035] Further information regarding organosilicon compounds can be found in Silicone Surfactants (Randal M. Hill, 1999) and the references therein, and in U.S. Pat. Nos. 4,046,795; 4,537,595; 4,564,456; 4,689,085; 4,960,845; 5,098,979; 5,149,765; 5,209,775; 5,240,760; 5,256,805; 5,359,104; 6,132,638 and 6,830,811 and Canadian Patent No. 2,213,168 which are incorporated herein by reference.
[0036] Organosilanes can be represented by the formula
[0000] R n SiX( 4−n ) (I)
[0000] wherein R is an organic, radical having 1-50 carbon atoms that may posses functionality containing N, S, or P moieties that imparts desired characteristics, X is a halogen, alkoxy, acyloxy or amine and n has a value of 0-3. Examples of organosilanes include:
CH 3 SiCl 3 , CH 3 CH 2 SiCl 3 , (CH 3 ) 2 SiCl 2 , (CH 3 CH 2 ) 2 SiCl 2 ,(C 6 H 5 ) 2 SiCl 2 , (C 6 H 5 )SiCl 3 , (CH 3 ) 3 SiCl, CH 3 HSiCl 2 , (CH 3 ) 2 HSiCl, CH 3 SlBr 3 , (C 6 H 5 )SiBr 3 , (CH 3 ) 2 SiBr 2 , (CH 3 CH 2 ) 2 SiBr 2 , (C 6 H 5 ) 2 SiBr 2 , (CH 3 ) 3 SiBr, CH 3 HSiBr 2 , (CH 3 ) 2 HSiBr, Si(OCH 3 ) 4 , CH 3 Si(OCH 3 ) 3 , CH 3 Si(OCH 2 CH 3 ) 3 , CH 3 Si(OCH 2 CH 2 CH 3 ) 3 , CH 3 Si[O(CH 2 ) 3 CH 3 ] 3 , CH 3 CH 2 Si(OCH 2 CH 3 ) 3 /C 6 H 5 Si(OCH 3 ) 3 , C 6 H 5 CH 2 Si(OCH 3 ) 3 , C 6 H 5 Si(OCH 2 CH 3 ) 3 , CH 2 ═CHCH 2 Si(OCH 3 ) 3 , (CH 3 ) 2 Si(OCH 3 ) 2 , (CH 2 ═CH)Si(CH 3 ) 2 Cl, (CH 3 ) 2 Si(OCH 2 CH 3 ) 2 , (CH 3 ) 2 Si(OCH 2 CH 2 CH 3 ) 2 , (CH 3 ) 2 Si[O(CH 2 ) 3 CH 3 ] 2 , (CH 3 CH 2 ) 2 Si(OCH 2 CH 3 ) 2 , (C 6 H 5 ) 2 Si(OCH 3 ) 2 , (C 6 H 5 CH 2 ) 2 Si(OCH 3 ) 2 , (C 6 H 5 ) 2 Si(OCH 2 CH 3 ) 2 , (CH 2 ═CH 2 )Si(OCH 3 ) 2 , (CH 2 ═CHCH 2 ) 2 Si(OCH 3 ) 2 , (CH 3 ) 3 SiOCH 3 , CH 3 HSi(OCH 3 ) 2 , (CH 3 ) 2 HSi(OCH 3 ), CH 3 Si(OCH 2 CH 2 CH 3 ) 3 , CH 2 ═CHCH 2 Si(OCH 2 CH 2 OCH 3 ) 2 , (C 6 H 5 ) 2 Si(OCH 2 CH 2 OCH 3 ) 2 , (CH 3 ) 2 Si(OCH 2 CH 2 OCH 3 ) 2 , (CH 2 ═CH 2 ) 2 Si(OCH 2 CH 2 OCH 3 ) 2 , (CH 2 ═CHCH 2 ) 2 Si(OCH 2 CH 2 OCH 3 ) 2 , (C 6 H 5 ) 2 Si(OCH 2 CH 2 OCH 3 ) 2 , CH 3 Si(CH 3 COO) 3 , 3-aminotriethoxysilane, methyldiethylchlorosilane, butyltrichlorosilane, diphenyldichlorosilane, vinyltrichlorosilane, methyltrimethoxysilane, vinyltriethoxysilane, vinyltris(methoxyethoxy)silane, methacryloxypropyltrimethoxysilane, glycidoxypropyltrimethoxysilane, aminopropyltriethoxysilane, divinyldi-2-methoxysilane, ethyltributoxysilane, isobutyltrimethoxysilane, hexyltrimethoxysilane, n-octyltriethoxysilane, dihexyldimethoxysilane, octadecyltrichlorosilane, octadecyltrimethoxysilane, octadecyldimethylchlorosilane, octadecyldimethylmethoxysilane and quaternary ammonium silanes including 3-(trimethoxysilyl)propyldimethyloctadecyl ammonium chloride, 3-(trimethoxysilyl)propyldimethyloctadecyl ammonium bromide, 3-(trimethylethoxysilylpropyl)didecylmethyl ammonium chloride, triethoxysilyl soyapropyl dimonium chloride, 3-(trimethylethoxysilylpropyl)didecylmethyl ammonium bromide, 3-(trimethylethoxysilylpropyl)didecylmethyl ammonium bromide, triethoxysilyl soyapropyl dimonium bromide, (CH 3 O) 3 Si(CH 2 ) 3 P + (C 6 H 5 ) 3 Cl, (CH 3 O) 3 Si(CH 2 ) 3 P+(C 6 H 5 ) 3 Br−, (CH 3 O) 3 Si(CH 2 ) 3 P + (CH 3 ) 3 Cl − , (CH 3 O) 3 Si(CH 2 ) 3 P + (C 6 H 13 ) 3 Cl − , (CH 3 O) 3 Si(CH 2 ) 3 N + (CH 3 ) 2 C 4 H 9 Cl, (CH 3 O) 3 Si(CH 2 ) 3 N + (CH 3 ) 2 CH 2 C 6 H 5 Cl − , (CH 3 O) 3 Si(CH 2 ) 3 N + (CH 3 ) 2 CH 2 CH 2 Cl − , (CH 3 O) 3 Si(CH 2 ) 3 N + (C 2 H 5 ) 3 Cl − , (C 2 H 5 O) 3 Si(CH 2 ) 3 N + (CH 3 ) 2 C 18 H 37 Cl − .
[0038] Among different organosiloxane compounds which are useful for the present invention, polysiloxanes modified with organic amphoteric or cationic groups including organic betaine polysiloxanes and organic quaternary polysiloxanes are examples. One type of betaine polysiloxane or quaternary polysiloxane is represented by the formula
[0000]
[0000] wherein each of the groups R 1 to R 6 , and R 8 to R 10 represents an alkyl containing 1-6 carbon atoms, typically a methyl group, R 7 represents an organic betaine group for betaine polysiloxane, or an organic quaternary group for quaternary polysiloxane, and have different numbers of carbon atoms, and may contain a hydroxyl group or other functional groups containing N, P or S, and m and n are from 1 to 200. For example, one type of quaternary polysiloxanes is when R 7 is represented by the group
[0000]
[0000] wherein R 1 , R 2 , R 3 are alkyl groups with 1 to 22 carbon atoms or alkenyl groups with 2 to 22 carbon atoms. R 4 , R 5 , R 7 are alkyl groups with 1 to 22 carbon atoms or alkenyl groups with 2 to 22 carbon atoms; R 6 is —O— or the NR 8 group, R 8 being an alkyl or hydroxyalkyl group with 1 to 4 carbon atoms or a hydrogen group; Z is a bivalent hydrocarbon group with at least 4 carbon atoms, which may have a hydroxyl group and may be interrupted by an oxygen atom, an amino group or an amide group; x is 2 to 4; The R 1 , R 2 , R 3 , R 4 , R 5 , R 7 may be the same or the different, and X— is an inorganic or organic anion including Cl— and CH 3 COO − . Examples of organic quaternary groups include [R—N + (CH 3 ) 2 —CH 2 CH(OH)CH 2 —O—(CH 2 ) 3 —] (CH 3 COO − ), wherein R is an alkyl group containing from 1-22 carbons or an benzyl radical and CH 3 COO − an anion. Examples of organic betaine include —(CH 2 ) 3 —O—CH 2 CH(OH)(CH 2 )—N + (CH 3 ) 2 CH 2 COO − . Such compounds are commercial available. Betaine polysiloxane copolyol is one of examples. It should be understood that cationic polysiloxanes include compounds represented by formula (II), wherein R 7 represents other organic amine derivatives including organic primary, secondary and tertiary amines.
[0039] Other examples of organo-modified polysiloxanes include di-betaine polysiloxanes and di-quaternary polysiloxanes, where two betain or quaternary groups are attached to the siloxane chain. One type of the di-betaine polysiloxane and di-quaternary polysiloxane can be represented by the formula
[0000]
[0000] wherein the groups R 12 to R 17 each represents an alkyl containing 1-6 carbon atoms, typically a methyl group, both R 11 and R 18 group represent an organic betaine group for di-betaine polysiloxanes or an organic quaternary group for di-quaternary, and have different numbers of carbon atoms and may contain a hydroxyl group or other functional groups containing N, P or S, and m is from 1 to 200. For example, one type of di-quaternary polysiloxanes is when R 11 and R 18 are represented by the group
[0000]
[0000] wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , Z, X − and x are the same as defined above. Such compounds are commercially available. Quaternium 80 (INCI) is one of the commercial examples.
[0040] It will be appreciated by those skilled in the art that cationic polysiloxanes include compounds represented by formula (III), wherein Ru and R 18 represnets other organic amine derivatives including organic primary, secondary and tertiary amines. It will be apparent to those skilled in the art that there are different mono- and di-quaternary polysiloxanes, mono- and di-betaine polysiloxanes and other organo-modified polysiloxane compounds which can be used to render the solid surfaces hydrophobic and are useful in the present invention. These compounds are widely used in personal care and other products, for example as discussed in U.S. Pat. Nos. 4,054,161; 4,654,161; 4,891,166; 4,898,957; 4,933,327; 5,166,297; 5,235,082; 5,306,434; 5,474,835; 5,616,758; 5,798,144; 6,277,361; 6,482,969; 6,323,268 and 6,696,052 which are incorporated herein by reference.
[0041] Another example of organosilicon compounds which can be used in the composition of the present invention are fluoro-organosilane or fluro-organosiloxane compounds in which at least part of the organic radicals in the silane or siloxane compounds are fluorinated. Suitable examples are fluorinated chlorosilanes or fluorinated alkoxysilanes including 2(n-perfluoro-octyl)ethyltriethoxysilane, perfluoro-octyldimethylchlorosilane, (CF 3 CH 2 CH 2 ) 2 Si(OCH 3 ) 2 , CF 3 CH 2 CH 2 Si(OCH 3 ) 3 , (CF 3 CH 2 CH 2 ) 2 Si(OCH 2 CH 2 OCH 3 ) 2 and CF 3 CH 2 CH 2 Si(OCH 2 CH 2 OCH 3 ) 3 and (CH 3 O) 3 Si(CH 2 ) 3 N + (CH 3 ) 2 (CH 2 ) 3 NHC(O)(CF 2 ) 6 CF 3 Cl − . Other compounds which can be used, but less preferable, are fluoro-substituted compounds, which are not organic silicon compounds, for example, certain fluoro-organic compounds.
[0042] The following provides several non-limiting examples of compositions and methods according to the present invention.
Example 1
[0043] 300 g of 20/40 US mesh frac sand was added into 1000 ml of water containing 2 ml of a solution containing 20 vol % Tegopren 6924, a di-quaternary polydimethylsiloxane from Degussa Corp., and 80 vol % of ethylene glycol mono-butyl ether, and 1 ml of TEGO Betaine 810, capryl/capramidopropyl betaine, an amphoteric hydrocarbon surfactant from Degussa Corp. The slurry was shaken up and then let stand to allow sands settle down. When tilted slowly, the settled sand tended to move as cohesive masses. After 1 ml of silicon oil, where its viscosity is 200 cp, was mixed into the slurry and shaken up sand grains were visually observed to clump together forming strong bridge among each other.
[0044] The solution was decanted, and the sand was dried overnight at the room temperature for further tests.
Example 2
[0045] 200 g of pre-treated sand according to Example 1 was placed in a fluid loss chamber to form a sand pack and wetted with water. Afterward, 300 ml of water was allowed to filter from the top through the sand pack. The time was stopped when water drops slowed to less than one every five seconds. Same test using untreated sand was carried out as the reference. The average filter time over 6 runs for the pre-treated sand was 2 minutes and 5 seconds, while it was 5 minutes for the untreated sand.
Example 3
[0046] 200 g of pre-treated sand according to Example 1 was placed in a fluid loss chamber to form a sand pack and wetted with kerosene. Afterward, 300 ml of kerosene was allowed to filter from the top through the sand pack. The time was stopped when kerosene drops slowed to less than one every five seconds. Same test using untreated sand was carried out as the reference. The average filter time over 5 runs for the pre-treated sand was 3 minutes and 2 seconds, while it was 3 minutes and 28 seconds for the untreated sand.
Example 4
[0047] 100 ml of water and 25 grams of 30/50 US mesh fracturing sands were added into each of two glass bottles (200 ml). The first sample was used as the reference. In the second sample, 2 ml of a solution containing 20% Tegopren 6924 and 80% of ethylene glycol mono-butyl ether, and 0.05 ml of kerosene were added. The slurry was shaken up and then let stand to allow sands settle down. When tilted slowly, the settled sand tended to move as cohesive masses. Sand grains were visually observed to clump together forming strong bridge among each others.
Example 5
[0048] 100 ml of water and 25 grams of 30/50 US mesh fracturing sands were added into each of two glass bottles (200 ml). The first sample was used as the reference. In the second sample, 2 ml of a solution containing 20% Tegopren 6924 and 80% of ethylene glycol mono-butyl ether, and 0.05 ml of frac oil were added. The slurry was shaken up and then let stand to allow sands settle down. When tilted slowly, the settled sand tended to move as cohesive masses. Sand grains were visually observed to clump together forming strong bridge among each others.
|
An aqueous slurry composition for use in industries such as petroleum and pipeline industries that includes: a particulate, an aqueous carrier fluid, a chemical compound that renders the particulate surface hydrophobic, and a small amount of an oil. The slurry is produced by rendering the surface of the particulate hydrophobic during or before the making of the slurry. The addition of the oil greatly enhances the aggregation potential of the hydrophobically modified particulates once placed in the well bore.
| 4
|
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.