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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a grid structure for a suspended ceiling, and more particularly to the assembly that interlocks a pair of intersecting cross-beams and a main beam in such grid structure.
2. Background Information
Suspended ceilings having a metal grid structure framework, which supports acoustical panels within rectangular enclosures formed by the grid, are used extensively in commercial and industrial buildings. The grid is suspended from a structure above the ceiling.
Such grid, as is well known, consists generally of parallel extending main beams and intersecting cross-beams. At an intersection, the main beam has a slot in its web which receives a pair of connector clips, with each connector clip, which is on the end of a cross-beam, inserted from opposing sides of the web to form a connector assembly. Such assemblies sometimes interlock the opposing cross-beams to the main beam in a first lock only, but more generally also have a second lock that interlocks the two cross-beams to each other.
Where it is particularly necessary that the assembly resist tension forces that tend to pull the assembly apart, as for instance from seismic events, as well as compressive forces, which tend to push the assembly apart, a first and second lock as referred to above is used. Where the compressive forces arise from fire, it may be desirable to provide expansion means in the assembly to keep the beams directionally in place to retain the panels in the ceiling.
One type of prior art assembly is the stab type, wherein the cross-beam connector clips are inserted into the main beam slot by a longitudinal thrust stab action. Another type of assembly is the hook type, wherein the cross-beam is hooked into the assembly.
Prior art assemblies of the stab type, generally depend on a spring action to engage components to interlock the clips to the main beam in the first lock, and to each other in a second lock. Such spring action is often complicated and does not provide a particularly high degree of resistance to separation from either tension or compressive forces, since the spring components must be made relatively light.
Prior art assemblies of the hook type, without spring action, generally only connect the cross-beams to the main beam in a first lock, without connecting the cross-beams to each other in a second lock. Such hook types are of rigid construction and are relatively simple to make and install, but lack substantial resistance to tension that pulls the assembly apart because of the lack of the second lock.
SUMMARY OF THE PRESENT INVENTION
The present invention is for a hook lock assembly that interlocks a main beam and two intersecting cross-beams in a first lock, and the cross-beams to each other in a second lock, in a simple and positive way. The second lock is formed by a connector clip on the end of a cross-beam that interlocks with an identical connector clip on another cross-beam within a slot on the main beam by means of a rigid gapped ridge that extends longitudinally on each clip.
The second lock is engaged as the hook on the second clip is moved vertically downward to engage the hook with the web of the main beam. This vertically downward movement causes the gapped ridge of one clip to intermesh and interlock with the gapped ridge of the other clip. The gaps in one clip are aligned with the ridge portions between the gaps in the other clip when vertical downward movement occurs, as guided by a generally vertical shoulder. Both first and second locks are of the positive type, without spring action.
The assembly, by means of the combination of both locks, strongly resists tension forces, such as imparted to a ceiling from a seismic event, in a simple effective way.
The assemblies can be made to permit expansion from fire, or alternatively, to resist expansion. A stop in the assembly made in the form of a shearable tab permits beam expansion from fire, or in the alternative, the stop can be relatively solid to resist expansion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-6 show the connector clip construction. FIG. 1 is an enlarged isometric view of the cross-beam connector clip of the invention.
FIG. 2 is a side elevational view of the connector clip shown in FIG. 1 .
FIG. 3 is a plan view of FIG. 2 .
FIG. 4 is a left hand end elevational view of FIG. 2 .
FIG. 5 is a right hand end elevational view of FIG. 2 .
FIG. 6 is a rear side elevational view of FIG. 2 .
FIGS. 7-17 show an assembly with a main beam and an opposing cross beam.
FIG. 7 is an enlarged fragmentary side elevational view showing one end of a cross-beam having a connector clip such as shown in FIGS. 1-6 attached to its terminal end and positioned with respect to the slot of the main beam prior to securing the cross-beam to the main beam in the first lock. The cross-beam, connector clip and main beam details are shown in full line and the initial insertion of the connector clip within the slot of the main beam is shown in dot and dash outline.
FIG. 8 is a plan view of FIG. 7 with some portions broken away and in section to show certain details of construction.
FIG. 9 is an enlarged fragmentary side elevational view taken on the line 9 , 9 of FIG. 7 showing details of the main beam and its slotted slot for the insertion of confronting cross-beam connector clips.
FIG. 10 is a side elevational view similar to FIG. 7 but showing the connector clip of the cross-beam inserted within the slot of the main beam to its initial limit position, just prior to completing a first lock. The cross-beam and associated connector clip as well as the main beam are then slightly angularly positioned with respect to one another to allow the connector clip of the cross-beam to be forced downwardly with respect to the slot of the main beam as shown by the arrow to complete a first lock.
FIG. 11 is a side elevational view similar to FIGS. 7 and 10 of the drawings but showing the cross-beam and associated connector clip of FIG. 10 in a seated in a first lock position. In addition, there is shown, in full line, the fragmented terminal end of an opposed cross-beam and connector clip, spacedly positioned with respect to the slot of the main beam, prior to securing the opposed cross-beam to the main beam to complete the first lock. The initial insertion of the opposed connector clip of the opposed cross-beam within the slot of the main beam is shown in dot and dash outline.
FIG. 12 is a fragmentary sectional elevational view taken on the line 12 , 12 of FIG. 11 showing the positioning of the connector clip of the cross-beam of FIGS. 7, 10 and 11 in a first lock position within the slot of the main beam.
FIG. 13 is a side elevational view similar to FIG. 11 of the drawings but showing the connector clip of the opposed cross-beam inserted within the slot of the main beam to its initial limit position, the opposed cross-beam and associated connector clip are angularly disposed with respect to the main beam and slot prior to forcing the opposed connector clip downwardly as shown by the arrow into a completed first lock and second lock position. Portions of the locked-in connector clip of FIG. 11 have been broken away, for clarity, and the profile of the connector clip overlying the opposed connector clip is shown in dot and dash outline.
FIG. 14 is a fragmentary sectional elevational view taken on the line 14 , 14 of FIG. 13 showing the relative positions of the cross-beam connector clips within the slot of the main beam just prior to completing the first and second locks of the opposed cross-beam and associated connector clip to the main beam and adjacent cross-beam connector clip.
FIG. 15 is a side elevational view similar to FIG. 13 showing the assembly of the invention with the first and second locks engaged.
FIG. 16 is a fragmentary sectional elevational view taken on the line 16 , 16 of FIG. 15 showing the interlocked positioning of the connector clips within the slot of the main beam when the first and second locks are engaged.
FIG. 17 is a fragmentary sectional plan view taken on the line 17 , 17 of FIG. 15 showing the axial alignment of the cross-beams when their connector clips are in interlocking engagement within the slot of the main beam with the first and second locks engaged.
FIGS. 18 and 19 show the assembly being disassembled under restricted conditions.
FIG. 18 is an enlarged fragmented sectional elevational view similar to FIG. 15 but showing the first step in freeing one end of an interlocked cross-beam from the assembly of interlocked cross-beams and main beams.
FIG. 19 is a view similar to FIG. 18 showing the remaining step in removing the freed end of a cross-beam from an assembly of interlocked cross-beams and main beams.
FIGS. 20 to 26 show a connector clip assembly expansion under fire conditions.
FIG. 20 is an enlarged fragmenting sectional elevational view similar to FIG. 15 but showing the left hand terminal end and associated interlocking connector clip being moved toward the right hand cross-beam through the slot of the main beam due to expansion of the left hand cross-beam from a source of heat:
a) upper tab sheared away;
b) left hand connector clip being moved upwardly and inwardly out of engagement with the gaps in the ridge of the opposing connector clip, compared to FIG. 15.;
c) lower flange of cross-beam is raised above the upper surface of the main beam flange;
d) the upward movement of the connector clip is created by the contact of the cam face on the lower end of the connector clip and the lower edge of the slot in the main beam.
FIG. 21 is a view similar to FIG. 20 but showing the left hand cross-beam terminal end and associated connector clip having moved its connector clip through the slot of the main beam to its cross-beam expansion limit.
FIG. 22 is a fragmentary sectional elevational view taken on the line 22 , 22 of FIG. 20 showing the separation of the ridges of the opposed interlocking connector clip of the cross-beams within the slot of the main beam.
a) with reference to FIGS. 15, 16 and compared to FIGS. 20, 22 it can be seen that the interlocked gaps in the ridges of the cross-beam connector clips are disengaged, as shown in FIG. 22 as the left hand connector clip moves upwardly and inwardly toward the opposing connector clip.
b) the apexes of the gaps in the ridges and their sides no longer interengage with each other.
c) the left hand connector clip can now advance to the right, its gapped ridge raised above the plane of the opposed gapped ridge.
FIG. 23 is a fragmentary sectional plan view taken on the line 23 , 23 of FIG. 21 showing details of the left hand cross-beams terminal end and associated connector clip having traveled to its limit of expansion due to a source of heat as shown in FIG. 21 and the corresponding horizontal displacement of the cross-beams axial center lines and flexing of the right hand connector clip with respect to the slot in the web of the main cross-beam.
a) resistance forces during expansion are generated by the ridge of the connector clips engaging the vertical end faces of the opposed cross-beam webs and the frictional forces generated by the side walls of the connector clips with side walls of the slot in the main cross-beam, which exerts a pinching effect on the connector clips.
FIG. 24 is a view similar to FIG. 21 but showing the right hand terminal end of the right hand cross-beam and its associated chip expanding due to a continued source of heat against the opposed fully expanded left hand cross-beam and connector clip.
a) the upper tab of the right hand connector clip is sheared away;
b) the upper right hand connector clip rises due to the inclined front face of the lower flange engaging the lower edge of the main beam slot until the apexes of the gaps in the ridge of both connector clips comes into contact. See FIG. 23 .
c) since the right hand connector clip is prevented from rising fully, the lower edge of the bottom flange must cut through the corner of the slot on the lower right hand side;
d) the bottom flange of the right hand cross-beam is raised enough to ride over the bottom flange of the main beam.
FIG. 25 is a fragmentary sectional elevational view similar to FIG. 24 but showing the right hand cross-beam terminal end and associated connector clip having traveled to its limit of expansion due to a continued source of heat.
FIG. 26 is a fragmentary sectional plan view taken on the line 26 , 26 of FIG. 25 showing details of both terminal ends of the cross-beams and associated connector clips with respect to the slot of the main beam in their fully expanded mode.
a) slight offset of the cross-beams centerlines in the horizontal plane
b) (FIG. 25) slight offset of cross-beams centerlines in the vertical plane
c) deformation of slot due to frictional forces.
DESCRIPTION OF THE PREFERRED EMBODIMENT
1. Construction of Connector Clips as Seen in FIGS. 1-6.
Connector clip 20 is stamped or otherwise formed of suitable spring steel or the like. The connector clip is generally rectangular as seen in profile in FIGS. 5 and 6. The connector clip has an upper portion 21 , a lower portion 22 , a rear portion 23 , and a front portion 24 , and a middle portion 25 . These portions are all in planes that are offset from one another. Each portion serves a distinct function in the connector clip assembly.
Transitional surfaces 26 serve to connect the portions together.
The rear portion 23 serves as a base to anchor the connector clip 20 to the end of a cross-beam.
Portion 23 will also be used as a datum plane to provide a reference for the other offset portions.
Holes 15 provide means to stake the connector clip onto the beam as well known. Tabs 26 are simply leftover from the forming operation wherein the connector clips are generally stamped, in groups, from strip metal, in a well known manner.
Upper portion 26 has a bevel 27 , a shoulder 28 , a tab 30 and a recessed shelf 31 . The upper portion 21 is in a plane offset from rear portion 23 .
Lower portion 22 is likewise offset from rear portions 23 and has a hook 32 , a recess 33 , and a shoulder 34 with a ramp 39 .
The middle portion 25 is in the form of a generally V-shaped cross-section ridge 36 with gap openings 37 and 38 . Gaps 37 and 38 have rear edges 40 and 41 in the form of an apex, and relatively straight rearwardly extending, front edges 42 and 43 . The ridge 36 straddles the plane of the rear portion 23 .
2. Clip Assembly as Seen in FIG. 7-17
A connector clip 20 is staked 45 or otherwise fastened to the web 46 at the end of cross-beam 47 . The connector clip is adapted to be inserted through slot 48 in web 50 of main beam 51 . Front portion 24 is inserted through slot 48 of main beam 50 as seen in FIG. 7, in a hooking action shown in detail in the drawings, and then brought into the position as seen in solid line in FIG. 11 .
In the hooking action as seen in the drawings, there occurs a generally vertical downward movement, as seen particularly in FIG. 10 . At the beginning of the downward movement, as seen in broken lines, the front portion 24 of clip 20 has passed through slot 48 in a raised position, so that hook 32 can clear the bottom of the slot. Shoulder 28 prevents further movement horizontally into the slot 48 . Clip 20 is then forced downward, as shown by the arrow in FIG. 10 until shoulder 28 can clear the top of slot 48 , and recess 33 engages the bottom edge of slot 28 . Flange 52 will engage flange 53 , on main beam 51 . Clip 20 is shown fully seated in slot 48 of main beam 51 in FIGS. 11 and 12. The first lock between the main beam 51 and cross-beam 47 is completed at this position.
The opposing connector clip 20 ′ is brought into engagement with the connector clip 20 by being inserted in a hooking action from the opposing side. It is this hooking action that is critical to the assembly since it permits the ridge 36 ′ of 20 ′ to by-pass the ridge 36 of 20 during insertion without interference and then have gaps 37 and 38 in the ridge 36 interlock with the gaps 37 ′ and 38 ′ in the ridge 36 ′ in a relatively vertical movement. It is this movement which simultaneously completes the first and second locks. When interlocked, the relatively straight, rearwardly extending, edges 42 and 43 in gaps 37 and 38 abut relatively straight, rearwardly extending, front edges 42 ′ and 43 ′ in gaps 37 ′ and 38 ′, thus resisting any tension forces that tend to separate the connector clips.
The hooking action, which results in an interlock of the gaps during assembly to form a second lock, can also be seen in the end sections as shown in FIGS. 14 and 16 as well as the top view of FIG. 17 . During the insertion by a hooking action of the connector clip 20 ′ as seen in FIG. 14, ridge 36 ′ extends above ridge 36 of connector clip 20 . When beam 47 ′ and clip 20 ′ are brought into a horizontal position, the gapped ridges 36 and 36 ′ are interlocked into a second lock, whereby they exert substantial resistance against separation by tension from opposing forces exerted by beams 47 and 47 ′ on connector clips 20 and 20 ′ such as encountered during seismic disturbances.
The first and second locks are completed in this position.
Connector clips 20 and 20 ′ also resist compressive forces by means of tabs 30 and 30 ′ and the abutment of flanges 52 and 52 ′ against flange 53 on main beam 51 .
When tab 30 is formed in a solid manner, so that it extends substantially rearward so that it is not shearable, the front surface of the tab also presents a substantial resistance against compression.
Where rear edges 40 and 41 of gaps 37 and 38 of connector clip 20 are also not pointed, but are substantially straight, such interlocking back edges will also provide a resistance against compression.
When connector clips 20 and 20 ′ are interlocked, as shown particularly in FIG. 15, hooks 32 and 32 ′ will engage web 50 of main beam 51 to also resist withdrawing of the connector clips from the main beam.
3. Disassembly of the Connector Clip Assembly Under Restricted Conditions as Seen in FIGS. 18-19
Where there is available room in a grid ceiling, an assembly may be disassembled in the reverse steps of the way it was assembled.
Where space is restricted, the assembly can be disassembled as shown in FIGS. 18 and 19. The main beam 51 is twisted to shear off a tab 30 as seen in FIG. 18 . With the main beam held in twisted position, the main beam is clear of the recessed shelf 31 , permitting in cross-beam 47 to be lifted up so that hook 32 clears web 50 of main beam 51 , permitting cross-beam 47 to be withdrawn. Main beam 51 is permitted to resume its vertical web position with the web vertical. Beam 47 can be reinserted if desired and used without the sheared tab.
4. Clip Assembly Expansion Under Fire Conditions, as Seen in FIGS. 20 to 26
As seen in FIG. 20, as the beams expand under fire conditions, tab 30 on connector clip 20 is sheared off and the connector clip 20 rises within the slot 48 of main beam 51 as it rides on inclined surface 39 . This raises ridge 36 slightly above ridge 36 ′ as seen in FIG. 22, while the apexes of edges 40 and 41 of the rear of gaps 37 and 38 cause the ridges 36 and 36 ′ to slide apart and separate from one another. Such movement of connector clip 20 ′ occurs until a position as shown in FIG. 21 is reached.
Upon further expansions of cross-beams 47 and 47 ′, tab 30 ′ on connector clip 20 ′ is sheared, and the same movement occurs, as occurred with beam 47 , until full expansion occurs as shown in FIG. 26 .
The expansion is permitted by the shearing of tabs 30 and 30 ′, and the action of the apexes of edges 40 and 41 . Where such tab is in effect a solid barrier, and the apexes of edges 40 and 41 are in straight edge form, rather than pointed into an apex, no such expansion occurs, since there is a substantial resistance against compressive forces, since the straight edges interfere with expansion. In either a fire resistant assembly, or a compression resistant assembly, the inventive feature of a hook action that permits interlocking of a middle section ridge and gaps of the connector clips remains the same.
When an increase in beam strength is desired, stitches 55 can be provided in the beam web is as disclosed in copending U.S. patent application Ser. No. 08/773,250 for Rollformed Sections and Process of Producing Same. Such increase in strength is particularly helpful to prevent collapse of the beam during expansion from fire, where the assembly of the invention includes the embodiment which permits expansion from heat during a fire.
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A hook type assembly that interlocks a pair of intersecting cross-beams and a main beam in a grid for a suspended ceiling. A gapped ridge in a clip on each cross-beam engages the other gapped ridge in a vertical movement that is part of a hooking action while the assembly is formed. The assembly can be optionally made to provide for expansion during a tire.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a diagnostic system for a jacquard machine, in particular, a jacquard machine for a weaving loom.
2. Description of the Related Art
Jacquard machines for weaving looms usually include a plurality of heald hooks arranged in rows extending in the weft direction, the rows being located side by side in the warp direction.
Each row of hooks is acted upon by a reciprocating knife such that selected hooks in the row are moved from one shed position to and held at another shed position during a pick in the weaving cycle. Depending upon the type of jacquard machine, the knife may move only selected hooks from said one shed position or may move all hooks from said one shed position such that selected hooks can be retained at said one shed position.
In order to ensure that fabric being woven has no faults caused by failure to select a chosen heald hook it is known to provide detection means which act to produce a signal should the chosen heald hook not be selected. Such detection means are usually in the form of mechanically operated electrical switches and these tend to be unreliable. In addition, in a Jacquard machine, there can be several thousand heald hooks and so the use of mechanical switches becomes increasingly more unsatisfactory and costly.
BRIEF SUMMARY OF THE INVENTION
According to one aspect of the present invention, there is provided a diagnostic system for a jacquard machine having a plurality of heald hooks movable between at least two discrete shed positions, the system including visual sensing means for producing a visual image of hooks located at one of said shed positions during each weaving cycle, and control means for comparing said visual image with a predetermined shed pattern for each corresponding weaving cycle in order to determine whether or not all the appropriate hooks have been selected to define the required shed pattern.
Preferably, the visual sensing means comprises at least one video camera located to one side of the jacquard machine so as to view the heald hooks at an inclined angle.
Preferably, datum means are provided to enable the control means to determine the location of each heald hook. The datum means may be in the form of a pattern located around the periphery of the rows of heald hooks to thereby enable the control means to create an orthogonal virtual grid of imaginary lines, the location of each hook being at the intersection of said imaginary lines.
The heald hooks may be adapted to make them more visibly distinct, for example, by being coated with a suitable paint.
According to another aspect of the present invention, there is provided a diagnostic method for a jacquard machine having a plurality of heald hooks movable between at least two shed positions, the method including the steps of creating a visual image of hooks located at one of said shed positions during each weaving cycle, and comparing said visual image with a predetermined shed pattern for each corresponding weaving cycle in order to determine whether or not all the appropriate hooks have been selected to define the required shed pattern.
Various aspects of the present invention are hereinafter described with reference to the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of the upper part of a Jacquard machine including a diagnostic system according to the present invention; and
FIG. 2 is a schematic diagram showing the image viewed by the camera in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
A jacquard machine 10 is schematically shown in FIGS. 1 and 2 having a frame 12 in which a plurality of lifting knives 14 are mounted for reciprocal movement.
Each knife 14 co-operates with a row 15 of heald hooks 16, there being shown eight rows 15 of heald hooks and eight lifting knives. It will be appreciated that any number of knives 14 and corresponding rows 15 may be provided. Each row 15 contains the same number of heald hooks 16. The heald hooks 16 are regularly spaced along the corresponding knife and are aligned with heald hooks 16 located at the same position on neighbouring rows.
Accordingly, the heald hooks 16 are also arranged in rows 18 which are spaced side-by-side along the knives 14.
It will be appreciated therefore that the heald hooks 16 are arranged in an orthogonal grid pattern composed of rows 15 and rows 18, each heald hook 16 being located at the intersection of each row 15 and row 18.
In accordance with the present invention, there is provided a diagnostic system which includes a visual sensing means 30 and an electronic control 40.
The visual sensing means 30 is preferably in the form of a video camera 31 which is mounted above and to one side of the top of the jacquard machine 10 so as to view hooks 16 as they rise to their upper shed position. The image viewed by the camera is schematically shown in FIG. 2.
The electronic control 40 preferably comprise a computer which receives the video image from the camera, preferably via a digitizer interface.
The computer is arranged to receive an operating signal O during each weaving cycle. The operating signal O may be generated by, for example, a sensor on the drive shaft 42 of the jacquard in the case of a jacquard having mechanically operated pattern selection or may be generated from the electronic control of a jacquard having electronically controlled pattern selection.
On receipt of signal O, the computer is arranged to grab an image from the camera and use the image to identify the presence of hooks located at their upper shed position and then determine whether or not all selected hooks have been raised.
Preferably, the camera is a monochrome camera and preferably, the upper portion 16a of the hooks 16 have been adapted, for example, by painting to define a high contrast with their background. In this respect, preferably the upper portions 16a and painted white so that the upper portions 16a when viewed by the camera appear light compared to the background.
Accordingly, the presence of a hook 16 at its upper shed position is identified in the grabbed image by the computer software locating the areas of bright pixels.
Having identified the presence of a hook, it is necessary for the computer to determine its location in the array of hooks so as to enable the computer to determine whether or not that hook should be at its upper shed position.
It is appreciated that the computer could be programmed with a look-up map identifying the locations of each hook. However, this would require the camera to be accurately positioned and for it to remain in that position during its working life. Accordingly, it is preferred to provide a system whereby the computer can determine the grid locations of the heald hooks using the image produced by the camera.
A first method is to locate targets at predetermined positions on the jacquard frame 12. For example, as seen in FIG. 1 a pair of targets 50 may be provided at diagonally opposite corners of the jacquard frame 12. The shape and contrast of the target 50 is chosen so as to be easily recognised by the software and provides a pair of fixed reference points in the image produced by the camera.
Prior to a weaving operation, a set-up routine is performed.
This initially involves the computer locating the targets 50 and storing in memory their co-ordinates. The jacquard machine is then run with a predetermined weave pattern, for example, a plain weave, and the software reconciles the pattern of the lifted hooks 16 in the image with the predetermined pattern sequence and provides and stores in memory co-ordinates in the image for each hook grid location.
After this set-up procedure, the computer is able to accurately monitor lifting of each hook as long as the camera position does not change. Accordingly, the computer preferably continually monitors the co-ordinates of the viewed targets 50 and compares them with the co-ordinates stored during set-up. If the comparison shows that the camera position has changed, weaving is stopped and a new set-up routine is performed.
A second method of determining the grid location of each hook 16 is illustrated in FIG. 2.
In FIG. 2, a rectangular target 60 is provided on the top of the machine frame 12 and is arranged to identify the position of rows 15 and rows 18. The target 60, for example as shown in FIG. 2, consists of dark areas 81 contrasting with light areas 82. The dark areas 81 may, for example, be aligned with each row 15 or 18.
The software is arranged to scan the image and using the target 60 create a virtual grid of imaginary orthogonal lines. The software determines the cross-over points of the orthogonal lines and thereby determines the grid location of each heald hook 16. Scanning of the image to create the virtual grid occurs during each weaving cycle. Accordingly, movement of the camera does not affect determination of the grid location of each hook.
It will be appreciated that it is not necessary to provide a visual identification for every row 15 or 18 since the dimensions of the hook array are known and so some rows positions can be interpolated knowing the positions of the other rows.
Also, since the geometry of the target panel 60 are known, the scanned information used to determine the virtual grid will automatically compensate for perspective errors in the image caused by some hooks being closer to the camera than others.
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A diagnostic system for a jacquard machine having a plurality of heald hooks (16) moveable between at least two discrete shed positions, the system including visual sensing means (30) for producing a visual image of hooks (16) located at one of said shed positions during each weaving cycle, and control means (49) for comparing said visual image with a predetermined shed pattern for each corresponding weaving cycle in order to determine whether or not all the appropriate hooks have been selected to define the required shed pattern.
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[0001] This application is a continuation of U.S. patent application Ser. No. 09/255,228, filed Feb. 22, 1999, which is a divisional of U.S. patent application Ser. No. 08/851,368, filed May 5, 1997, now U.S. Pat. No. 6,091,717.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to cellular telephone network data transmission, specifically to a method of scheduling packet data transmission for a connection-less packet service.
[0004] 2. Prior Art
[0005] Packet data communication is known in cellular telephone systems, as is evidenced by, for example, commonly assigned U.S. Pat. No. 5,257,257, issued Oct. 26, 1993, entitled “Method of Controlling the Operation of a Packet Switched CDMA Communication Network for Controlling the Operation of Transmitters and Receivers”, by X. H. Chen and J. Oksman.
[0006] One further example is defined in TIA/EIA/IS-657, Packet Data Service Option for Wideband Spread Spectrum Cellular System. IS-657 is used along with TIA/EIA/IS-95A, Mobile Station-Base Station Compatibility Standard for Dual-Mode Wideband Spread Spectrum Cellular System, and, TIA/EIA/IS-99 Data Services Option Standard for Wideband Spread Spectrum Digital Cellular System. The current IS-657 based packet data scheme for code division multiple access (CDMA) does not allow the traffic channel to be shared between more than one user. The IS-657 scheme is based on a make-and-break of multiple traffic channel connections during the life of a packet data session. In the worst case, a packet may suffer a call set-up delay which can range from tens of milliseconds to a few seconds. Also, it is possible for a mobile station (MS) to transmit idle (eighth rate) frames for a user defined time if there are no packets to send. This results in wasted bandwidth, especially in high-speed data systems, because the traffic channel capacity is reserved for this user and cannot be utilized by any other user. Thus, an access scheme that allows two or more users to share traffic channels, and allows the network to control the packet delay is needed.
[0007] In connection-less packet data transmission in mobile communication systems, discrete packets are transmitted on a packet-basis, that is, no dedicated end-to-end connection is set up. Sharing of traffic channels in connection-less packet data transmission has generally been supported via random access or random reservation media access control (MAC) protocols. Under these MAC protocols, multiple mobile stations compete for traffic channels in order to receive packet data service from a base station (BS). The number of available traffic channels for packet service within a cell is defined by the BS.
[0008] Random reservation protocols are generally believed to offer high channel utilization. However, in a CDMA based system that is approaching the system's maximum capacity, random access attempts are more likely to be unsuccessful due to higher interference levels. Thus, as a cell approaches its maximum capacity of available traffic channels, multiple MSs compete for fewer and fewer available traffic channels. This normally leads to even further access attempts by the MSs. Often, the random attempts themselves increase the communications load in the cell and reduce traffic channel capacity.
OBJECTS AND ADVANTAGES OF THE INVENTION
[0009] It is a first object and advantage of this invention to provide an efficient method for transmitting packet data over a cellular communication network that overcomes the foregoing and other problems.
[0010] Another object and advantage of this invention is to maintain scheduled traffic channel sharing among multiple packet data users who are attached to a cell of a mobile communication network.
[0011] Another object and advantage of this invention is to provide the base station of a cellular communication network with control over which mobile station(s) may attempt access to the system during a specified period of time.
[0012] Another object and advantage of this invention is to provide the base station of a cellular communication network the ability to preemptively control priority and duration of mobile station access by employing a scheduling method which considers one or more parameters including priority access service, quality of service, and a maximum number of bytes per transmission.
SUMMARY OF THE INVENTION
[0013] The foregoing and other problems are overcome and the objects of the invention are realized by methods and apparatus in accordance with embodiments of this invention. More particularly, this invention is directed to solving the problem of inefficient packet data transmission in CDMA based mobile communication systems.
[0014] Scheduled packet access, as taught by this invention, leads to more stable load conditions, offers higher channel utilization, and enables determination and control of a maximum delay in packet data transmission experienced by users. According to the teachings of this invention, the BS divides access to the traffic channel(s) allocated for packet data services into time slots. The right to access a given traffic channel for a specific time slot is referred to as a packet token, hereinafter simply a token. One or more token(s) are allocated to the MSs from time slot to time slot, in a pre-defined manner. The token allocation schedule is determined at the BS, which may employ a variety of schemes to determine how the token is assigned. This pre-defined, scheduled token allocation is distinguishable over conventional random access and random reservation protocols. Token allocation, as taught by this invention, is accomplished by granting transmission access to an available traffic channel to each packet data MS in the cell according to specific, scheduled time intervals. This scheduled approach allows the BS to preemptively control traffic channel access among packet data MSs. Random access protocols, on the other hand, allow access to an available traffic channel as a packet data MS requests it. Thus, the conventional random protocols employ a first-come-first-serve method of traffic channel access assignment.
[0015] Allocating the right to access an available traffic channel may not always result in a transmission from the packet data MS. If, at the end of a time slot, the BS has not received a valid transmission from the MS(s) who are allocated the token(s), either because the MS has nothing to send or an access preamble did not reach the BS successfully, then the BS allocates the token to the next MS(s) in the cell. In this way, the MSs share the packet traffic channels in a time-multiplexed fashion, and the BS schedules and controls the allocation of the traffic channels at all times. This technique eliminates the problems associated with conventional MS random access attempts to gain a traffic channel for transmitting a packet.
[0016] This invention preferably employs a technique in which a BS transmits at least one dedicated MAC channel on the forward link. When transmitting the MAC channel messages to a specific MS the BS may use a permuted electronic serial number (ESN) of the MS as a long code mask, and when broadcasting MAC channel messages to all MSs within a cell the BS preferably uses a public long code mask. The MAC channel messages convey packet data traffic channel information and status information on the allocation of the token(s) to packet mobile stations in the cell. The MAC channel messages are updated to reflect the latest token usage. By decoding the latest MAC channel message a MS evaluates who has the token(s) for the next time slot, and is able to predict when it should next be allocated the token from the BS. The MS holding a token may attempt to access the traffic channel if it has data to send. The MS preferably uses its own private long code for reverse link transmission, as the BS expects a preamble signal from the MS(s) currently holding a token. Every packet traffic channel has a pre-defined Walsh code associated on the forward link to which the MS listens to determine whether its access was successful. After an access acknowledgement is received from the BS, the MS terminates the preamble and starts to transmit its packet data. At this point, the MS may negotiate the traffic channel data rate with the BS. The initial traffic channel data rate is pre-defined by a Service Option and may be as low as a predefined low speed data service, such as 9.6 kpbs.
[0017] Once occupied, the traffic channel is preferably allocated to that MS until the end of the packet. The maximum time a MS is allowed to occupy a channel is predefined by the network, so that the BS can predict worst case channel usage. The BS may employ various techniques to ensure efficient channel usage. For example, when assigning a token, the BS may define a maximum number of bytes that a MS may transmit. If this maximum number of bytes per transmission is exceeded, the BS has the option to terminate a packet transmission by sending a transmission stop bit on the associated forward link traffic channel. If the transmission is stopped, the MS relinquishes the token at the next time slot and rejoins the pool of MSs awaiting the next available token. Similarly, if the transmission of packet data completes the MS yields the token at the next time slot. These techniques for monitoring transmissions may be based on equal sharing between MSs, or allow for different priorities of transmission which depend on the quality of service selected.
[0018] In accordance with the present invention, the BS allows the MS to turn off its receiver and save power during the periods when the MS does not hold the token. If the MS does shut down its processing between tokens the BS informs the MS, before the MS shuts down, when it should start its processing again, i.e. when the MS will be allocated the token again. This notification by the BS before the MS shuts down is possible as the token is assigned in advance. Thus, a “dynamic slotted mode” operation is provided, the operation being dynamic in that the position of the slot need not be the same in every cycle. The slot position is a function of how many active MSs are on the channel, and on how much data each MS can transmit. Additionally, the number of slots is a function of the number of available channels at the BS.
[0019] The BS may transmit packets destined for a MS, if any, or fill data, on the forward link at the same time that the MS is allocated a token and is transmitting packets on the reverse link. This allows the BS to send power control information to the MS.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The above set forth and other features of the invention are made more apparent in the ensuing Detailed Description of the Invention when read in conjunction with the attached Drawings, wherein:
[0021] FIG. 1 is a block diagram of a cellular terminal that is suitable for practicing this invention;
[0022] FIG. 2 depicts the terminal of FIG. 1 in communication with a CDMA cellular network;
[0023] FIG. 3A is a pictorial representation of a media access control (MAC) channel frame structure employed, in accordance with the invention, by the BS to broadcast packet data traffic channel information and token allocation information to each MS;
[0024] FIG. 3B is a pictorial representation of the Forward Link BS MAC Transmissions in relation to the Reverse Link MS Transmission Time Slots;
[0025] FIG. 4 is a logic flow diagram, according to the invention, for a MS to predict its next allocation of a token;
[0026] FIG. 5 is a state flow diagram, according to the invention, for MS packet operation; and
[0027] FIG. 6 is a state flow diagram, according to the invention, for BS packet operation.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Reference is first made to FIGS. 1 and 2 for illustrating a wireless user terminal or mobile station (MS) 10 , such as but not limited to a cellular radiotelephone or a personal communicator, that is suitable for practicing this invention. The MS 10 includes an antenna 12 for transmitting signals to and for receiving signals from a base site or base station (BS) 30 . The BS 30 is a part of a cellular network 32 that includes a mobile switching center (MSC) 34 , and a plurality of additional BSs, such as BS 30 ′. Each BS, for example BS 30 , services an associated cell within the network 32 and is assumed to include a plurality of receivers 30 a and transmitters 30 b , some of which can be allocated for packet data services. The MSC 34 provides a connection to landline trunks when the mobile station 10 is involved in a call. It is assumed for the purposes of this invention that the network 32 supports packet data service. For example, the network 32 may be coupled to a packet data network 36 such as the internet, and/or to a LAN or WAN.
[0029] The mobile station includes a modulator (MOD) 14 A, a transmitter 14 , a receiver 16 , a demodulator (DEMOD) 16 A, and a controller 18 that provides signals to and receives signals from the transmitter 14 and receiver 16 , respectively. These signals include signalling information in accordance with the air interface standard of the applicable cellular system, and also user speech and/or user generated data. The air interface standard is assumed for this invention to include a capability to convey packet data.
[0030] In the presently preferred embodiment of this invention the modulator 14 A, transmitter 14 , receiver 16 , and demodulator 16 A are adapted to operate with a code division multiple access (CDMA) system, such as one specified in IS-95A. The teaching of this invention is not, however, limited for use with only this type of system, but may be employed with a number of different types of systems having different modulation and access characteristics, such as time division, multiple access (TDMA) systems.
[0031] It is understood that the controller 18 also includes the circuitry required for implementing the audio and logic functions of the mobile station. By example, the controller 18 may be comprised of a digital signal processor device, a microprocessor device, and various analog to digital converters, digital to analog converters, and other support circuits. The control and signal processing functions of the mobile station are allocated between these devices according to their respective capabilities.
[0032] The mobile station 10 may be capable of voice transmissions also, and thus can include a user interface comprised of a conventional earphone or speaker 17 , a conventional microphone 19 , a display 20 , and a user input device, typically a keypad 22 , all of which are coupled to the controller 18 . The keypad 22 includes the conventional numeric (0-9) and related keys (#,*) 22 a , and other keys 22 b used for operating the mobile station 10 . These other keys 22 b may include, by example, a SEND key, various menu scrolling and soft keys, and a PWR key. The mobile station 10 may also include a battery 26 for powering the various circuits that are required to operate the mobile station.
[0033] It should be realized that in other embodiments the mobile station 10 may function only as a data terminal for at least one of transmitting or receiving packet data. The mobile station 10 which functions as a data terminal can include a data port 28 which is coupled to the controller 18 . As a data terminal, certain of the user interface components described above may not be included. It should also be appreciated that in some embodiments the mobile station 10 may not be mobile at all, but may be operated at a fixed location (for example, as a component of a wireless facsimile machine in an office environment).
[0034] The mobile station 10 also includes various memories, shown collectively as the memory 24 , wherein are stored a plurality of constants and variables that are used by the controller 18 during the operation of the mobile station. For example, the memory 24 may store the values of various cellular system parameters and the number assignment module (NAM). An operating program for controlling the operation of controller 18 is also stored in the memory 24 (typically in a ROM device). The memory 24 may also store packet data prior to transmission or after reception. The memory 24 includes routines for implementing the methods described below in relation to FIGS. 4 , 5 and 6 .
[0035] Packet data service options provide a mechanism of establishing and maintaining traffic channels for packet data service. A packet data service option is negotiated during call origination or at a later time during a call. The details of establishing packet data service can be found in, by example, IS-95A, IS-657, and IS-99.
[0036] In accordance with this invention, the call origination messages are modified from the definitions in the above mentioned standards to include a MAC channel frame structure as shown in FIG. 3A . The MAC channel frame structure is broadcast by the BS 30 to all MSs 10 within the cell at regular intervals of time, referred to as a MAC transmission period. The BS 30 divides access to the traffic channel(s) allocated for packet data services according to time slots. A time slot is defined as the time period required for a MS to transmit all or some of its packet data. A time slot is limited to the maximum transmission time set by the BS 30 . Time slots may be of unequal duration, as each time slot's duration can be defined by the amount of packet data a MS 10 is transmitting, up to a maximum transmission time. Additionally, one or more MAC transmission periods may elapse within a time slot, however, each time slot has a duration that is a whole multiple of the duration of the MAC transmission period. The relationship between time slots and MAC transmission periods is illustrated in FIG. 3B . In essence, the time slot represents a given period of time in which a MS 10 has the right to access a traffic channel. The MS 10 that is allocated this access right is allocated a token. The MAC channel frame structure contains various fields that are used by the BS 30 to schedule traffic channel access, i.e. token allocation. As is shown in FIG. 3B , a portion of an assigned time slot may be unused by a MS 10 .
[0037] The MAC channel frame structure includes a plurality of one bit wide fields, 1 to n. These fields are referred to as “activity” fields. Each activity field defines the status of a corresponding MS 10 , and may have a value of either zero (“0”) or one (“1”). A field value of zero indicates that the corresponding MS 10 has not been assigned to a traffic channel by the BS 30 . A field value of one indicates that either the MS has been assigned to receiver hardware in the BS 30 , or that the activity field is not currently assigned to any MS within the cell. In the preferred embodiment the activity field is a one bit wide field, however, a field width of more than one bit may be used for conveying the activity status information of one or more MSs 10 .
[0038] Additionally, each activity field corresponds to a temporary identification number that is assigned by the BS 30 to the MSs 10 for purposes of media access control. These temporary identification numbers are referred to as MAC IDs. The BS 30 allocates a different MAC ID, and hence a different corresponding activity field, to each MS 10 within the cell. A MAC ID is valid for the BS 30 that assigns it, and multiple BSs 30 may each assign different MAC IDs to the MS 10 in order to support virtual “soft handoff”. Thus, each packet may be routed via a different BS 30 , but never via more than one BS for one packet, depending on the signal condition to/from that BS. The virtual soft handoff is preferably mobile-assisted and is based on the pilot signal condition seen by the MS 10 , in the similar manner as in conventional soft handoff procedures.
[0039] According to the embodiments of this invention, the virtual soft handoff procedure differs from conventional soft handoff procedures. In conventional soft handoff procedures, the traffic channel is handoff from a first BS to a second BS. In accordance with this invention, the mobile station's monitoring of the MAC channel is handoff from the MAC channel of the first BS 30 to the independent MAC channel of the second BS 30 ′. In other words, the MS 10 is first receiving MAC information from the MAC channel of the first BS 30 . At some point, the MS 10 will be receiving the MAC channel of the first BS 30 as well as the MAC channel of the second BS 30 ′. Because token allocation and scheduling information is maintained within the MAC information the MS may receive a token from either BS 30 or 30 ′ and transmit to that BS during the virtual soft handoff process. Once a token is received it is held until transmission is completed. For example, a token received from the first BS 30 does not give the MS 10 the right to transmit to the second BS 30 ′. Additionally, there may be an occurrence when a token is simultaneously offered by both BSs, 30 and 30 ′, servicing the MS 10 . In this event, the MS 10 preferably accepts the token that is allocated by the “best” quality channel (e.g. lowest bit error rate or frame error rate) and transmits the packet data to the associated BS 30 or 30 ′. When the pilot signal of the first BS 30 drops below a predetermined level the MS 10 drops the MAC channel of the first BS 30 and monitors only the MAC channel of the second BS 30 ′. After the MS 10 drops the first BS 30 , the first BS 30 is free to reassign the MAC ID it previously assigned to the MS 10 .
[0040] Because every packet MS 10 has its own MAC ID the total number of required MAC IDs could become excessively large for a large cell. Therefore, packet users may be divided into MAC sub-groups, and MAC ID numbers can be re-used within the sub-groups of different channels.
[0041] MAC IDs are preferably allocated by the BSs 30 during a “virtual call set-up”procedure. The BS 30 that performs the virtual connection is preferably the BS from which the MS 10 receives the strongest pilot signal. This invention assumes that the interworking function (IWF) that has been established with a fixed packet data network, e.g. internet, resides in the mobile network, not at the first BS where the MS sets up the virtual connection. That is, the IWF in the MSC 34 is connected to two or more BSs.
[0042] The MAC channel frame structure also includes a Next MAC ID field. This field is an n-bit wide field, where n represents a number of bits which can accommodate the maximum allowable width of the MAC ID field. The Next MAC ID field indicates which MS(s) 10 are allowed to transmit data during the next time slot, i.e. who will have the next token. The Next MAC ID field is sent in each MAC frame message. As a result, if any MSs 10 miss one or more MAC frames they are enabled to quickly determine the access token rotation.
[0043] Lastly, the MAC channel frame structure includes a #Free Channels field. This field is an m-bit wide field, where m represents a number of bits which can accommodate an integer that indicates the maximum number of traffic channels within a BS that are allocated for packet data transmission. The value of the #Free Channels field indicates the number of currently available traffic channels in the BS 30 in a given time slot.
[0044] In accordance with this invention, and referring to FIGS. 3A and 4 , a MS 10 evaluates the fields within the MAC channel frame structure and predicts when it will be allocated a token. A MS 10 accomplishes this prediction in the following manner. First, at Block A, an initialization step for a counting process is performed. This initialization step evaluates the MAC channel frame structure and locates, within the MAC channel frame, the activity field that corresponds to the MS 10 whose MAC ID is equal to the value of the Next MAC ID field. Additionally, the initialization step sets to a value of zero a variable which represents the result of the counting process. The counting process is performed at Blocks B through D inclusive. Within the process a predicting MS 10 counts, in a cyclic manner, activity fields within the MAC control frame structure with values of zero. At Block B, the counting process starts at the Next MAC ID's activity field position and, moving from left to right, retrieves the next activity field in the MAC control frame whose value is zero. At Block C, this retrieved activity field is evaluated to determine whether it corresponds to the MAC ID of the predicting MS 10 . If this retrieved activity field corresponds to the MAC ID of the predicting MS 10 then the counting process is complete, and the prediction algorithm continues at Block E. However, if the retrieved activity field does not correspond to the predicting MS, then the variable which represents the counting result is incremented by one at Block D. Note, because the accounting process begins after retrieval of the activity field which corresponds to the Next MAC ID, this activity field is excluded from the count. The counting process will cycle through Blocks B, C, and D until the activity field corresponding to the predicting MS 10 is encountered, i.e. the condition evaluated in Block C is “YES”.
[0045] After the counting process has completed, the prediction procedure continues, at Blocks E and F, by performing a calculation which uses the current value of the #Free Channels field and the counting variable defined above. For purposes of illustration, if the predicting MS 10 assigns the result of the counting process to a variable “x”, and assuming the current #Free Channels field is assigned to a variable “M”, the calculation at Blocks E and F is represented by the following formula:
[0000] y =INT( x/M )+1. (1)
[0000] If the current slot number is j, then the (j+y)th slot is the predicting MS's turn to have the token. Also, this implies that if the predicting MS's position is within M−1 zero bits of the MS corresponding to the Next MAC ID, then a token will be allocated to the predicting MS in the next slot because a traffic channel will be available.
[0046] In the minimum form, the prediction of token usage is only valid for the next time slot. That is, the BS 30 may update the token allocation information every time slot. To reduce the MS's 10 receiving activity, the BS 30 may choose to update the token allocation information differently so that the calculation from Equation (1) is valid for the next x time slots, or a time period referred to as a super-frame. Consequently, the MS 10 does not have to decode the MAC message in every time slot in order not to miss its turn for transmission. The super-frame time period is controlled by the BS 30 .
[0047] In accordance with this invention, and referring to FIG. 5 , packet MS operation is as follows. Whenever a MS 10 with packet data service mode activated enters the cell, or when a MS 10 in the cell activates packet data mode, the BS 30 assigns a MAC ID number, and thus a corresponding activity field, to the MS 10 . This assignment, referred to as virtual call set-up, is shown at Block A. At Block B, the MS 10 stores the temporary MAC ID in the memory 24 .
[0048] Once the MAC ID and activity field are assigned, the MS 10 decodes the broadcast MAC messages sent from the BS 30 . This decoding, shown at Block C and D, continues until the MS 10 determines that it was allocated the token by the BS 30 . Allocation of the token enables the MS 10 to transmit its packet data. However, at Block E, the MS 10 must first determine whether it has packet data to send. If the MS 10 does not have packet data to send it continues to decode MAC messages and the BS 30 will allocate the token to the next MS 10 in the subsequent time slot. If the MS 10 does have data to transmit then it begins a transmission process as shown in Blocks F through I. First, at Block F, the MS 10 transmits a preamble message on the reverse link to the BS 30 . If the BS 30 receives the preamble it replies with an acknowledgment. If the acknowledgment is received then the MS 10 , as shown in Blocks G and H, transmits its packet data. The transmission continues until all MS 10 packet data is sent, or a maximum number of bytes to transmit is surpassed, or a predetermined time-out period is exceeded, shown in Block H and I. If the maximum number of bytes to transfer is encountered or the time-out period is exceeded, transmission may be stopped and the transmitting MS 10 returned to the decoding step, Block C, described above. However, if packet data transmission is successful the packet data call is terminated, the transmission process is complete, and the token is allocated by the BS 30 in the subsequent time slot to the next MS 10 in the cell.
[0049] In accordance with the present invention, the BS 30 allows the MS 10 to turn off its receiver and save power during the periods when the MS is not allocated the token. If the MS 10 does shut down its processing between tokens, the BS 30 informs the MS 10 , before the MS 10 shuts down, when it should start its processing again, i.e. when the MS 10 will be allocated the token again. This notification by the BS 30 before the MS 10 shuts down is possible as the token is assigned in advance. Thus, a “dynamic slotted mode” operation is provided, the operation being dynamic in that the position of the slot need not be the same in every cycle. The slot position is a function of how many active MSs 10 are on the channel, and on how much data each MS 10 can transmit. Additionally, the number of slots is a function of the number of available channels at the BS 30 .
[0050] The BS 30 may transmit packets destined for a MS 10 , if any, or fill data, on the forward link at the same time that the MS 10 is allocated a token and is transmitting packets on the reverse link. This allows the BS 30 to send power control information to the MS 10 .
[0051] In accordance with this invention, and referring to FIG. 6 , packet BS 30 operation is as follows. Note, FIG. 6 assumes that the BS 30 has divided traffic channel access into the discrete time periods referred to above as time slots. Thus, BS 30 operation, as shown in FIG. 6 , begins when a MS 10 activates packet data mode. At Block A, the BS 30 assigns a MAC ID number and activity field to the MS 10 with packet data mode active, this assignment is referred to as virtual call set-up. In virtual call set-up, the BS 30 initially assigns the activity field corresponding to the MS 10 a value of one. On the subsequent MAC frame, shown at Block B, the BS 30 sets this activity field value to zero, which indicates that the MS 10 of the newly assigned MAC ID is in the queue for access to a traffic channel. Whenever a MS 10 with packet data service mode active leaves the cell, or deactivates the packet data mode, the BS 30 release the MAC ID number from the MS 10 and, in the subsequent MAC message, the BS 30 sets the corresponding activity field of the released MAC ID to one, thus dequeuing the MS 10 from traffic channel access.
[0052] At Block C, the BS 30 evaluates the queue of MSs 10 awaiting a token. If no MSs are waiting, the scheduling process is complete. However, if one or more MSs remain queued for access, the BS determines a scheduling sequence. At Block D, a scheduling algorithm is employed which considers one or more parameters including, for example, prioritized access, service quality factors, and a maximum number of bytes to transmit by each MS 10 . Once a schedule is determined which ensures efficient packet data transmission the BS 10 updates the MAC control structure frame to reflect the schedule.
[0053] The BS 30 performs this updating, shown at Block E, as follows. A change in token scheduling status begins when the BS 30 cycles the value assigned to the Next MAC ID field to identify the MAC ID of the MS 10 that is to be allocated the token in the next time slot. Once this MS 10 is allocated the traffic channel and begins transmission of its packet data the BS 30 updates the MS's corresponding activity field to a value of one, decreases the value of the #Free Channels field by a value of one, and reassigns the value of the Next MAC ID field to identify the MS 10 that is to transmit its packet data in the next time slot.
[0054] This cyclic assignment can be further demonstrated by considering the MAC control frame structure fields in both an inactive and active state. In the inactive state, when there are no packet data MSs 10 within a cell, all activity fields of the MAC control structure frame are a value of one, the Next MAC ID field has a value of zero, and the #Free Channels field has a value equal to the maximum number of receivers 30 a in the BS 30 that are allocated for packet services. In the active state, after the BS 30 has assigned a unique MAC ID to each packet mode MS 10 in a cell, the MAC control frame activity fields corresponding to the assigned MAC IDs without a token are a value of zero, the Next MAC ID field is a value which corresponds to the MAC ID of the MS 10 that is scheduled to be allocated a token in the next time slot, and the #Free Channels field is a value which represents the number of receivers 30 a in the BS 30 that support packet service, less the number of channels occupied by MSs 10 that currently are allocated the token or tokens. Note, the BS 30 decreases the value of the #Free Channels field by one whenever a MS 10 successfully acquires a traffic channel and starts to transmit packet data. Likewise, the BS 30 increases the value of the #Free Channels field by one when the traffic channel is released at the end of packet transmission. Thus, the transmission schedule is defined by the values of the MAC control frame structure fields.
[0055] At Block F, the BS 30 broadcasts the MAC control frame structure to each MS 10 within the cell. As discussed above, when broadcasting MAC channel messages to all MSs 10 within a cell the BS 30 preferably uses a public long code mask, and when transmitting the MAC channel messages to a specific MS 10 the BS 30 may use a permuted electronic serial number (ESN) of the MS 10 as a long code mask.
[0056] The MS 10 decodes the MAC message and evaluates the MAC control frame fields to determine the traffic channel access schedule. To ensure preemptive control of channel access the BS 30 monitors, at Block G, the transmissions of the MS 10 that is allocated the token. For example, at Block H, if the maximum number of bytes per transmission is exceeded the BS 30 may force the termination of the MS 10 transmission and return the MS to the queue for token assignment. If the MS 10 transmission completes, as shown in Block I, the BS 30 reallocates the token in the next time slot. This reallocation process is accomplished by looping back to the above evaluation of MSs awaiting packet data transmission permission, Blocks C through I. If transmission is not complete, the BS 30 may rebroadcast the MAC message and continue to monitor the MS's transmission. This scheduling process continues until there are no packet data MSs queued for transmission, i.e. all MS packet data transmissions are complete.
[0057] It should be realized that a plurality of MSs 10 could each be allocated a token, giving the mobiles the right to access respective available traffic channels in the BS 30 , in a given time slot. By example, if there are n available traffic channels, up to n mobile stations can be granted the token to transmit during a next time slot.
[0058] While the invention has been particularly shown and described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that changes in form and details may be made therein without departing from the scope and spirit of the invention.
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In a packet data transmission and reception system, a media access control (MAC) message is broadcast by a base station to a plurality of mobile stations. The MAC message contains packet data transmission scheduling information which allows the base station to preemptively control mobile station access to traffic channels in order to maximize the efficiency of packet data transmissions and allow scheduling consideration including priority access, quality of service and maximum bytes per transfer. The MAC message consists of a control frame structure, which comprises scheduling parameters including MAC IDs fields, activity fields, and a field representing the number of free traffic channels in a cell. These parameters enable multiple mobile stations to share, in a time multiplexed fashion, traffic channels for packet data transmission on CDMA based mobile communication systems.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to liquid crystalline polycarbonates, and more particularly relates to liquid crystalline polycarbonates derived from diphenyl carbonate, 4,4'-dihydroxybiphenyl and 4,4'-dihydroxyphenylether.
2. Description of Related Art
Polycarbonate resins exhibiting liquid crystalline properties have been prepared in the melt by a transesterification reaction between diphenyl carbonate and mixtures of methyhydroquinone and 4,4'-dihydroxybiphenol, see Schissel, U.S. Pat. No. 4,831,105. Schissel discloses that the polycarbonates are resistant to solvents.
SUMMARY OF THE INVENTION
The present invention involves liquid crystalline polycarbonates which are capable of forming an anisotropic melt and which are the reaction products of 4,4'-dihydroxybiphenyl and 4,4'-dihydroxyphenylether and diphenyl carbonate. The polymers exhibited liquid crystallinity at approximately 350° C. and above, readily formed high strength fibers from the melt and were insoluble in solvents such as dichloromethane.
DETAILED DESCRIPTION OF THE INVENTION
The present invention involves aromatic polycarbonates which exhibit liquid crystalline properties and which are prepared by reacting a mixture of 4,4'-dihydroxybiphenyl and 4,4'-dihydroxyphenylether with diphenylcarbonate via a melt process.
The 4,4'-dihydroxybiphenyl also referred to as biphenol can be represented by the formula: ##STR1##
The 4,4'-dihydroxyphenylether can be represented by the formula: ##STR2##
The diphenyl carbonate can be represented by the formula: ##STR3##
The polycarbonate of the invention forms an isotropic melt consisting essentially of first units of the formula: ##STR4## chemically combined with second units of the formula: ##STR5## where the first units are present in the polycarbonate at a level of from about 50 mole percent to 80 mole percent based on the total moles of first units and second units, more preferably about 60 mole percent to 75 mole percent thereof, and most preferably 70 mole percent thereof; and second units being present at a level of from about 20 mole percent to 50 mole percent based on the total moles of first and second units present in the polycarbonate, more preferably from 25 mole percent to 40 mole percent thereof, and most preferably 30 mole percent thereof.
The polycarbonate is made by melting a mixture of 4,4'-dihydroxybiphenyl, 4,4-dihydroxyphenylether and diphenyl carbonate under an inert, nonoxidizing atmosphere such as a nitrogen atmosphere, at a temperature range of from 200° C. to 380° C. The mixture can be agitated to effect the removal of phenol during the transesterification reaction. The diphenylcarbonate can be employed at a level of from 50 mole percent to 55 mole percent based on the total moles of 4,4'-dihydroxybiphenyl, 4,4'-dihydroxyphenylether and diphenyl carbonate. During transesterification, a vacuum can be used in combination with agitation, such as achieved with the use of an extruder reactor, or stirrer to facilitate the removal of phenol.
The 4,4'-dihydroxybiphenyl is preferably present at a level of from about 50 mole percent to about 80 mole percent based on the total moles of 4,4'-dihydroxybiphenyl and 4,4'-dihydroxyphenylether reacted to form the polycarbonate, more preferably the 4,4'-dihydroxybiphenyl is present at a level of from 60 mole percent to 75 mole percent and most preferably is present at a level of 70 mole percent thereof, and the 4,4-dihydroxyphenylether is preferably present at a level of from about 20 mole percent to 50 mole percent based on the total moles of 4,4'-dihydroxybiphenyl and 4,4'-dihydroxyphenylether reacted, more preferably at a level of from 25 mole percent to 40 mole percent and most preferably at a level of about 30 mole percent thereof.
In order that those skilled in the art will be better able to practice the present invention, the following examples are given by way of illustration and not by way of limitation.
EXAMPLES
A mixture of 50.21 grams (a slight excess) of diphenyl carbonate, 28.55 grams of biphenol, and 13.28 grams of dihydroxyphenylether were reacted in the presence of LiOH catalyst (2.5×10 -5 moles) at a temperature of 200° C. for 1 hour, followed by reacting the mixture at 360° C. for 30 minutes and at a reduced pressure of 1 mm Hz to remove the phenol produced in the reaction. Preferably the reaction temperature is raised further to 380° C. to build molecular weight. The resulting polymer has a glass transition temperature of 154° C. and a melting temperature of 346° C.
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Polycarbonates are provided exhibiting anisotropic properties in the melt. Transesterification of diphenyl carbonate is effected in the melt with a mixture of 4,4'-dihydroxybiphenyl and 4,4'-dihydroxyphenylether. The polymer readily forms high strength fibers from the melt.
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RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 09/479,694 filed Jan. 7, 2000 now U.S. Pat. No. 6,444,367, which in turn claims the benefit of U.S. Provisional Application No. 60/115,172 filed Jan. 8, 1999, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to nonwoven webs. More particularly, the invention is directed to nonwoven polyolefin webs which have durable hydrophilic properties and to articles formed from such webs.
BACKGROUND OF THE INVENTION
Polyolefin fibers have been widely used in the nonwovens industry in the manufacture of nonwoven webs, fabrics, and composites. Olefin polymers, such as polyethylene, polypropylene, polybutene, polypentene, and copolymers of ethylene or propylene with other olefinic monomers, are known for their hydrophobic properties. Thus, nonwoven webs of polyolefin fibers are frequently used in applications where their hydrophobic properties are advantageous. For example, polyolefin nonwovens are often used in diapers, other hygiene products and medical applications where it is desired to keep moisture away from a wearer's skin.
However, there are numerous other nonwoven fabric applications where the hydrophobic nature of polyolefin fibers is not required and where hydrophilic properties are desired. If a nonwoven fabric formed of polyolefin fibers is to be used, the fibers must be treated in some way to alter the normally hydrophobic properties of the fibers to impart hydrophilic properties. One well-known practice involves the topical application of compositions, such as surfactants, to render the fabric more hydrophilic. However, topical chemical applications are not entirely satisfactory for some applications, since they are not durable. The hydrophilic property is lost after washing or after extended use. The extra processing steps required for topical chemical treatments or other fiber surface modification treatments also undesirably increase the cost of the fabric. The few processes known to render the polyolefins wettable are environmentally unfriendly, relatively slow and have limited durability.
An alternative to chemical surface modification is to directly melt blend a hydrophilic additive into the thermoplastic polymer rendering the fibers themselves hydrophilic. Published PCT Patent Specification WO99/00447 discloses a product and process for making wettable fibers prepared from an olefin polymer, polyester or polyamide including a wetting agent consisting essentially of a monoglyceride or a combination of a monoglyceride and a mixed glyceride with the monoglyceride amounting to at least 85% by weight in the case of the combination.
The monoglyceride corresponds to the formula
wherein —OR 1 , OR 2 , and —OR 3 are hydroxyl or a fatty acid ester group, but only one of them is a fatty acid ester group (C 12-22 ). The mixed glyceride (di- or tri-) corresponds to the formula
wherein —OR 4 , OR 5 , and —OR 6 are hydroxyl or a fatty acid ester group (C 12-22 ). The combination of this di- or tri-glyceride with the monoglyceride constitutes the wetting agent in accordance with one embodiment.
However, the use of hydrophilic melt additives can add significantly to the cost of the nonwoven webs. Also, the addition of a hydrophilic melt additive to the polyolefin polymer can alter the properties of the fibers or filaments, resulting in unacceptable changes to important physical or aesthetic properties of the nonwoven web, such as strength, softness or hand, for example.
SUMMARY OF THE INVENTION
The present invention overcomes the foregoing limitations and provides a polyolefin nonwoven web which has durable hydrophilic properties, while achieving a highly desirable combination of cost, physical properties and aesthetics.
Nonwoven webs in accordance with the present invention include multicomponent fibers bonded by a multiplicity of bond sites to form a coherent web. The multicomponent fibers include a first component formed of a hydrophobic polypropylene and a second component formed of a blend of a hydrophobic polyolefin and a hydrophilic melt additive. This second component is disposed at the surface of the fibers. The hydrophilic melt additive-modified polyolefin component can be arranged in various configurations in the cross-section of the fiber and the fibers can have various cross sections. For example, the hydrophilic component can occupy a portion of the surface of the fiber, as would occur for example with a side-by-side or segmented pie multicomponent fiber configuration. Alternatively, the modified hydrophilic polyolefin can occupy substantially the entire surface of fiber, as for example by producing the fibers in a sheath-core configuration with the hydrophilic modified component forming the sheath. A particularly preferred configuration is a sheath-core bicomponent fiber where the hydrophobic polypropylene forms the core and the modified hydrophilic polyolefin forms the sheath. Other configurations include non-concentric sheath-core, multi-lobal or tipped cross sections, and islands-in-the-sea cross sections.
The multicomponent fibers may be formed into a nonwoven web using various processing techniques known in the nonwovens industry. For example, the multicomponent fibers may comprise an air-laid web of staple fibers, a carded web of staple fibers, a wet-laid web staple fibers, a web of meltblown fibers or a spunbonded web of substantially continuous filaments or a combination of two or more of these techniques.
There are various melt additives available which can be melt blended with a hydrophobic polyolefin composition to impart durable hydrophilic properties to the polyolefin. Melt additives suitable for the present invention must not undesirably alter the melt-spinability of the multicomponent fibers and should be relatively compatible with the polyolefin composition such that the additive will not prematurely leach out and lose the hydrophilic properties. Certain suitable melt additives useful in the present invention will be at least partially immiscible with the polyolefin polymer composition and will tend to bloom to the fiber surface over time or with application of heat to impart a prolonged hydrophilic surface modification. Particularly suitable are compounds with a molecular structure which includes at least one functional group which is tethered to the olefin polymer structure, with other functional groups which provide reactive hydrophilic sites.
Suitable hydrophilic melt additives for use in the present invention include monomer or dimer fatty acids, hydroxy phenols, polyethylene glycol, fluorohydrocarbons, polyvinyl alcohol and polyvinyl formal.
One particularly suitable class of melt additives is an admixture of hydroxy phenols and polyethylene glycols. The hydroxy phenol is characterized in that it contains the functional group HOC 6 H 4 —.
Another particularly suitable class of melt additives are monomer and dimer fatty acids having a carbon chain length in the range of 6 to 50, preferably 18 to 36.
According to one embodiment of the invention, the nonwoven web is fabricated employing wet laid and/or carded thermal bonding processes. It is possible to use combinations of hydrophobic and hydrophilic fibers in the web. In other words, all fibers in the web need not be permanently wettable.
In one specific preferred embodiment, the web includes bicomponent fibers in which the melt additive is incorporated into the sheath constituent of the fiber. Use of bicomponent fibers, as well as combinations of hydrophobic and hydrophilic fibers, reduces costs and permits optimization of the web for diverse applications.
Thus, a broad aspect of the present invention is to provide a nonwoven web that has the wettability and strength for use in various end uses (such as rechargeable alkaline batteries, hygiene products, medical products, or filtration products) by directly incorporating hydrophilic melt additives into one or more normally hydrophobic polyolefin components of a multicomponent fiber during melt processing. This fiber can be meltblown, spunbonded or made into staple fibers to form a wettable web. Alternatively the wettable fiber can be mixed with binder fibers that are wettable or non-wettable or mixtures of both which are then made into a nonwoven web.
Another aspect of the invention is to provide a nonwoven web with increased wettability and strength for use as battery separator material. Another broad aspect of the invention is a nonwoven that is durable and wettable in harsh environments.
A further aspect of the invention is a nonwoven web that has both hydrophilic and hydrophobic regions.
Still another aspect of the invention is to provide a method for producing products that can be designed to have varied wettablility and strength properties depending on the desired end use applications.
One specific embodiment of the invention is the provision of a lower cost battery separator material including sheath-core bicomponent fibers, wherein melt additives are incorporated in the sheath of the bicomponent fiber and not the core.
Another specific embodiment of the invention is the provision of an economical battery separator material made of both wettable and non-wettable polymeric fibers.
A still further embodiment of the invention is a nonwoven web that can be used for other applications such as diapers and feminine care products, and medical applications which would require durable wettability.
Another aspect of the invention is to provide a nonwoven web that can be used in clothing applications, wherein products produced remain durable and hydrophilic after multiple machine washings.
Another aspect of the invention is to provide a nonwoven that can be used in filtration applications, wherein durable and wettable properties are required.
The thermoplastic polymeric multicomponent fibers are preferably staple fibers or continuous filaments with a hydrophobic polypropylene component and another component formed of a hydrophobic polyolefin, such as polyethylene or polypropylene, containing a hydrophilic melt additive.
In one of the embodiments of the present invention, the wettable fibers are blended with non-wettable binder fibers. Preferably these binder fibers are polyethylene/polypropylene bicomponent fibers having a polyethylene sheath and a polypropylene core.
In another embodiment of the invention, the nonwoven web includes both non-wettable binder fibers and wettable binder fibers. The wettable binder fibers are preferably polyethylene/polypropylene bicomponent fibers where the hydrophilic melt additive is incorporated into the polyethylene sheath of the bicomponent fiber. The non-wettable binder fibers may comprise polyethylene/polypropylene bicomponent fibers.
In yet another embodiment, the nonwoven web is formed substantially entirely of wettable binder fibers of the type described.
In one suitable embodiment the nonwoven web is 30-90 weight percent of the wettable binder fibers; and 10-70 weight percent of the non-wettable binder fibers. In a more specific embodiment the nonwoven web is 50% wettable binder fiber and 50% non-wettable binder fibers.
In another suitable embodiment the nonwoven web comprises up to 40 weight percent of a wettable fiber matrix; up to 40 weight percent of non-wettable binder fibers; and up to 30 weight percent of the wettable binder fibers. Although specific exemplary ranges are described, any combination of wettable fiber matrix, non-wettable binder fibers and wettable binder fibers are encompassed by the invention with the amounts of each component depending on the desired wettability and strength properties of the resulting web.
In general, battery separator materials formed from nonwoven webs of the invention have enhanced wettability and strength and provide good permeability to gases.
The invention also includes the related process for making nonwoven webs which can be used as battery separators and in other applications which require durability and wettability. In general, wettable multicomponent fibers with at least one hydrophilic melt additive are produced and formed into a nonwoven web by meltblowing, spunbonding other nonwoven formation methods. In one embodiment the fibers are further mixed with binder fibers which are then laid on a papermaking machine to form a wet-laid web. The water is removed from the wet-laid web, thermal bonded and calendered to form the nonwoven.
The nonwoven mats produced, in addition to use as battery separators, can be used in other applications such as absorbent and hygiene products, medical products, clothing and filtration products which require durable wettability and strength.
Other objects, features and advantages of the present invention will become apparent from the following detailed description of the best mode of practicing the invention as follows:
DETAILED DESCRIPTION OF THE INVENTION
The hydrophilic melt additives are incorporated into the thermoplastic olefin polymer and are converted into a nonwoven using any of various forming technologies available for the production of nonwoven webs. The material can be converted directly from the polymer into a nonwoven by spunbonding or meltblowing or a combination of the two. Alternatively, the material may be first formed into fibers and the fibers may thereafter be converted into a nonwoven web by techniques such as wet-laying, air-laying or carding. By combining the melt additives and the nonwoven process, a durably hydrophilic nonwoven web is produced.
In one embodiment of the invention, the hydrophilic melt additives are blended with polypropylene and formed into multicomponent staple fibers to form a wettable fiber matrix. This matrix is then further combined with non-wettable binder fibers and wet-laid to form the nonwoven material of the invention. The non-wettable binder fibers used may also include a bicomponent fiber comprising a polyethylene sheath and a polypropylene core, available as Chisso fibers from Chisso, Japan. The nonwoven material formed has both discrete hydrophobic and hydrophilic regions due to the different types of fibers used in making the web.
In an alternate embodiment the hydrophilic melt additives are blended with bicomponent fibers comprising a polypropylene sheath and a polypropylene core to form the wettable fiber matrix. The bicomponent sheath/core fiber proportions used in the invention may vary over a wide range, with from 50/50 sheath/core to 60/40 sheath/core being exemplary. Essentially the melt additives are incorporated into the outer polypropylene sheath of the fibers. Use of bicomponent fibers having 60/40 sheath/core permit higher incorporation of the melt additive into the sheath portion. The wettable fibers may be then further combined with non-wettable binder fibers to form the nonwoven web.
In all embodiments, the durable hydrophilic web is manufactured by blending a concentrate of hydrophilic melt additives with the thermoplastic polymer and converting the polymer into multicomponent fibers, and a nonwoven fabric directly or through an intermediate fiber formation process. The chemistry and physical properties of the additives, its compatibility with the thermoplastic resin, as well as the process conditions and constructional features of the nonwoven separator are necessary to yield the desired performance. The type of melt additive and proportion are important to the durable wettability of the nonwoven fabric.
In one embodiment, the melt additives used in the invention are selected from the group consisting of monomer and dimer fatty acids having a carbon chain length in the range of 6 to 50, preferably 36. In a preferred composition of this embodiment, the blend contains 2 to 15% Acintol® tall oil fatty acid, Acintol® distilled tall oils (monomer acids) and Sylvadym® dimer acids, which are all commercially available from Arizona Chemical Company, Panama City, Fla. and are fully described in the Technical Data Sheets for these materials, which are incorporated herein by reference. These are polar liquid materials which migrate to the surface of the polyolefin and remain as liquid on the surface thereof. Uniform mixing of the components is important to achieve effective hydrophilic properties.
In another embodiment, the hydrophilic melt additives are fluorohydrocarbons, such as 3M FC 1296. In another embodiment, the melt additives used in the invention are an admixture of hydroxy phenols and polyethylene glycols. Examples of melt additives used are commercially available from Techmer PM, California under the product designations PPM 11211, PPM 11249, PPM 11212, PPM 11267 and PPM 11268. The technical brochures of each of these materials are incorporated herein by reference.
A variety of different melt additive formulations can be used to form the wettable fiber matrix. Specific formulations are illustrated in Examples 1 to 5 herein. In general, the formulas include an active chemical which is an admixture of hydroxy phenols and polyethylene glycols. This active or functional chemical is provided in a carrier resin, preferably polypropylene, of a given melt flow rate (MFR) suitable for meltblowing, spunbonding or staple fiber manufacture. Accordingly, the formulations have different melt flow rates depending on the end use applications. The MFR listed in the formulations below were measured at 230° C., 2.16 kg. Melt blown grade polypropylene resins typically have a much higher melt flow rate (MFR 800-1200), whereas spunbond and staple fiber grade polypropylene resins have a lower melt flow rate (MFR 7-35). The base chemicals in the formulations include durable hydrophilic materials or non-durable hydrophilic materials depending on the desired wettability properties and end use applications.
The non-durable hydrophilic materials provide initial wetting of the fibers to enhance and maximize incorporation of the durable hydrophilic materials. The durable hydrophilic materials impart the wettability and strength properties to the fiber materials. In particular, in battery separator applications, the more durable chemical loaded, absorbency and wicking increase and the longer the life of the battery.
Melt Additive formulations 1 to 5 are illustrative of the types of melt additive formulations used in the invention and shown in Examples 1 to 5.
Melt Additive 1 contains approximately 30% of the active chemical and includes the same durable hydrophilic materials as in Melt Additive formulation 4 but a different melt flow rate. This additive is commercially available as PPM 11211 from Techmer PM, California.
Melt Additive 2 contains approximately 30% of the active chemical and includes the same non-durable hydrophilic materials as in Melt Additive formulation 5 but a different melt flow rate. This additive is commercially available as PPM 11212 from Techmer PM, California.
Melt Additive 3 contains approximately 20% of the active chemical and includes non-durable hydrophilic materials. This additive is commercially available as PPM 11249 from Techmer PM, California.
Melt Additive 4 contains approximately 25% of the active chemical and includes the same durable hydrophilic materials as in Melt Additive formulation 1. This additive has a MFR of 54 grams/10 minutes and is commercially available as PPM 11267 from Techmer PM, California.
Melt Additive 5 contains approximately 20% of the active chemical and includes the same non-durable hydrophilic materials as in Melt Additive formulation 2. This additive has a MFR of 109 grams/10 minutes and is commercially available as PPM 11268 from Techmer PM, California.
For melt blown nonwoven structures, in illustrative applications, Melt Additive formulations 1, 2 and 3 are used. Preferred proportions for melt blown structures include use of 15-35% of Melt Additive 1 formulation, i.e., 4-10% of the active chemical or up to 10% of Melt Additive 2 formulation, i.e., up to 3% of the active chemical. Most preferred proportions for melt blown structures include 30% of Melt Additive formulation 1, i.e. 9% of the active chemical and 5% of Melt Additive 2 formulation, i.e. 1.5% of the active chemical.
For spunbond and nonwoven mats containing staple fibers, in illustrative applications, Melt Additive formulations 4 and 5 are used. Suitable proportions for such structures include use of 15-30% of Melt Additive 4 formulation, i.e., 4-8% of the active chemical or up to 10% of Melt Additive 5 formulation, i.e., up to 2% of the active chemical. More specific exemplary proportions for these structures include 25% of Melt Additive formulation 4, i.e. 6% of the active chemical and 5% of Melt Additive 5 formulation, i.e. 1% of the active chemical. For staple fibers, a preferred proportion includes 20 weight percent of Melt Additive 4 and 2½ weight percent of Melt Additive 5.
The hydrophilic melt additives can be used in the following exemplary forms of nonwovens, namely meltblown, spunbond, SMS (spunbond/meltblown/spunbond), wet-laid, dry-laid or a combination of these forms. Fiber deniers for melt blown structures typically range from 0.1 to 2.0 deniers, with less than 1.0 most preferred. In the case of staple fiber and spunbond filaments deniers, fiber deniers of less than 3.0 are used, but less than 2.0 are most preferred. For spunbond and staple fiber nonwoven structures, in preferred applications Melt Additive formulations 4 and 5 are used.
To understand the present invention more fully, the following examples of the invention are described below. These examples are for purposes of illustration only and this invention should not be considered to be limited by any recitation used therein. The examples demonstrate the preparation of various battery separator materials in accordance with the process of the invention.
As in the examples below, unless otherwise specified, the test procedures for testing electrolyte initial wet out time, retention (absorbency %) and wicking in battery separator fabric are as follows:
Preparation of 31% KOH Solution:
Ingredients:
Distilled water and potassium hydroxide pellets (KOH).
Procedure:
The distilled water is freed of dissolved carbon dioxide by boiling and covering with a watch glass. The boiled water is allowed to cool to room temperature. The solution should be 31% KOH by weight. Since solid KOH contains approximately 10% water, 34.5 g of solid KOH is used for every 100 g of solution required. The solution is made by slowly adding the 34.5 g of KOH to 65.5 g of water.
Wet Out Time
10 ml of 31% potassium hydroxide (KOH) was placed in a five inch watch glass. One ⅝″ diameter disc sample was placed on the surface of the KOH. The time in seconds was recorded for initial wet out time up to 120 secs. These measurements were taken of the sample “as is” (WET OUT BEFORE) and of the sample after 7 days aging in the 31% KOH (WET OUT AFTER). The average time in seconds was reported for the samples. In some examples, the samples were only aged for 5 days.
Electrolyte Retentively (Absorbency %)
Retentively refers to the amount of potassium hydroxide solution that will be retained by a specimen. Values are obtained by determining the amount of solution of KOH that is retained by a specimen soaked in the solution.
specifically, three (3) specimens from each sample are cut (such that the “V” shaped portion of the die runs in the MD direction). The specimens are conditioned by drying in an oven at 70° C. (158° F.) for 1 minute, removed from the oven, and conditioned to the lab environment for 15 minutes prior to testing.
Each specimen of the fabric is weighed (“dry weight”) and then is soaked in a 31% solution of KOH. The amount of solution retained by the specimen is measured after 1 hour. The specimen is removed, allowed to drip for 10 minutes, and weighed and recorded as “wet weight”. The percent retention is calculated using the following formula: ( Weight weight - Dry weight ) ( Dry weight × 100 ) = % Retention
Electrolyte Absorbing (Wicking)
Wicking refers to the ability of a fabric to absorb a liquid through capillary action. Wicking values are obtained by determining the distance a solution of potassium hydroxide (KOH) is absorbed (wick) by a fabric specimen held vertically.
Specifically, three (3) specimens from each sample are cut 1″ CD×7″ MD. The specimens are conditioned by drying in an oven at 70% (158° F.) for 1 minute, removed from the oven, and conditioned to the lab environment for 15 minutes prior to testing. Each specimen of the fabric is suspended vertically in a 31% solution of KOH and the distance the liquid is absorbed by the specimen is measured after 30 minutes.
Alkali Proof Character
A pre-weighed specimen of the fabric is soaked in a 31% solution of potassium hydroxide (KOH) for 7 days at a temperature of 70° C. (158° F.) and then re-weighed to determine weight loss. This method is used to determine the effects on the fabric when subjected to a long term exposure in a solution of KOH, at an elevated temperature.
Specifically, three (3) specimens from each sample are cut 2″ CD×8″ MD. The specimens are conditioned by drying in an oven at 70° C. (158° F.) for 1 minute, removed from the oven, and conditioned to the lab environment for 15 minutes prior to testing. Each specimen of the fabric is weighed and then submerged in the KOH solution and soaked for 7 days. After 7 days the samples are removed and rinsed thoroughly with distilled water to remove all the KOH solution (6 or 7 times in a beaker with distilled water). The specimens are dried and re-weighed to determine weight loss.
EXAMPLE 1
A wettable battery separator material was prepared from a mixture of a wettable fiber matrix and non-wettable binder fibers.
In Samples 1, 2 and 3 the wettable fiber matrix used is a bicomponent fiber comprised of a polypropylene sheath and a polypropylene core. Combinations of Melt Additive formulations 4 and 5 were incorporated into the polypropylene sheath with essentially none of the additives migrating to the fiber core. The bicomponent fibers are 1.5 denier×½ inch and are obtainable from Fiber Inovation Technologies, Johnson City, Tenn.
Specifically in Samples 1, 2 and 3, 20% of the melt additive (30% active material) was incorporated into the polypropylene sheath (6% active material). The proportion of sheath/core in the bicomponent fiber is 50/50, thus the amount of active material in the total fiber was 3%.
The non-wettable binder fibers comprised a bicomponent fiber having a polyethylene sheath and a polypropylene core. The binder fibers are 2.0 denier×5 mm and are available as Chisso fibers from Chisso, Japan.
In each sample 50% of the wettable fiber matrix was mixed with 50% of the non-wettable binder fibers. The fiber mixture was dispersed and wet-laid to form the nonwoven substrates. The substrates were evaluated after calendering for absorbency, wicking and wet-out to KOH. The tests were also done after 7 days exposure to KOH at 70° F. The results are summarized in Table I below.
TABLE I
ABSORB.
WICKING
WET-OUT
BASIS
%
mm
sec
WT.
THICKNESS
BEFORE/
BEFORE/
BEFORE/
WT. LOSS
SAMPLE
gsy
mils
AFTER
AFTER
AFTER
%
1
27.09
4.52
230.8/
13
3
50.18/
0.123
247.6
6 min 58 sec
2
26.26
3.6
193.6/
19
3
55/
0.862
213.7
4 min 29 sec
3
44.24
6.12
237.8/
13
4
Lmin 40 sec/
0.333
261.1
8 min 4 sec
EXAMPLE 2
A wettable battery separator material was prepared from a mixture of a wettable fiber matrix and non-wettable binder fibers.
In Samples 4, 5 and 6 the wettable fiber matrix used is a bicomponent fiber comprised of a polypropylene sheath and a polypropylene core. The proportion of sheath/core in the bicomponent fiber is 60/40. Combinations of Melt Additive formulations 4 and 5 were incorporated into the polypropylene sheath. The bicomponent fibers are 1.5 denier ×½ inch and are produced by Fiber Innovations Technologies, Johnson City, Tenn. In particular the samples were as follows.
Sample 4 the fiber sheaths are 77.5% 12 mfr polypropylene, 20% Melt Additive 4 and 2.5% Melt Additive 5. The fiber core is 18 mfr polyproylene.
Sample 5 the fiber sheaths are 73.55% 12 mfr polypropylene, 24%. Melt Additive 4 and 2.5% Melt Additive 5. The fiber core is 18 mfr polyproylene.
Sample 6 the fiber sheaths are 71.50% 12 mfr polypropylene, 26% Melt Additive 4 and 2.5% Melt Additive 5. The fiber core is 18 mfr polypropylene.
In Samples 4, 5 and 6, 50% of the wettable fiber matrix were combined with 50% of non-wettable binder fibers comprised of a bicomponent fiber having a polyethylene sheath and a polypropylene core. The binder fibers are 2.0 denier×5 mm available as Chisso fibers from Chisso, Japan.
Sample 7 was prepared from a mixture of a wettable fiber matrix and a wettable binder fiber. The wettable fiber matrix used is a polypropylene staple fiber containing combinations of Melt Additive formulations 4 and 5. The polypropylene staple fibers are 1.8 denier×12 mm and are available from American Extrusion. The wettable binder fiber is a bicomponent fiber wherein the fiber sheath is 77.5% low density polyethylene, 20% Melt Additive 4 and 2.5% Melt Additive 5. The fiber core is 18 mfr polypropylene. The binder bicomponent fibers are 1.5 denier×½ inch and are obtainable from Fiber Innovation Technologies, Johnson City, Tenn.
As a positive control, 50% of the non-wettable bicomponent binder fibers having a polyethylene sheath and a polypropylene core (Chisso fibers) were mixed with 50% of a polypropylene fiber matrix (American Extrusion fibers) without melt additives. The fiber furnish mixtures in each sample was dispersed and wet-laid to form the nonwoven substrates.
The handsheets were evaluated after calendering for absorbency, wicking and wet-out to KOH. The tests were also done after 5 days exposure to KOH at 70° F. The results are summarized in Table II below.
TABLE II
STRIP
Initial
Initial
5 days
5 days
TENSILE
WICK
ABSORB.
WICK
ABSORB.
SAMPLE
lbs/1″
mm
%
mm
%
CONTROL
3.58
70
257
75
237
4
4.06
84
338
82
370
5
4.07
73
283
80
308
6
3.95
72
305
91
357
7
1.43
68
302
78
378
As illustrated in Table II the tensile and absorbency of the handsheet samples increased. The strength and wettability of the nonwovens remained even after aging. These results indicate that the separate properties of tensile and absorbency can be provided in a nonwoven. In addition, nonwovens are produced that have both increased tensile and absorbency.
EXAMPLE 3
A wettable battery separator material was prepared from a mixture of a wettable fiber matrix, non-wettable binder fibers and wettable binder fibers.
In Samples 8 and 9 the wettable fiber matrix used is a bicomponent fiber comprised of a polypropylene sheath and a polypropylene core. The proportion of sheath/core in the bicomponent fiber is 60/40. Combinations of Melt Additive formulations 4 and 5 were incorporated into the polypropylene sheath. The bicomponent fibers are 1.8 denier ×½ inch and are obtainable from Fiber Innovation Technologies, Johnson City, Tenn.
The non-wettable binder fibers are bicomponent fibers having a polyethylene sheath and a polypropylene core. The binder fibers are 2.0 denier×5 mm and are commercially available as Chisso fibers from Chisso, Japan.
The wettable binder fibers used are bicomponent fibers comprised of a polyethylene sheath and a polypropylene core.
Combinations of Melt Additive formulations 4 and 5 were incorporated into the polyethylene sheath. The bicomponent fibers are 1.6 denier×½ inch and are obtainable from Fiber Innovation Technologies, Johnson City, Tenn.
The fiber furnish in each of the samples were as follows.
Sample 8
40% wettable fiber matrix;
40% non-wettable binder fiber; and
20% wettable binder fiber
Sample 9
30% wettable fiber matrix;
30% non-wettable binder fiber; and
40% wettable binder fiber
The fiber furnish mixtures in each sample was dispersed and wet-laid to form the nonwoven substrates. The substrates were evaluated after calendering for absorbency, wicking and wet-out to KOH. The tests were also done after 7 days exposure to KOH at 70° F. The results are summarized in Tables III and IV below.
TABLE III
AIR
AIR
BASIS
MD
CD
PERME-
PERME-
WT.
TENSILE
TENSILE
ABILITY
ABILITY
SAMPLE
gsm
kg/50 mm
kg/50 mm
cfm
CM3/cm3/s
8
59.4
11.2
6.3
84.2
42.4
9
57.4
9.7
5.6
134.8
68.9
TABLE IV
WETTABILITY
BEFORE AND AFTER AGING
BEFORE
AFTER
WICK-
WICK-
ALKALI
ABSORB
ING
ABSORB
ING
PROOF
SAMPLE
%
mm
%
mm
% loss
8
226.8
85.3
237.9
93
0.67
9
297.2
79.3
333.9
100.7
0.5
In still another embodiment of the present invention, nonwoven webs are produced by wet-laying a blend of lower denier non-wettable binder fibers and higher denier wettable binder fibers. For example, 10 to 90 weight percent of the wettable binder fibers described in EXAMPLE 3 may blended with 90 to 10 weight percent of 0.7 one-half inch long non-wettable polyethylene/polypropylene sheath-core binder fibers. The lower denier fibers provide enhanced uniformity to the web. For a higher basis weight sheet on the order of 55 gsm, about 20 weight percent of the non-wettable fibers is preferred. For a sheet on the order of about 30 gsm, about 30 weight percent of the non-wettable binder fibers is preferred. These sheets are suitable for use as battery separators or for other applications, such as an ink-receptive inkjet printing substrate.
It is known that current nylon based battery separators degrade in the presence of the potassium hydroxide electrolyte. The nonwoven mats of the present invention present a replacement for the nylon based battery separators by providing separator materials that have been made permanently wettable, or if desired only partially wettable. Polypropylene is naturally hydrophobic. Known methods to make polypropylene wettable involves surface grafting of acrylic acid by ultraviolet radiation or by other surface modification methods such as plasma which are slow and expensive.
For fibrous battery separator applications the polypropylene needs to be resistant to the KOH and exhibit permanent wettability throughout the life of the product. Wettability is quantified by contact angle measurements in the case of a film and additionally by the rate of wicking and % absorbency in the case of a fibrous web used as the battery separator.
The process of the present invention provides advantages over prior practice by providing a nonwoven having both hydrophilic and hydrophobic regions as opposed to hydrophilic topical treatments. Additional wettability is achieved with incorporation of the surfactant that has more resistance to KOH solution than surfactants used in the prior art. Increased wettability is achieved simultaneously with an increase in strength. The wettability claimed in the invention is permanent and durable in a KOH solution as opposed to the prior art.
Finally, variations from the examples given herein are possible in view of the above disclosure. Therefore, although the invention has been described with reference to certain preferred embodiments, it will be appreciated that other processes may be devised, which are nevertheless within the scope and spirit of the invention as defined in the claims appended hereto.
The foregoing description of various and preferred embodiments of the present invention has been provided for purposes of illustration only, and it is understood that numerous modifications, variations and alterations may be made without departing from the scope and spirit of the invention as set forth in the following claims.
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Nonwoven webs in accordance with the present invention include multicomponent fibers bonded by a multiplicity of bond sites to form a coherent web. The multicomponent fibers include a first component formed of a hydrophobic polypropylene and a second component formed of a blend of a hydrophobic polyolefin and a hydrophilic melt additive. This second component is disposed at the surface of the fibers. The hydrophilic melt additive-modified polyolefin component can be arranged in various configurations in the cross-section of the fiber and the fibers can have various cross sections. For example, the hydrophilic component can occupy a portion of the surface of the fiber, as would occur for example with a side-by-side or segmented pie multicomponent fiber configuration. Alternatively, the modified hydrophilic polyolefin can occupy substantially the entire surface of fiber, as for example by producing the fibers in a sheath core configuration with the hydrophilic modified component forming the sheath. A particularly preferred configuration is a sheath-core bicomponent fiber where the hydrophobic polypropylene forms the core and the modified hydrophilic polyolefin forms the sheath.
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[0001] This application claims priority to U.S. provisional application No. 60/834,071, filed Jul. 28, 2006, which is hereby incorporated by reference. All references, patents and publications cited herein are hereby incorporated by reference.
[0002] The work disclosed herein was supported in part by NIH grants AI44063 and AI49485 from the National Institutes of Health, USA. The Government of the United States of America has certain rights in the invention.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention relates to 8-quinolinol (8Q) and derivatives thereof for use in the treatment of proliferative diseases such as cancer, in particular slow metabolizing quiescent cancer stem cells.
[0005] 2. Background Information
[0006] Cancer stem cells, defined as an initiation subpopulation of tumor cells or a small population of cancer cells that are capable of giving rise to new tumor, were first demonstrated in acute myelogenous leukemia (AML) by John Dick and colleagues 1-3 . The biology of cancer stem cells is poorly understood and cancer drugs developed to date cannot eliminate cancer stem cells. Although progress has been made on leukemia stem cell research, cancer stem cell research did not draw much attention until the first solid tumor stem cells, breast cancer stem cells, were reported by Clarke and colleagues 4 . These authors isolated a population of highly tumorigenic cells from human breast cancer clinical specimens 4 . This highly tumorigenic subpopulation expressed the CD44 + CD24 −/low surface markers and had the capacity to form tumors following transplantation into NOD/SCID mice. As few as one hundred CD44 + CD24 −/low cells were able to form tumors, whereas tens of thousands of the CD44 − /CD24 −/low cells did not 4 . A variety of cancer stem cells have been since identified in different tumors, including multiple myeloma 5 , human brain tumors 6-9 , retinoblastoma 10 , and melanomas 11 .
[0007] The study of cancer stem cells is important as it could provide new approaches for cancer treatment. Existing therapeutic approaches may eradicate the bulk of a tumor but spare the cancer stem or initiating cells 2,12-15 . It is conceivable that targeting cancer stem cells will eradicate tumor-initiating cells 2,12-15 . Because of the quiescence of (cancer) stem cells and their high expression of the ABC (ATP binding cassette) transporter genes which encode efflux pump proteins capable of extruding commonly used drugs, the cancer stem cells have proved difficult to eradicate by current clinical drugs 14,16,17 . Both leukemia stem cells and glioblastoma stem cells have decreased sensitivity to commonly used clinical drugs 14,17,18 . Even imatinib (Gleevec), an effective drug for chronic myeloid leukemia (CML), was unable to eradiate CML leukemia stem cells 19,20 . Thus, there remains an urgent need for new pharmaceutical compounds and compositions to effectively target cancer stem cells.
[0008] Human breast cancer is the most common malignancy among women in Western countries 21,22 . Sphere culture method has been widely used in neural stem cell research and shown to enrich stem cells 23-25 . In particular, sphere culture methods have been successfully used to isolate brain cancer stem cells 6,8,26 . Very recently, sphere culture method was also used to culture human breast stem cell or breast cancer stem cells and shown to enrich both normal and cancer stem/progenitor cells 27-30 .
SUMMARY
[0009] The present inventors developed a sphere culture derived from the breast cancer cell line MCF7. The sphere cells were enriched with cancer stem cells expressing surface marker CD44 + /CD24 − , exhibiting higher colony forming ability, having increased resistance to cancer drugs and higher expression of ABC transporters than parental cells. The NF-κB pathway was found to be important for the sphere cell survival. Using the sphere cells as a model for cancer stem cells, the inventors screened a compound library and identified a class of compounds having preferential activity for sphere cells.
[0010] Accordingly, the present invention provides compounds, pharmaceutical compositions, methods and kits for the treatment of proliferative diseases and disorders such as tumors, in particular the treatment of cancer. Described herein are compounds of formula
[0000]
[0000] wherein R 1 -R 6 independently represent, for example, hydrogen, hydroxyl, a halide, lower alkyl or alkoxy, or a long or short chain fatty acid or ester, pharmaceutically acceptable salts thereof, compositions containing the compounds, and methods of use. These compounds include the compound designated NSC125034 and its analog 8-quinolinol (8Q), and its salt form 8-hydroxyquinol hemisulfate salt, a metal chelator and NF-κB inhibitor.
[0011] In one aspect, the invention provides a pharmaceutical composition comprising a pharmaceutically acceptable carrier or excipient and an effective amount of at least one compound of formula:
[0000]
[0000] wherein R 1 -R 6 independently represent, for example, hydrogen, hydroxyl, a halide, lower alkyl or alkoxy, or a long or short chain fatty acid or ester, and pharmaceutically acceptable salts thereof.
Examples of such compounds are
[0000]
[0000] The pharmaceutical composition may optionally further comprise an effective amount of at least one secondary chemotherapeutic agent selected, for example, from the group consisting of paclitaxel, doxyrubicin, vinblastine, and vincristine, Vinorelbine, Topotecan, Carboplatin, Cisplatin, Pemetrexed, Irinotecan, Gemcitabine, Gefitinib, Erlotinib, Etoposide, Fluorouracil, cyclophosphamide, Mercaptopurine, Fludarabine, Ifosfamide, Procarbazine, Mitoxantrone.
[0012] The pharmaceutical composition may be formulated for any suitable route of administration, for example, intranasal administration; oral administration; inhalation administration; subcutaneous administration; transdermal administration; intradermal administration; intra-arterial administration, with or without occlusion; intracranial administration; intraventricular administration; intravenous administration; buccal administration; intraperitoneal administration; intraocular administration; intramuscular administration; implantation administration; topical administration; intratumor administration, and central venous administration.
[0013] Pharmaceutically acceptable carriers and excipients include any those known in the art, for example, alcohols, dimethyl sulfoxide (DMSO), phosphate buffered saline, saline, a lipid based formulations, liposomal formulations, nanoparticle formulations, micellar formulations, water soluble formulations, and biodegradable polymers.
[0014] It is also an object to provide a method of treating cancer in a subject comprising administering to the subject an effective amount of a compound of formula:
[0000]
[0000] wherein R 1 -R 6 independently represent, for example, hydrogen, hydroxyl, a halide, lower alkyl or alkoxy, or a long or short chain fatty acid or ester, or a pharmaceutically acceptable salt thereof, optionally along with a pharmaceutically acceptable carrier or excipient. Examples of compounds to be used in the method are 8-quinolinol and 8-Hydroxyquinol hemisulfate salt. Effective amounts to be administered can be determined by the skilled practitioner without undue experimentation. The appropriate dose to be administered depends on the subject to be treated, such as the general health of the subject, the age of the subject, the state of the disease or condition, the weight of the subject, the size of the tumor, for example. It is expected that dosages of 0.1-100 mg/kg/day, preferably 1-10 mg/kg will be typical. Generally, between about 0.1 mg and about 500 mg or less may be administered to a child and between about 0.1 mg and about 3 grams or less may be administered to an adult.
[0015] In an alternative embodiment, dosage is defined in terms of the amount of agent delivered to a target tissue (e.g. a tumor, or an organ). In this instance, dosages may be defined as concentrations, e.g. 0.01 μM-10 mM, 0.01 μM-100 mM, etc.
[0016] The methods should be useful for treating a variety of cancers, including solid tumors, lymphomas and leukemias. Examples of tumors for which the treatment methods should be useful include brain tumors, nasal tumors, pharyngeal tumors, head tumors, neck tumors, liver tumors, kidney tumors, prostate tumors, breast tumors, bladder tumors, pancreatic tumors, stomach tumors, colon tumors, ovarian tumors, cervical tumors, and skin tumors; as well as metastases thereof.
[0017] Routes of administration include, for example, intranasal administration; oral administration; inhalation administration; subcutaneous administration; transdermal administration; intradermal administration; intra-arterial administration, with or without occlusion; intracranial administration; intraventricular administration; intravenous administration; buccal administration; intraperitoneal administration; intraocular administration; intramuscular administration; implantation administration; topical administration and central venous administration, and intratumor administration.
[0018] Pharmaceutically acceptable carriers or excipients for use in the method include, for example, alcohols, dimethyl sulfoxide (DMSO), physiological salines, lipid based formulations, liposomal formulations, nanoparticle formulations, micellar formulations, water soluble formulations, biodegradable polymers, aqueous preparations, hydrophobic preparations, lipid based vehicles, and polymer formulations.
[0019] The pharmaceutical composition administered can be in the form of a powder, an aerosol, an aqueous formulation, a liposomal formulation, a nanoparticle formulation, hydrophobic formulation et al.
[0020] It has been found that the compounds of the invention exhibit an additive or synergistic effect with other types of chemotherapeutic agents. 8Q and analogs thereof may thus be used as primary chemotherapeutic agents with a variety of cytotoxic agents that are used as chemotherapeutic agents for cancerous or benign tumors, for example, doxyrubicin, vinblastine, paclitaxel, and vincristine, Vinorelbine, Topotecan, Carboplatin, Cisplatin, Pemetrexed, Irinotecan, Gemcitabine, Gefitinib, Erlotinib, Etoposide, Fluorouracil, cyclophosphamide, Mercaptopurine, Fludarabine, Ifosfamide, Procarbazine, Mitoxantrone. As used herein, such additional chemotherapeutic agents will be referred to as “secondary” chemotherapeutic agents. When in combination with 8Q analogs, reduced concentrations of these secondary chemotherapeutic agents should be sufficient to achieve high efficacy. A listing of additional commonly used chemotherapeutic agents to be included in the meaning of “secondary chemotherapeutic agents” as used herein can be found in Blagosklonny, Cell Cycle 3: e52-e59 (2004); other cytotoxic compounds will be known to those of skill in the art. The two (or more) compounds may be administered substantially contemporaneously, or at different times.
[0021] The active agent can be administered in a single or, more typically, multiple doses. Preferred dosages for a given agent are readily determinable by those of skill in the art by a variety of means. Other effective dosages can be readily determined by one of ordinary skill in the art through routine trials establishing dose response curves. The amount of agent will, of course, vary depending upon the particular agent used.
[0022] The frequency of administration of the active agent, as with the doses, will be determined by the practitioner based on age, weight, disease status, health status and patient responsiveness. Thus, the agents may be administered one or more times daily, weekly, monthly or as appropriate as conventionally determined. The agents may be administered intermittently, such as for a period of days, weeks or months, then not again until some time has passed, such as 3 or 6 months, and then administered again for a period of days, weeks, or months.
[0023] Kits with multiple or unit doses of the pharmaceutical compounds and compositions are also included in the present invention. In such kits, in addition to the containers containing the multiple or unit doses of the compositions containing the pharmaceutical compounds and compositions, may also include an informational package insert with instructions describing the use and attendant benefits of the drugs in treating pathological conditions.
[0024] In another aspect, the invention provides a method of inhibiting, arresting or killing a cancer stem cell, the method comprising administering an effective amount of a compound of formula:
[0000]
[0000] wherein R 1 -R 6 independently represent hydrogen, hydroxyl, a halide, lower alkyl or alkoxy, or a long or short chain fatty acid or ester, or pharmaceutically acceptable salts thereof to the cancer stem cell. Compounds mentioned above, including 8-quinolinol, will be useful in the method. Effective dosages can be determined by those of skill in the art and are expected to be in the range of 0.01 μM to about 100 mM, preferably about 0.01 μM to about 10 mM. This method should be useful for the types of cancer mentioned above, in connection with the method for treating cancer, and can be carried out in vivo or in vitro.
[0025] In yet another aspect, the invention provides a method of obtaining a purified culture of cancer stem cells comprising the steps of using flow cytometry sorting to obtain side population (SP) enriched in cancer stem cells from a tumor or a cancer cell line, culturing the side population cells to form spheres that are further enriched with cancer stem cells. In particular, a purified culture of stem cells from human breast cancer cell line MCF7 is provided. The invention also provides a purified culture of cancer stem cells derived by the method. The purified culture of cancer stem cells can be used in a method to screen for anticancer agents, wherein test compounds are contacted with the cancer stem cells and their effects on cell growth and/or viability are determined. Thus, the invention provides a method of screening for an anticancer agent comprising contacting a test compound with the purified culture of cancer stem cells, and measuring growth and/or viability, wherein a compound that reduces growth and/or viability is a candidate compound, e.g. for further testing as an anticancer pharmaceutical agent.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIGS. 1A-1E . MCF7 sphere cell morphology and characteristics. A: MCF7 sphere cell morphology. Single sphere cell after 14 days of cultivation was photographed under bright field under inverted microscope. The diameter of the sphere shown in this picture was about 250 μm. B: Surface marker analysis of MCF7 sphere cells. MCF7 cells were stained with Hoechst 33342, then 10 6 cells were aliquoted and further stained with antibodies including CD44-PE-Cy5 and CD24-PE. The cells were stained with the antibodies on ice for 30 minutes and kept on ice until flow cytometry analysis. C: Comparison of sphere formation ability and colony formation ability of MCF7 and MCF7 sphere cells. Experiments were carried out as described in Materials and Methods. Experiments were performed in triplicate. D: Characteristic Hoechst 33342 dye staining profiles of MCF7 and MCF7 sphere cells. Cells were stained using Hoechst dye 33342 and fluorescence displayed at two wavelength emissions, blue and red. SP region was indicated by trapezoids within each flow diagram. E: Flow cytometry analysis of MCF7 and MCF7 sphere cell cycle status. Single MCF7 and MCF7 spheres were obtained and stained with PI for the quantification of DNA as described in Methods. Distribution of G1/G0 and G2/M phase cells was shown in the figure.
[0027] FIG. 2 . Susceptibility of MCF7 sphere cells to common anticancer drugs compared with MCF7 cells. Single MCF7 and MCF7 sphere cells were inoculated into 96 well plates at a concentration of 5000 cells per well. After overnight culture, cells were subject to selected clinical drug treatment at the indicated dose for three days. Cell proliferation was determined by MTT assay.
[0028] FIGS. 3A-3B . A: Susceptibility of MCF7 and MCF7 sphere cells PI3K pathway inhibitor, rapamycin and NF-κB pathway inhibitors, PTL and PDTC at indicated doses. Experiment was performed as described in FIG. 2 and Materials and Methods. B: Inhibition of NF-κB activity of MCF7 and MCF7 sphere cells after treatment with PTL and PDTC at indicated concentrations. Cells were treated with these compounds at indicated doses for 24 hours. Nuclear extract was prepared from control and treated cells. The quantification of NF-κB activation was performed according to product manual.
[0029] FIGS. 4A-4D . Self-renewal ability assays of MCF7 and MCF7 sphere cells. A: Soft agar colony formation assay of MCF7 and MCF7 sphere cells, and these cells with overexpression and knockdown expression of p65. B: Sphere formation assay of MCF7 and MCF7 sphere cells, and these cells with overexpression and knockdown expression of p65. C: Western Blot confirmation of p65 overexpression by transfection of p65 plasmid. D. Western Blot confirmation the expression of p65 in MCF7 sphere cells transfected with dsRNA oligo.
[0030] FIGS. 5A-5F . A: Susceptibility of MCF7 sphere cells to compound NSC 125034, compared with MCF7 cells. Experiment was performed as described in FIG. 3 and Materials and Methods. B: Structure of NSC 125034 and 8Q. C: Susceptibility of MCF7 sphere cells to compound 8Q, compared with MCF7 cells. D: In vivo effect of 8Q (4 mg/Kg) by intratumor injection. Nude mouse xenograft assays using MDA-MD-435 human breast cancer cells was carried out using 8Q or paclitaxel or a combination of the two compounds. Mice were treated twice weekly for 3 weeks. Treatment was indicated in the figure as arrows. Tumor sizes were measured weekly. E: In vivo effect of 8Q (20 mg/Kg) by tail vein injection on two different types of breast cancer cell lines, MCF7 (estrogen dependent, xenograft model reflect the early-stage breast malignancy) and MDA-MB435 (estrogen interdependent, xenograft model reflect the later-stage breast malignancy). Mice were treated twice weekly for 4 weeks. (1) MCF7 xenograft (2) MDA-MB435 xenograft. F: Total body weight of individual mouse in the tail vein injection experiment was determined weekly and the average body weight was plotted.
DETAILED DESCRIPTION
Definitions
[0031] As used herein, the term “lower alkyl” means C 1 -C 6 alkyl.
[0032] As used herein, the term “lower alkyoxy” means C 1 -C 6 alkoxy.
[0033] As used herein “halide” refers to fluoride, chloride, bromide, or iodide.
[0034] As used herein, “buffers” includes any buffer conventional in the art, such as, for example, Tris, phosphate, imidazole, and bicarbonate.
[0035] As used herein, “target tissue” means any tissue to which it is desired to deliver an effective concentration of a compound of the invention, e.g., blood, brain, a specific tumor.
[0036] As used herein, the terms “treatment,” “treating,” and the like, refer to obtaining a desired pharmacological and/or physiological effect. The effect may be prophylactic in terms of completely or partially preventing a condition or disease or symptom thereof and/or may be therapeutic in terms of a partial or complete cure for a condition or disease and/or adverse affect attributable to the condition or disease. “Treatment,” thus, for example, covers any treatment of a condition or disease in an animal, particularly in a human, and includes: (a) preventing the condition or disease (e.g. cancer) from occurring in a subject which may be predisposed to the condition or disease but has not yet been diagnosed as having it; (b) inhibiting the condition or disease, such as, arresting its development; and (c) relieving, alleviating or ameliorating the condition or disease, such as, for example, causing regression of the condition or disease.
[0037] A “pharmaceutically acceptable carrier” refers to a non-toxic solid, semisolid or liquid filler, diluent, encapsulating material or formulation auxiliary of any conventional type. A “pharmaceutically acceptable carrier” is non-toxic to recipients at the dosages and concentrations employed, and is compatible with other ingredients of the formulation. For example, the carrier for a formulation containing the present compounds preferably does not include oxidizing agents and other compounds that are known to be deleterious to such. Suitable carriers include, but are not limited to, water, dextrose, glycerol, saline, ethanol, buffer, dimethyl sulfoxide, Cremaphor EL, and combinations thereof. The carrier may contain additional agents such as wetting or emulsifying agents, or pH buffering agents. Other materials such as anti-oxidants, humectants, viscosity stabilizers, and similar agents may be added as necessary.
[0038] A “pharmaceutically acceptable salt” or “physiologically acceptable salt” refers to a nontoxic salt form of a compound that is suitable for therapeutic administration. Information on suitable physiologically acceptable salts and carriers can be found, inter alia, in Gennaro, A. (1995). “Remington: The Science and Practice of Pharmacy”, 19th edition, Lippincott, Williams, & Wilkins; Ansel, H. C. et al. (1999), Pharmaceutical Dosage Forms and Drug Delivery Systems eds., 7 th ed., Lippincott, Williams, & Wilkins; Kibbe, A. H. (2000) Handbook of Pharmaceutical Excipients, eds., 3 rd ed. Amer. Pharmaceutical Assoc. Pharmaceutically acceptable salts herein include, inter alia, acid addition salts which are formed with inorganic acids such as, for example, hydrochloric or phosphoric acids, or such organic acids as acetic, mandelic, oxalic, and tartaric. Salts may also be derived from inorganic bases such as, for example, sodium, potassium, ammonium, calcium, or ferric hydroxides, and such organic bases as isopropylamine, trimethylamine, 2-ethylamino ethanol, and histidine.
[0039] By “effective amount” or “therapeutically effective amount” is meant an amount that will cause a measurable effect or therapeutic effect, either when delivered as a single dose, or when delivered continuously or repeatedly over a time period (e.g. minutes, hours, days, weeks or months).
[0040] The term “pharmaceutically acceptable excipient,” includes vehicles, adjuvants, or diluents or other auxiliary substances, such as those conventional in the art, which are readily available to the public. For example, pharmaceutically acceptable auxiliary substances include pH adjusting and buffering agents, tonicity adjusting agents, stabilizers, wetting agents and the like.
[0041] The terms “individual”, “subject,” “host,” and “patient,” are used interchangeably herein to refer to an animal being treated with the present compositions, including, but not limited to, simians, humans, felines, canines, equines, bovines, porcines, ovines, caprines, mammalian farm animals, mammalian sport animals, and mammalian pets.
[0042] As used herein “parenteral administration” herein means intravenous, intra-arterial, intramuscular, subcutaneous, transdermal, intradermal and intraperitoneal administration.
[0043] A “substantially purified” compound in reference to the compounds described herein is one that is substantially free of compounds that are not the compound in question. By “substantially free” is meant at least 50%, preferably at least 70%, more preferably at least 80%, and even more preferably at least 90%, most preferably greater than 95% or 99% free of extraneous materials.
[0044] A “purified cell culture” is one in which greater than 50% of the cells, preferably greater than 75%, 80%, 85%, 90%, 95%, 99% of the cells in the culture are of the specified phenotype. (Cultures described in the examples below have a purity of about 78.5%).
[0045] It is to be understood that this invention is not limited to particular embodiments described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.
[0046] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges, and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.
[0047] As used herein, “about” means±10%.
[0048] As used herein, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a compound” includes a plurality of such compounds and equivalents thereof known to those skilled in the art.
Methods
[0049] MCF7 and MCF7 sphere cell culture. Human breast cancer cell line MCF7 cells, MDA-MB-435 cells were obtained from ATCC (American Type Culture Collection). Cells were grown in Dulbecco's Modified Eagle's Medium (DMEM) (Invitrogen) supplemented with 10% fetal bovine serum (FBS) (Invitrogen), 100 units/ml penicillin and 100 ug/ml streptomycin (Invitrogen), in a 37° C. incubator containing 5% CO 2 . To isolate and culture MCF7 sphere cells, SP cells were sorted based on protocol shown below. Sphere cell culture was performed according to published protocol with modifications 28-30 . Briefly, single cells were plated in ultralow attachment plates (Corning, N.Y.) at a density of 20,000 viable cells/mL in primary culture and 1000 cells/mL in passages. Cells were grown in a serum-free mammary epithelial growth medium without bovine pituitary extract (MEGM, BioWhittaker), but supplemented with serum substitute B27 (Invitrogen), 20 ng/mL, Epidermal Growth Factor (EGF), 20 ng/mL, and 20 ng/mL basic fibroblast growth factor (bFGF) (BD Biosciences). In order to passage sphere cells, spheres were collected into 15 ml conic tubes and allowed to settle for 15 minutes. Supernatant was removed. Sphere cells were dissociated enzymatically with 0.05% trypsin, 0.5 mM EDTA (Invitrogen) and mechanically by a glass Pasteur pipette. The cells obtained from dissociation were passed through a 40-μm sieve and analyzed microscopically for single cells and subjected to the experiments below.
[0050] Hoechst 33342 staining and flow cytometry analysis/sorting. To identify and sort SP and non-SP fractions, cells were washed with phosphate buffered saline (PBS) and detached from the culture dish with trypsin and EDTA, pelleted by centrifugation, and resuspended in 37° C. DMEM containing 2% FBS at 1×10 6 cell/ml. Cell staining was performed according to the protocol originally developed by Goodell et al with slight modification 46 . The cells were then incubated with Hoechst 33342 (Sigma) at 5 μg/ml for 90 mM at 37° C. Following staining, the cells were spun down and resuspended in Hanks'Balanced Salt Solution (HBSS) (Invitrogen) containing 1 μg/ml propidium iodide and maintained at 4° C. for flow cytometry analysis/sorting. Cell analysis and sorting were performed on a MoFlo cytometer (Dako Cytomation, Fort Collins, Colo. USA) equipped with a Coherent Enterprise II laser emitting MLUV at 351 nm and blue 488 nm lines. The Hoechst 33342 emission was first split using a 610 dsp filter and then the red and the blue emissions were collected through 670/30 run and 450/65 nm bandpass filters respectively.
[0051] Antibody staining. The antibody staining was performed after Hoechst dye staining. After staining with Hoechest 33342, MCF7 cells were spun down and 10 6 cells were aliquoted, washed and resuspended with washing/staining buffer (PBS supplemented with 1% bovine serum albumin and 0.1% azide). Antibodies used in this study included CD44-PE-Cy5 (eBioscience, San Diego) and CD24-PE (eBioscience, San Diego). Antibody staining was performed on ice for 30 minutes, after which cells were washed with washing/staining buffer for 3 times. Cells stained with antibodies were kept on ice until flow cytometry analysis.
[0052] Sphere formation assay. To compare sphere formation ability between MCF7 and MCF7 sphere cells, single cells were seeded at 3000 cells per well in 3 ml of the medium indicated above in 6 well ultralow attachment plates (Corning, N.Y.). To determine the sphere formation ability of MCF7 sphere cells transfected with p65 plasmid and p65 targeted dsRNA oligo, experiments were performed in 24 well ultralow attachment plates (Corning, N.Y.) with inoculation of 1000 cells per well in 1 ml medium. The number of spheres for each well was counted after 7 days of culture. Experiments were done in triplicate.
[0053] Soft agar colony formation assay. The colony formation assay was carried out in 35 mm dishes. Briefly, tested cells were plated in 35-mm dishes at 5000 cells/well in 0.35% agar in culture medium over a 0.5% agar layer. Plates were further incubated in cell culture incubator for 12 days until colonies were large enough to be visualized. Colonies were stained with 0.01% Crystal Violet for 1 hour and counted. Experiments were done in triplicate.
[0054] Cell proliferation assay. To test the sensitivity of MCF7 and MCF7 sphere cells to specific compounds, both MCF7 and MCF7 sphere single cells were seeded at 3×10 4 cells/ml in 96-well plates. After overnight incubation, serial concentrations of tested compounds were added. Each concentration was repeated three times. These cells were incubated in a humidified atmosphere with 5% CO 2 for 3 days. Then, 20 ul MTT (3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyl tetrazolium bromide) (Sigma) solution (4.14 mg/ml) was added to each well and incubated at 37° C. for 4 hours. The medium was removed and formazan was dissolved in DMSO and the optical density was measured at 590 nm using a Bio-assay reader (Bio-Rad, USA). The growth inhibition was determined using: Growth inhibition=(control's O.D.−sample's O.D.)/control's OD.
[0055] Cell cycle analysis. Cell cycle analysis was performed on single MCF7 and MCF7 sphere cells. Briefly, single MCF7 and MCF7 sphere cells were washed with PBS, fixed with 70% ethanol and stained with propidium iodide (PI) solution (PI solution contains 0.1% Triton X-100, 0.1 mM EDTA, 50 μg/mL RNase A, and 50 μg/mL PI in PBS) for at least 1 hours or until analysis.
[0056] Compound library screen for activity against sphere cells. Small-molecule libraries used in this study were from the NCI/NIH. The NO Structural Diversity Set is a library of 1,992 compounds selected from the approximately 140,000-compound NCI drug depository. These compounds were selected based on various criteria including drug-like structure, uniqueness of pharmacophore, and anticancer activity as determined by cell growth inhibition assays against a panel of human tumor cell lines. Detailed data on the selection, structures, and activities of these diversity set compounds can be found on the NCI. Developmental Therapeutics Program web site (http://dtp.nci.nih.gov/index.html).
[0057] Since the MCF7 sphere cells grow very slowly and a limited number of cells were available for the screen, we used a more sensitive cell proliferation assay than MTT assay, i.e., a fluorescence-based cell proliferation assay (CyQUANT Cell Proliferation Assay Kit, Molecular Probe) for in vitro compound screening. Briefly, both MCF7 and MCF7 sphere cells were seeded into 96-well culture plates at 5×10 2 cells per well and incubated in DMEM with 10% FBS, as described above, at 37° C. in an incubator containing 5% CO 2 for 24 h. After a 72 hour incubation, growth of the cells was determined by the fluorescence-based cell proliferation assay. Fluorescence signal was detected by a Bio-assay reader (Bio-Rad, USA) according to the manufacturer's instructions.
[0058] Quantitative RT-PCR. Expression levels of 48 ABC (ATP binding cassette) transporters were measured by real-time quantitative RT-PCR using the SuperScript III Platinum SYBR Green One-Step qRT-PCR Kit (Invitrogen) in ABI Prism® 7300 machine (Applied Biosystems, Foster City, Calif.). Specific primers used were according to Szakacs G et al. 47 with a change in primers for ABCB1. The primers used for ABCB1 were: F: 5-AGCTGCTGTCTGGGCAAAGATACT-3; R: 5AGATCAGCAGGAAAGCAGCACCTA-3. RT-PCR was carried out on 50 ng total RNA, in the presence of 250 nM specific primers. Following reverse transcription (20 min at 55° C.), the PCR reaction consisted of 45 cycles of denaturation (15 s at 95° C.), annealing (30 s at 58° C.), and elongation (30 s at 72° C.). No-template (water) reaction mixture was included as a negative control.
[0059] P65 siRNA-mediated knockdown and over-expression. Single MCF7 and MCF7 sphere cells were prepared and cultured in serum free medium as describe above in ultralow attachment 6 well plates on the day of performing gene knockdown and over-expression. For p65 gene knockdown, the Signalsilence p65 siRNA kit from Cell Signaling Technology (Danvers, Mass.) was used. Experiments were performed according to manufacturer's instructions. Briefly, cells were transfected with 50 nM p65 siRNA or control siRNA for gene knockdown. Twenty four hours after transfection, cells were subjected to the soft agar colony formation assay and sphere formation assay as describe above. Cell lysates were prepared 72 hours after transfection with dsRNA oligo for Western Blot analysis of the effect of the gene knockdown.
[0000] In order to over-express the p65 gene 48 , FuGENE 6 reagent (Roche Molecular Laboratory, Indianapolis, Ind.) was used according to manufacturer's instructions. Briefly, diluted transfection solution (3 μl FuGENE 6+97 μl serum-free DMEM medium) was incubated for 5 min and mixed with 1 μg of p65 plasmid for 15 min. The FuGENE 6-DNA mixture was then applied to MCF7 and MCF7 sphere cells. Twenty four hours after transfection, cells were subjected to the soft agar colony formation assay and sphere formation assay as described above. Cell lysates were prepared 72 hours after transfection for the Western Blot experiment.
[0060] Western blot analysis. Cells were collected, washed with PBS and lysed in RIPA buffer (0.1% SDS, 1% NP-40, 5 mM EDTA, 0.5% Sodium deoxycholate, 150 mM NaCl and 50 mM Tris-HCl) supplemented with protease Inhibitor Tablet (Roche). After centrifugation, cell extracts were collected and the protein concentration determined using the BCA protein assay kit (Pierce, Rockford, Ill.). About 10 μg of protein was run on SDS-polyacrylamide gel and after electrophoresis the proteins were transferred onto nitrocellulose membranes (Bio-Rad). Membranes were probed with primary antibodies against p65 (Cell Signaling Technology) and then secondary antibody alkaline phosphatase-conjugated anti-mouse immunoglobulin G (Jackson Immunoresearch, Inc.). The color reaction was developed with 5-bromo-4-chloro-3-indolyl phosphate and Nitro Blue Tetrazolium solutions (Sigma).
[0061] Nuclear extract preparation. Nuclear extracts were prepared according to the protocol recommend by Active Motif Company (Active Motif, Carlsbad, Calif.). Cells were washed and collected in ice-cold PBS/PIB buffer and resuspended in 10 ml of ice-cold hypotonic buffer containing 20 mM HEPES (pH 7.5), 5 mM NaF, 10 μM Na 2 MoO 4 , 0.1 mM EDTA. PBS/PIB buffer was prepared by adding 0.5 ml of PIB (125 mM NaF, 250 mM β-glycerophosphate, 250 mM p-nitrophenyl phosphate (PNPP) and 25 mM NaV0 3 ) to 10 ml of 1×PBS prior to use. Following a 15 min incubation on ice, 50 μl of a 10% Nonidet P-40 solution was added and mixed by gentle pipetting. Nuclei were then pelleted by centrifugation at 14,000×g for 30 seconds, washed with the hypotonic buffer and resuspended in 50 μl ice-cold complete lysis buffer (Active Motif, Carlsbad, Calif.). After the nuclear lysates were centrifuged, supernatants were collected for quantification of NF-κB activation. The protein concentrations in the supernatants were determined using the BCA protein assay kit (Pierce, Rockford, Ill.).
[0062] Quantification of NF-κB activation. Trans- AM NF-κB assay, an enzyme-linked immunosorbent assay (ELISA)-based method (Trans- AM NF-κB; Active Motif, Carlsbad, Calif.) was used for NF-κB activity quantification according to the manufacturer's instruction. Briefly, cell nuclear extracts were placed in 96-well plates coated with an oligonucleotide containing the NF-κB consensus sequence, and the presence of active NF-κB was detected by using antibodies specific for p50 subunits that are not complexed to IκB and thus able to bind the consensus sequence. A horseradish peroxidase (HRP) conjugated secondary antibody is used to quantify NF-κB binding by conversion of an applied chromogenic substrate.
[0063] Antitumor activity in xenograft model. Female athymic (NCR-nu/nu, Tacomic) nude mice were injected with 2×10 6 MDA-MD-435 tumor cells subcutaneously, and about 3 weeks later, when the tumor volumes reached 100-250 mm, the mice were divided into four groups such that each group had tumors of a similar volume. Stock solutions of paclitaxel alone, 8-Quinolinol (8Q) alone or in combination with paclitaxel were prepared by dissolving the drugs in a vehicle solution (EtOH:cremophor, 50:50 v/v). Vehicle or paclitaxel alone, 8Q alone and 8Q in combination with paclitaxel stock solution were mixed with saline (10:90 v/v). For intratumor injection, the 8Q dose was 4 mg/kg, given twice weekly for three weeks. For tail vein injection, the 8Q dose was 20 mg/kg, given twice weekly for 4 weeks. The paclitaxel dose was 15 mg/kg. Tumor measurements were done twice a week using traceable digital vernier calipers (Fisher). The tumor volumes were determined by measuring the length (l) and the width (w) and calculating the volume (V=lw 2 /2). The procedures of r animal care and use were in accordance with institutional and NIH guidelines.
[0064] Statistical analysis. The growth inhibition effects were compared by Student's t test. P<0.05 was considered significant. One-way ANOVA analysis was performed to determine the statistical significance of treatment related changes in tumor volume in athymic nude mice. Software R package was used for statistical calculation.
Example 1
MCF7 Sphere Cell Culture
[0065] Side population (SP) cells were first defined by Goodell et al in hematopoietic system in 1997 and proved to enrich stem cells 31 . Studies with mammary sphere cells indicate that compared to bulk cells, side population (SP) cells were more capable of forming sphere cells 28 . In addition, neurosphere cells cultured from SP cells were found to be enriched in stem cells compared to neurosphere cells directly derived from bulk patient samples 24 . Therefore we attempted to culture MCF7 sphere cells from MCF7 SP cells. The MCF7 SP cells were isolated by flow cytometric cell sorting. The MCF7 sphere cells were then cultured in a serum-free mammary epithelial growth medium, supplemented with B27, 20 ng/mL and EGF and 20 ng/mL bFGF. Using this method we were able to successfully maintain a culture MCF7 sphere cells for more than 1.5 years. The sphere, consisting of many cells associated together, was about 250 μm in diameter ( FIG. 1A ) and presumably represents many cells associated together from a single clone. As a control, sphere cells cultured from MCF7 non-SP cells could not be passaged for more than 5 generations. The sphere cells were enriched with cancer stem cells expressing surface markers CD44 + CD24 −4 . An increase of 34.7 fold in the breast cancer stem cell population was seen in sphere cells (78.52%) compared with MCF7 parental cells (1.85%) ( FIG. 1B ). The MCF7 sphere cells did not express lineage-specific markers of mammary epithelium such as CD 10 (myoepithelial lineage marker) and casein (functional alveolar cell marker) (data not shown). Compared to parental MCF7 cells, the sphere cells showed much higher sphere formation ability and soft agar colony formation ability, as shown by 26.0 and 10.9 fold increase, respectively, than the MCF cells ( FIG. 1 C). MCF7 sphere cells also had SP properties with high efflux activity. The SP cell fraction in MCF7 sphere cells was 26.81%, compared to 0.87% in parental MCF7 cells ( FIG. 1D ).
Example 2
MCF7 Sphere Cells are Resistant to Common Cancer Drugs
[0066] To test the drug sensitivity of the sphere cells, both MCF7 and MCF7 sphere cells were sorted into 96 well plates and treated with various clinical drugs, including adriamycin (doxorubicin), mitomycin C, paclitaxel (Taxol), and tamoxifen, at indicated concentrations for 3 days. Compared to MCF7 cells, MCF7 sphere cells were resistant to all the drugs tested at different concentrations, as shown in FIG. 2 . The highest resistance was shown for paclitaxel treatment, which at a concentration of 0.25 uM caused growth inhibition at 44.5% for MCF7 parental cells compared with 6.1% for the MCF7 sphere cells. The drug resistance of MCF7 sphere cells was associated with the relative quiescence of the MCF7 sphere cells. As shown in FIG. 1E , most of MCF7 sphere cells (68.8%) were in G0/GI phase (58.8% for MCF7 cells), and only 4.57% at G2 phase, while the proportion in G2 phase for MCF7 cells was 13.1% ( FIG. 1E ).
[0067] To determine if the high expression of ABC transporters might be responsible for the drug resistance in the sphere cells, we examined the expression levels of all functional 48 ABC transporters in human genome by RT-PCR on MCF7 sphere cells with MCF7 parental cells as a control. Interestingly, some ABC transporters, including ABCA2, ABCB5, ABCCI, ABCC4, ABCC5, ABCC6 and ABCC11, which are known to efflux common drugs and cause drug resistance 32,33 , were over-expressed by more than 2 fold compared with the control MCF parent cells (Table 1). Sphere cells were also found to over-express several ABC transporters with unknown functions or not known for drug efflux, including ABCA5, ABCA6, ABCA10, ABCA12, ABCB9, ABCB10 and ABCD1. Compared to MCF7 cells, expression of these transporters was 3 fold or higher in the sphere cells. Over-expression of at least some of these ABC transporters may cause the resistance phenotype in the MCF sphere cells.
[0000]
TABLE 1
Expression of 48 functional ABC transporters of MCF7 sphere cells
compared to MCF7 cells. ABC transporters were quantified by
RT-PCR. Primers were taken from Szakacs G et al 47 . All the ABC
transporters, either up-regulated or down-regulated by more than 2
fold, were shown.
Fold change
Function
ABCA2
2.6 ± 0.9
Efflux of drug Estramustine 33
ABCA4
2.0 ± 1.0
Rod photoreceptor retinoid transport 49
ABCA5
3.1 ± 0.7
N-retinydilester-PE efflux 50
ABCA6
11.0 ± 3.2
ABCA7
2.8 ± 1.4
ABCA10
4.9 ± 0.8
ABCA12
3.4 ± 1.0
ABCB5
2.1 ± 0.8
Efflux of drug doxorubicin 32
ABCB9
3.5 ± 1.4
ABCB10
3.3 ± 1.7
ABCC1
2.5 ± 0.01
Efflux of drug doxorubicin, daunorubicin,
vincristine, etoposide, colchicine,
camptothecins, methotrexate 33
ABCC2
0.3 ± 0.4
Efflux of drug vinblastine, cisplatin,
doxorubicin, methotrexate 33
ABCC4
2.8 ± 1.3
Efflux of drug 6-Mercaptopurine,
6-thioguanine and metabolites,
methotrexate 33 ; Nucleoside transport 48
ABCC5
2.1 ± 0.8
Efflux of drug 6-Mercaptopurine,
6-thioguanine and metabolites 33
ABCC6
4.0 ± 0.8
Efflux of drug etoposide 33
ABCC7
2.4 ± 2.1
Chloride ion channel 49
ABCC11
10.3 ± 3.9
Efflux of drug 5-Fluorouracil 33
ABCC12
2.1 ± 1.1
ABCD1
3.0 ± 1.5
VLCFA transport 49
ABCD2
2.2 ± 0.8
ABCD3
2.1 ± 0.3
Example 3
NF-κR Pathway is Important for MCF7 Sphere Cell Survival
[0068] Signaling pathways that show key differences between normal and cancer stem cells could provide therapeutic targets. Wnt, Sonic Hedgehog and Notch pathways were proposed to be active in cancer stem cells and could be important for their self-renewal and survival 12,21,34,35 . We first determined whether these pathways are important for MCF7 sphere cell survival by comparing the growth inhibition of specific inhibitors of Wnt, Sonic Hedgehog and Notch pathways on MCF7 sphere cells with that for the parental MCF7 cells. However, Wnt pathway inhibitor DKK1, Notch pathway inhibitor GSI1 and Sonic Hedgehog pathway inhibitor cycloparnine showed no higher growth inhibitor ability on MCF7 sphere cells than MCF7 cells (data not shown). Since NF-κB and PI3K pathways are critical for leukemia stem cell survival 35-38 , we tested inhibitors of these pathways for their ability to inhibit MCF7 sphere cells compared with MCF7 cells. Rapamycin, an inhibitor of mTOR, a downstream molecule of PI3K pathway, showed higher growth inhibition effect on MCF7 sphere cells than MCF7 cells ( FIG. 3A ). Interestingly, NF-κB pathway inhibitors, including parthenolide (PTL) and pyrrolidine dithiocarbamate (PDTC), exerted very marked growth inhibition on MCF7 sphere cells compared to MCF7 cells ( FIG. 3A ). In particular, PDTC at 1 uM inhibited MCF7 sphere cell growth by 50.8% but had no growth inhibition effects on MCF7 cells. To confirm the NF-κB pathway inhibition effects by these compounds, we quantified the activity of NF-κB by Trans-Am NF-κB assay. As expected, both inhibitors, PTL and PDTC, decreased NF-KB activity ( FIG. 3B ). For both compounds, the inhibition was greater for MCF7 sphere cells than for MCF7 parental cells. With treatment of 5 μM PTL and PDTC for 24 hours, NF-κB activity in MCF7 sphere cells was decreased by 94.6% and 61.8%, respectively. The same dose of PTL and PDTC only inhibited the NF-κB activity by 38.8% and 33.6%, respectively, in MCF7 cells ( FIG. 3B ). However, no difference was detected of the NF-κB activity between MCF7 and MCF7 sphere cells (data not shown).
[0069] To further confirm the importance of the NF-κB pathway for MCF7 sphere cell self-renewal, we over-expressed and knocked down the expression of the p65 gene, encoding a component of NF-κB by transfection and siRNA. Self-renewal ability of MCF7 sphere cells was determined by soft agar colony formation assay and sphere formation assay. As expected, MCF7 sphere cells over-expressing p65 had higher colony formation ability and sphere formation ability. MCF7 sphere cells over-expressing NF-κB subunit p65 produced 551 colonies and 225 spheres in the same conditions, compared with 325 colonies on soft agar and 161 spheres in their respective controls ( FIG. 4 A, B). However, when p65 gene was down-regulated by specific siRNA, MCF7 sphere cells showed decreased ability to form colony on soft agar. As shown in FIGS. 4A and B, MCF7 sphere cells transfected with p65 siRNA formed 244 colonies and 44 spheres, compared with 413 colonies and 158 spheres for the control sphere cells. The over-expression and knockdown of p65 were verified by Western blot ( FIG. 4 C, D). A similar effect was observed when another NF-κB subunit, p50, was knocked down by siRNA (data not shown). Taken together, these results suggest that the NF-κB pathway is important for MCF7 sphere cell survival and self-renewal.
Example 4
Identification of Compounds that Specifically Inhibit MCF7 Sphere Cells by Compound Library Screening
[0070] As indicated above, MCF7 sphere cells are resistant to clinical drugs compared with parental MCF7 cells. We sought to identify compounds that preferentially inhibit MCF7 sphere cells over MCF7 cells. For this purpose, we screened the NCI diversity set compound library on both MCF7 and MCF7 sphere cells. One promising compound NSC 125034 was identified to have higher growth inhibition effect on MCF7 sphere cells than MCF7 cells in a dose dependent manner ( FIG. 5A ). At 25 μM, NSC125034 inhibited sphere cell growth by 33.5%, compared with 0% on MCF7 cells. As NSC125034 has poor solubility even in DMSO, compounds with similar structure were further tested. Ethanol soluble 8Q (8-Quinolinol) was found to have similar or even better activity on MCF7 sphere cells compared with NSC125034 ( FIG. 5B , C). For example, at 5 μM, 8Q inhibited sphere cell growth by 86.0% but inhibited MCF7 cells by 30.0% after three day treatment. To further verify the effect of these compounds on potential breast cancer stem cells, we tested these compounds on MCF7 SP cells, another accepted breast cancer stem cell model 39-41 . Similar to their effects on the sphere cells, 8Q at 5 μM showed better growth inhibition effects on MCF7 SP cells than on MCF7 non-SP cells, with inhibition of 84.7% on SP cells compared to 71.9% on non-SP cells. Since both sphere cells and SP cells are known to the enriched in cancer stem cells 39-41 , these compounds are thus preferentially active against breast cancer stem cells and were further evaluated for their ability to improve cancer therapy in the mouse model as described below.
Example 5
Antitumor Activity of 8Q in the Nude Mouse Tumor Xenograft Model
[0071] To demonstrate that the identified compounds can inhibit tumor growth in vivo, we evaluated their antitumor activity in a breast cancer mouse xenograft model. Since MCF7 cell line represents the early stage of breast malignancy and its growth in vivo is dependent on estrogen, we used MDA-MB-435 cell line, which is more malignant, forms tumors more rapidly in mice, and is estrogen independent. Due to poor solubility, NSC 125034 was not used for testing. Compound 8Q was tested in mice bearing MDAMB-435 tumor either alone or in combination with clinical drug paclitaxel. The compound 8Q is a less toxic compound according to U.S. National Toxicology Program acute toxicity studies (http://www.pesticideinfo.org/List_NTPStudies.jsp?Rec_Id=PC34299) and often used as fungicide and microbicide. The LD 50 s (oral) for mouse, rat and mammal were 20 g/kg, 1.2 g/kg and 1 mg/kg, respectively. 8Q when given through the tail vein at a dose of 20 mg/kg did not show significant toxicity as judged by lack of apparent symptoms and body weight loss ( FIG. 5F ).
[0072] As shown in FIGS. 5D and 5E , the compound 8Q alone significantly inhibited tumor growth in the mouse model either with intratumor injection (4 mg/kg) (P<0.001) or tail vein injection (20 mg/kg) (P<0.001) ( FIGS. 5D and 5E ). The positive control paclitaxel inhibited the tumor growth as expected. Furthermore, 8Q plus paclitaxel produced an antitumor effect that was superior to paclitaxel or 8Q alone in both intratumor and tail vein injection model. In one of the five mice of the group that received both 8Q and paclitaxel, the tumor completely disappeared. These data suggest a marked synergistic effect on inhibition of tumor growth (FIGS. 5 D and 5 E( 1 ). We further tested PDTC in another breast cancer xenograft model, MDA-MB-435 xenograft. Since MCF7 represents the early stage of breast malignancy and is easier to be cured, whereas MDA-MB-435 model reflect the late-stage breast malignancy. It will be more valuable if PDTC also shows growth inhibition effect on MDA-MB-435 model. Indeed, PDTC showed similar growth inhibition effect on MDA-MB-435 tumor growth in nude mice either alone or in combination with paclitaxel (FIG. 5 E( 2 )).
[0073] As described hereinabove, we successfully established long-term culturable sphere cells from the MCF7 breast cancer cell line. While our work was ongoing, culture and characterization of MCF7 sphere cells was reported by Ponti and colleagues 30 . The MCF7 sphere cells they identified were enriched for tumorigenic cancer cells with stem/progenitor cell properties 30 . However, we found that the MCF7 sphere cells cultured by their published protocol could not be passaged more than 5 generations (data not shown). This is presumably because these authors did not use flow cytometry to enrich for SP cells during their sphere cell culture. The MCF7 sphere cells we isolated were enriched in known cancer stem cell surface markers CD44 + /CD24 − and had higher percentage of SP cells with increased efflux activity 4 . The sphere cells had higher colony formation ability ( FIG. 1C ), and were relatively quiescent and resistant to commonly used cancer drugs. The drug resistance property of MCF7 sphere cells was presumably because of the quiescent state of MCF7 sphere cells as shown by higher percentage of cells in G0/G1 phase and also increased expression of ABC transporters. All these features support the conclusion that the sphere cells we isolated have cancer stem cell properties. Seven ABC transporters known to involve in drug resistance were over-expressed in sphere cells by more than 2 fold (Table 1). In addition, expression of seven other functionally unknown ABC transporters was increased by 3 fold or more in sphere cells. Further studies are needed to confirm the role of these ABC transporters in conferring drug resistance in the sphere cells.
[0074] Identifying the pathways that are important for cancer stem cell survival is critical for understanding the biology of cancer stem cells and also for design and development of new drugs that target cancer stem cells. Although Wnt, Sonic Hedgehog and Notch were widely proposed to be active in cancer stem cells and might be important for their self-renewal and survival 12,21,34,35 , their inhibitors tested in this study, including DKKI, GSI1 and cyclopamine did not inhibit MCF7 sphere cells more than the MCF7 parental cells. Instead, we found that the PI3K pathway and, especially the NF-κB pathway, were critical for the MCF7 sphere cell survival, as demonstrated by their respective pathway inhibitor study. Raparnycin, a specific inhibitor for PI3K pathway, and PTL and PDTC, inhibitors of NF-κB pathway, were shown to specifically inhibit MCF7 sphere cells more strongly than the parental MCF7 cells ( FIG. 3A ). The importance of NF-κB pathway for MCF7 sphere cell survival was further substantiated by the NF-κB subunit p65 gene over-expression and knockdown experiments ( FIG. 4 ). These findings suggest that PI3K and NF-κB pathways could be good drug targets for breast cancer stem cells.
[0000] There is increasing awareness that cancer stem cells pose a significant challenge to effective treatment of cancer as they are resistant to current clinical drugs 14,17,18,42 . Current cancer drugs were developed by screening and testing on bulk actively growing cancer cells and are not effective for quiescent cancer stem cells. To identify drugs that target cancer stem cells, we screened a compound library using the quiescent and slow growing MCF7 sphere cells as a model for cancer stem cells. One compound, NSC125034, and its analog 8Q were shown to preferentially inhibit the cancer stem cells over bulk cancer cells. The mechanism by which 8Q kills cancer stem cells is not known. However, 8Q as a metal chelator, is believed to bind copper and bring the metal into the cancer cell, thereby causing cytotoxicity 43 . 8Q may also cause antimitotic effect by inhibiting mitotic kinesin Eg5 ATPase 44 . The most likely possibility is that 8Q may inhibit NF-κB pathway 45 , which has been shown to be important for the sphere cell survival in this study ( FIG. 4 ). Future study is needed to define the mechanism of 8Q inhibition of cancer sphere cells. We next evaluated the antitumor activity of 8Q in vivo in the breast cancer xenograft model. 8Q alone had significant activity in the mouse model but showed a pronounced synergistic effect when combined with clinical drug paclitaxel either by the intratumor injection or tail vein injection ( FIGS. 5D and E). Combination of current clinical drugs, which could effectively eliminate bulk cancer cells, and cancer stem cell targeting drugs, like PI3K and NF-κB pathway inhibitors, which could effectively eliminate cancer stem cells, may provide better therapeutic efficacy. Compounds like 8Q, which we have shown to kill a population of quiescent cancer stem cells and to synergize with the other clinical cancer drugs such as paclitaxel, hold promise for improved cancer treatment in the clinic due to the ability to eliminate the root of cancer and achieve longer term remission.
REFERENCES
[0075] References cited herein are listed below for convenience.
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Isolation and functional properties of murine hematopoietic stem cells that are replicating in vivo. J Exp Med 183, 1797-806 (1996). 47. Szakacs, G. et al. Predicting drug sensitivity and resistance: profiling ABC transporter genes in cancer cells. Cancer Cell 6, 129-37 (2004). 48. Agrawal, A., Cha-Molstad, H., Samols, D. & Kushner, I. Transactivation of Creactive protein by IL-6 requires synergistic interaction of CCAAT/enhancer binding protein beta (C/EBP beta) and Rel p50 . J Immunol 166, 2378-84 (2001). 49. Dean, M. & Allikmets, R. Complete characterization of the human ABC gene family. J Bioenerg Biomembr 33, 475-9 (2001). 50. Glavinas, H., Krajcsi, P., Cserepes, J. & Sarkadi, B. The role of ABC transporters in drug resistance, metabolism and toxicity. Curr Drug Deliv 1, 27-42 (2004).
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8-quinolinol (8Q) and derivatives thereof for use in the treatment of proliferative diseases such as cancer, in particular slow metabolizing quiescent cancer stem cells.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is adjustable fitting apparatus and system for plumbing, particularly for low pressure drain/waste/vent (“DWV”) plumbing.
[0004] 2. Related Art
[0005] There is a constant need in the plumbing arts to match plumbing fittings, particularly between an external fixture in a room and the drain, waste or vent pipes hidden behind the walls of the room. At least for the visible portion, there is a constant need that the fittings be made as visually appealing as possible. There is a further need for economy in the number of parts used, as well as economy in time and work required to complete an acceptable result.
[0006] Efficient fitting in plumbing is always desirable, particularly in DWV plumbing, and most especially for the type of construction that has become typical, that is to say, frame and drywall construction. Efficient fitting of plumbing fixtures to wall plumbing has been complicated by the fact that on typical construction projects the plumber and carpenter are on premise working on the same room at different times. Matching fittings can also be complicated by the very small amount of space within the wall for plumbing pipes and fixtures; space that might otherwise be available for adjustment. A commonplace situation is as follows: a building, either commercial or residential, is framed by a carpenter. A plumber will install plumbing lines within the walls that have been framed. Thereafter another carpenter or drywaller will follow and put the finish drywall on the frame, leaving a small hole allowing access to the pipes installed there previously by the plumber. After this step, another plumber returns to attach fixtures such as toilets, sinks and the like to the pipe in the wall, through the hole left in it for that purpose by the carpenter. It frequently happens that the fixture dimensions and/or changes in the wall dimensions made by the carpenter do not allow a properly fit in connection between the exit pipes of the fixture and the wall pipe. For example, carpenters sometimes move the wall out from the position indicated for it when the first plumber installed the wall pipes. For another example, the fixture might have a different dimension than planned for originally. A result of these events is that an unplanned for extension of the wall pipe must be created by the second plumber in order to adequately connect the fixture pipe in the room to the wall pipe provided for it.
[0007] Such adjustments are disadvantageous for at least two reasons. First, the extension fittings commonly available, most particularly typical PVC pipe and fixtures, must be on the room side of the wall and are frequently too large to be covered up by the escutcheon provided for it. Secondly, the second plumber must take extra time, frequently on the order of an hour, to install extension fittings. Moreover, simply in order to achieve the extension fitting to complete the installation, the second plumber sometime has to cut a large square hole in the wall for sufficient access to the wall pipes. Thereafter, the carpenter must return in order to patch the hole in the wall, requiring another one to three hours of work.
[0008] Presently in the art there is a series of adapters and slip joint couplings having a variety of male and female threaded and nonthreaded fitting arrangements. None of the presently available fittings are adjustable or variable in the desirable dimensions. None of the presently available fitting systems provide a direct, threaded, sealing joint that can be adapted to the type of unanticipated dimension changes described above. Hence, there is a need in the art for a system providing a variety of threaded slip joint coupling dimensions, and/or an adjustable fitting adaptable to a variety of dimensions.
SUMMARY OF THE INVENTION
[0009] The present invention includes an adaptive slip joint coupling for connecting a fixture exit pipe to a wall pipe and also includes a system of slip joint couplings, T fixtures and a quarter bend fixtures of varying dimensions, both providing for adaptable connections.
[0010] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0012] FIG. 1 is a T fitting having a male threaded throat;
[0013] FIG. 2 is a cross section view of a female threaded slip joint adjustable coupling;
[0014] FIG. 3 is a double T fitting;
[0015] FIG. 4 is a double 90 fitting; and
[0016] FIG. 5 is cross sectional view of a system of variously dimensioned female threaded slip joint couplings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0018] FIG. 1 depicts a T-fitting 10 having a throat 12 having an aperture with male threads 14 on the outside. A wall 16 is presented in cross section to indicate the anticipated installed position of the T-fitting 10 . FIG. 2 is a cutaway version of an adjustable slip joint coupling having a female thread on its internal diameter. Female coupling 20 is comprised of an unthreaded extension 22 providing length that can be varied for adjustment. The threaded internal diameter 24 comprises a female portion dimensioned to threadingly engage male portion 14 of the T-fixture or other fixtures. A seal abutment 26 separating the threaded portion 24 and non-threaded portion 22 is provided for seating of a seal (not shown) in order to apply a water tight seal between an end of the fixture exit pipe, such as a P-trap pipe, and the male portion of the T or other fixture. The outer diameter of the adjustable slip joint coupling 20 may include a marker 28 just behind the location of the lip 26 on the internal diameter. This marker will indicate to a plumber that portion of the non-threaded length 22 of the coupling that is the extension which may be cut for adjustment.
[0019] In operation, the female slip joint coupling 20 will be measured by the plumber and cut with any of a variety of standard pipe cutters at any selectable place in the unthreaded portion 22 of the coupling. The plumber may cut through a standard thickness of the coupling wall, as indicated on the top portion of FIG. 2 . Alternatively, the female coupling 20 may be fabricated such that preconfigured thin or weak portions of the coupling wall be included, such as notches or grooves on outside diameter 30 , on an inside diameter 34 , or hollow portions within the thickness of the coupling wall 32 . For hollow portions 32 and internal diameter thin portions 34 , one may alternatively include markers on the outside diameter indicating where these positions are. Alternatively, pieces could be screwed or glued together, using joining interfaces such as those shown on the top of FIG. 5 .
[0020] Having measured and cut the adjustable female slip joint coupling 20 to an appropriate length, the fixture exit pipe or P-trap pipe is inserted through female slip joint coupling 20 , through a standard seal and then into throat 12 of T-fitting 10 . The plumber then slides the female slip joint coupling 20 along the P-trap pipe until it engages male threads 14 on throat 12 , whereupon the plumber screws the coupling in. Having adjusted the female coupling 22 an appropriate length, any escutcheon or other fixture provided will appropriately fit over end portion 36 of female coupling 20 , thereby providing an esthetically acceptable finish.
[0021] FIG. 4 shows a double throated T-fitting, each throat 112 having male threads 114 . FIG. 5 shows a double threaded 90 fitting, which may also have the male threads of the present invention, 214 . A single 90 having a male thread 214 is indicated on the right hand side of FIG. 4 in a profile corresponding to the phantom line in that figure.
[0022] The adjustable slip joint female threaded coupling of the present invention may mate with any of the depicted single throat T-fixture, double throat T-fixture, single throat 90 or double throat 90 . Either or both of the fittings herein described may be made of any material, including cast iron, steel, plastic, and particularly polyvinylchloride (PVC).
[0023] FIG. 3 shows an alternate system wherein the adjustable female slip joint couplings 320 are each at a different length. The female threaded portions 324 and lips 326 are the same as depicted in FIG. 2 . However, the unthreaded portion 322 is a different length for each of the depicted examples. Accordingly, in operation, the system of the present invention would include a plumber having various lengths of female threaded slip joint couplings in his tool box. When presented with a mismatched dimension for joining a fixture exit pipe with the wall pipe fitting when the wall pipe fitting is behind the wall, the plumber may choose the length of female threaded coupling 320 best suited for the dimensions at hand and proceed to fit the fixture with that selected coupling.
[0024] This invention eliminates one and sometimes two pieces normally needed for installation of plumbing fixture to wall pipe. It eliminates the need to carry a saw, PVC cleaner and PVC glue when setting fixtures and saves labor and material.
[0025] As various modifications could be made to the exemplary embodiments, as described above with reference to the corresponding illustrations, without departing from the scope of the invention, it is intended that all matter contained in the foregoing description and shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.
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The present invention includes an adaptive slip joint coupling for connecting a fixture exit pipe to a wall pipe and also includes a system of couplings of varying dimensions, both providing for adaptable connections.
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BACKGROUND OF THE INVENTION
This invention relates to a safety device for the trigger mechanism of a shot-gun of the gas-pump type. In this specification and in the claims, by the term: shot-gun of the gas-pump type is meant a shot-gun in which the re-arming mechanism may be actuated either automatically, by the so-called gas-take-off method, or manually by the so-called pump-action technique. The re-arming mechanism of a gun of the type under consideration generally includes a breechblock mounted on a carrier guided for movement towards and away from a firing chamber, a spring which maintains the breechblock in a position in which it closes the firing chamber and which resists the movement of the carrier-breechblock group away therefrom, and a piston for driving the said carrier-breechblock group against the action of the firing-chamber-closure spring. When the re-arming mechanism of the gun is actuated by the so-called gas-take-off method, the piston is subjected to the action of a portion of the discharge gas which is drawn from the gun barrel into a cylinder in which the piston is axially movable. When the re-arming mechanism of the gun is actuated manually, the piston is made rigid with a fore-end-stock-slide, slidably mounted on the gun itself. A shot-gun of the gas-pump type is further provided with a device for converting it from automatic actuation to manual actuation of the re-arming mechanism and vice versa. Such a shot-gun of the gas-pump type is described in Patent Applications Nos. 22697 B/79 and 24595 A/80 filed on the 27th Sept. 1979 and the 11th Sept. 1980 respectively in the name of the same Applicant.
When a gun is in its ready-to-fire condition, the breechblock is held in its position in which it closes the firing chamber by a positive, removable catch, called a hook in this branch of the art, while the carrier is retained in a corresponding position by a stop member generally supported by the trigger mechanism housing of the gun, More particularly, the said stop member is constituted by a lever which is fixed at one end to the trigger mechanism housing and the other end of which bears against the rear wall of the carrier. Such a stop member must be of the escape type, that is to say, it must be displaceable into a non-operative position to allow the carrier to be displaced freely in the direction of opening of the firing chamber when it is required to re-arm the gun after firing. To this end, the cited stop member is connected to the hammer of the gun and follows its anguler displacement. At the moment of firing, as the hammer is angularly displaced to strike the firing pin, the cited stop member is angularly displaced about its respective pivot point so that its free end, which previously bore against the carrier, is displaced into a non-operative position, spaced from the said carrier or at least out of the path of movement thereof. From careful observation of the movement of the hammer towards the firing pin it could be seen that, in the act of striking the firing pin, the hammer rebounded before resting finally on the firing pin itself. This rebound, although rapid and limited in size, always causes an equivalent angular displacement of the cited stop member. In essence, at each firing, the cited stop member, before finally taking up its position in which it is spaced from the path of the carrier, undergoes a very rapid "return" angular displacement, which displacement, in the following description, will be called: rebound-effect displacement.
When the re-arming mechanism of a gas-pump shot-gun is actuated manually (pump action) the said rebound-effect displacement of the cited stop member is of no consequence since, because of the rapidity with which it occurs, the said stop member is safely in the non-operative position spaced from the path of the carrier at the moment at which the carrier is displaced (manually) in the direction of opening of the firing chamber.
However, when the re-arming mechanism is actuated automatically by the discharge gases drawn from the gun barrel, the displacement of the breechblock and its carrier in opening the firing chamber is so rapid and so violent that the carrier certainly strikes the free end of the lever-stop member while it is still effecting the said rebound-effect displacement. As a result, the lever-stop member and the trigger mechanism associated therewith may break.
OBJECT OF THE INVENTION
The problem which is at the root of this invention is, thus, to devise a safety device for the trigger mechanism of a shot-gun of the gas-pump type, which is such as to ensure the elimination of the rebound-effect displacement of the lever-stop member, that is to say, which ensures the retention of the lever-stop member in its inoperative position when the carrier is displaced in the direction of opening of the firing chamber; such a safety device must, moreover, allow the lever-stop member to take up its operative position again, with its free end bearing against the carrier, when the latter is in its position corresponding to closure of the firing chamber.
SUMMARY OF THE INVENTION
This problem is solved according to the invention by a safety device for the trigger mechanism of a gas-pump-type shot gun having a breechblock carrier supporting a breechblock for translational movement between a first position in which the firing chamber of the shot gun is closed and a second position in which the firing chamber is open, a stop member defining lever pivoted on the trigger-mechanism housing about an axis perpendicular to the direction of movement of the breechblock carrier for pivotal movement between an operative position, in which a free end thereof bears against the carrier when the breechblock is in the first position, and an inoperative position in which the said free end lies out of the path of movement of the carrier, characterised in that the safety device comprises a spring assembly pivotally connected at one end to the said lever and at the other end to a fixed point on the shot-gun, the straight line of action of the spring assembly extending to one side of a straight line joining the said fixed point to a point on the pivot axis of the said lever when the stop member defining lever is in its inoperative position such that the spring assembly biases the stop member defining lever towards the inoperative position, the spring assembly being in its condition of maximum loading when its straight line of action coincides with the said straight joining line.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages will become clearer from the following detailed description of one embodiment of a safety device according to the invention, made with reference to the appended drawings given purely by way of example, in which:
FIG. 1 shows schematically, in partial section, a portion of a shot-gun including the trigger mechanism of the gun and incorporating a safety device according to the invention;
FIGS. 2, 3 and 4 show schematically, on an enlarged scale, the trigger mechanism of FIG. 1, incorporating the safety device of this invention in different positions of operation;
FIGS. 5, 6 and 7 are schematic representations of the different positions taken up by the safety device of the invention in the respective positions illustrated in FIGS. 2, 3 and 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the said Figures, by 1 is generally indicated a housing for the trigger mechanism of a gas-pump-type shot-gun 2, that is to say, a shot-gun in which the same re-arming mechanism may be actuated equally well, either automatically by the so-called gas-take-off method or manually by the conventional, so-called pump-action, the gun 2 having members (not shown) for converting it from one type of actuation of the re-arming mechanism to the other type and vice versa. Of the re-arming mechanism, in the appended drawings there are shown the breechblock 3 with its firing pin 4, the carrier 5 for supporting and actuating the breechblock 3 and the cartridge conveyor 6. In particular, the carrier 5 is actuated conventionally by a pair of parallel rods 5a which extend above and to the side of the trigger mechanism assembly of the gun. The carrier 5, actuated manually or automatically as described above, is reciprocated along a predetermined path away from and towards a firing chamber 7, carrying with it the breechblock 3 to positions in which it opens and closes the firing chamber respectively.
In FIGS. 1 and 2, the carrier 5 and the breechblock 3 are shown in the closed position of the said firing chamber 7; while the breechblock 3 is maintained in this position by a spring (not shown since it is conventional) and by the engagement of a hook 3a in a respective retaining seat, the carrier 5 is retained by a stop device generally indicated 8, the presence of which and the action of which are required particularly during operation of the gun with manual re-arming by pump action.
The said stop device comprises essentially a lever 10 in the form of a plate pivoted substantially centrally on a pin 9 carried by the trigger mechanism housing 1 and extending perpendicular to the direction of displacement of the carrier 5. The plate-like lever 10 includes an elongate portion 11 extending from the pin 9 towards the firing chamber 7, the portion 11 having a free end 11a which bears against the carrier 5 when the latter is retained in the position corresponding to closure of the firing chamber. The plate-like lever 10 defines a further portion 12 above which is a lug 13 exgaged transversely in a slot 14 formed in an arm 15 in the form of a plate. This arm 15 is rotatably mounted at one end on a pin 16 carried by the trigger mechanism housing 1 and extending parallel to the pin 9 of the plate-like lever 10. The arm 15, which extends parallel to the plate-like lever 10, has a curved upper edge 15a which is upwardly convex and constituted by two lateral sections rising towards a central highest portion. The upper curved edge 15a of the arm 15 lies in the path of movement of the carrier 5 as will be better understood from the description below.
The plate-like lever 10 is angularly displaceable about the axis of the pin 9 from an operative position, in which the free end 11a thereof bears against the carrier 5 (stop action) to an inoperative position in which the said free end is lowered so as to be completely below the carrier, and so as not to lie in the path of movement thereof during its displacements away from and towards the firing chamber 7.
The angular displacements of the plate-like lever 10 are correlated with the angular displacements of the hammer 17 to which the said lever is connected by conventional means not shown. When the hammer 17, liberated by the trigger 18, is displaced angularly towards the breechblock 3 to strike the firing pin 4, the plate-like lever 10 is displaced angularly downwardly into its inoperative position specified above. By 19 is shown a thrust spring assembly including a shaft 20 which is pivotally attached at its opposite ends 21, 22 respectively to the portion 12 of the plate-like lever 10 and to the trigger mechanism housing 1, with pivot axes parallel to the axis of the pin 9 of the said plate-like lever 10. More particularly, the end 22 of the said shaft 20 is movable axially in a hole 23 formed in a spherical body 24 articulated in the form of a ball joint in a corresponding seat 25 formed in the housing 1. The thrust spring assembly 19 further includes a spring 26 fitted coaxially on to the shaft 20 and bearing at one end against a collar 21a of the shaft itself and at the other end against the spherical body 24 mentioned above. The points of pivoting of the thrust spring assembly 19 on the lever 10 and on the mechanism housing 1 respectively, are chosen so that when these are aligned with a point on the axis of the pin 9, in a straight joining line C, the spring 26 is in its condition of greatest compression. More particularly the said pivot points and the resilient strength of the spring 26 are chosen so that the thrust spring assembly 19 has two stable positions, disposed symmetrically with respect to the straight joining line indicated by C in the appended Figures, in which positions the straight line of action of the said spring 26 lies below and above the said joining line respectively. The presence of the thrust spring assembly 19 and its action on the plate-like lever 10 are such that the latter lever has two corresponding stable positions, angularly displaced with respect to the straight line C. More particularly, when the free end 11a of the lever 10 is in the operative position (FIG. 2), the straight line of action of the spring 26 lies in the position underneath the straight line C, while when the free end 11a of the lever 10 is in the inoperative position (FIG. 4) the straight line of action of the spring 26 lies completely above the straight line C.
The operation of the safety device of this invention is as follows.
In an initial condition (FIG. 2), the lever 10 has its free end 11a in the operative position that is to say bearing against the carrier 5 which is maintained in the position corresponding to closure of the firing chamber 7. The straight line of action of the spring 26 of the thrust spring assembly 19 lies completely below the straight line C considered above. When, after actuation of the trigger 18, the hammer 17 is displaced angularly to strike the firing pin 4, the lever 10 is displaced angularly about the pin 9 (in an anti-clockwise sense with reference to the appended drawings), so that the free end 11a is displaced into the inoperative position. The angular displacement of the lever 10 is resisted initially by the thrust spring assembly 19, a resistance which continues and increases until the spring 26 of the assembly has reached its point of maximum compression, that is to say until the straight line of action of the spring 26 coincides with the straight line C specified above. Immediately this point has been passed, the thrust spring assembly 19 facilitates the angular displacement of the lever 10 and, hence, the reaching of the inoperative position by the free end 11a of the lever itself.
The reaching of the inoperative position by the free end 11a of the stop member defining lever 10 simultaneously with the striking of the hammer 17 on the firing pin 4. The immediate, subsequent rebound of the hammer 17 does not result in the entrainment of the lever 10 since this is retained in its inoperative position by the thrust spring assembly 19.
Consequently, even when the gun is re-armed by the gas-take-off method, the immediate and violent displacement of the carrier 5 and of the breechblock 3 in opening the firing chamber may occur without any danger since the free end 11a of the stop member defining lever 10 is maintained in its position in which it does not lie in the path of the said carrier. The carrier 5 itself then causes the lever 10 to be brought to its operative position. Indeed, during the opening displacement, the carrier 5 encounters the upper edge 15a of the plate-like arm 15, causing it to rotate about the pin 16 in the lowering sense. The displacement of the arm 15, because of the engagement between the slot 14 thereof and the lug 13 of the lever 10, causes the latter to be displaced angularly (in the clockwise sense with reference to the Figures of the appended drawings) about its respective pin 9. This angular displacement is again resisted initially by the thrust spring assembly 19, then to be facilitated with reaching of the stable operative position immediately the carrier 5 and the shutter member 3 reach the position in which the firing chamber 7 is closed.
The invention conceived in this manner is susceptible of numerous variations and modifications. Thus, for example, the position of the thrust spring assembly 19 and the type of action which it exerts on the lever 10 may be changed (from the present action to a drawing action); variations of a geometric nature may also be made without thereby departing from the scope of protection of this invention as defined in the following claims.
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A safety device for the trigger mechanism of a gas-operated-automatic/pump-action-manual shot-gun comprises an over-center thrust spring assembly pivotally connected at one end to a fixed point on the gun and at the other end to a stop member defining lever. The thrust spring assembly is pivotable between a first position, in which it biases the said lever into an operative position, bearing against the breechblock carrier, and a second position in which it stabilizes the said lever in an inoperative position, out of the path of movement of the breechblock carrier, preventing rebound of the stop member defining lever into the said path.
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BACKGROUND OF THE INVENTION
The present invention relates to a flexible gear coupling capable of coupling a drive motor of a railway vehicle with a reduction gear unit.
A drive motor of a railway vehicle is disposed on a bogie frame and a reduction gear unit is disposed to an axle shaft. Therefore, the axial line of the output shaft of the motor is dislocated from that of the pinion shaft of the gear unit by the vibration of a body when the railway vehicle travels. Since a power must be smoothly delivered between both shafts even in the dislocated state, the motor is coupled with the gear unit through a flexible gear coupling.
FIG. 10 is a front elevational view, partly in cross section, of a conventional flexible gear coupling disclosed in, for example, Japanese Utility Model Publication No. 47-14804. In FIG. 10, numeral 1 denotes rotary shafts with one of them serving as, for example, the output shaft of a drive motor and the other of them serving as the input shaft to a reduction gear unit. Numeral 2 denotes pinions each fixed to the rotary shaft 1 and an external gear having crown teeth 2a is formed to each of the pinions 2. Numeral 3 denotes sleeves fixed to each other by bolts or the like and each sleeve 3 has the teeth 3a of an internal gear to be meshed with the teeth 2a of the pinion 2. Note, the vicinity of the portion where both gears 2a and 3a in the sleeves 3 are meshed each other is filled with grease as a lubricant.
Numeral 4 denotes end covers each fixed to the sleeve 3 to prevent the splashing of the grease in the sleeve 3. Numeral 5 denotes center plates each partitioning the interior of the sleeve 3, numeral 6 denotes shaft end nuts to prevent the pinions 2 from dropping off the rotary shafts 1. Numeral 7 denotes cushions to prevent the shaft end nuts 6 from being abutted against the center plates 5 and damaging them.
As described above, the conventional flexible gear coupling is arranged symmetric with respect to the center plates 5 in the right to left direction.
Since the conventional flexible gear coupling is arranged as described above, even if the axial line of the output shaft of the motor is dislocated or misaligned from that of the pinion shaft of the gear unit by the vibration of the body when the railway vehicle travels, a drive force can be smoothly transmitted from one of the rotary shafts 1 to the other of them because the teeth 2a of the external gears of the pinions 2 are crowned. Further, even if both rotary shafts 1 are dislocated in an axial direction, the teeth 2a of the external gears 2 of the pinions 2 freely move along the grooves of the teeth 3a of the internal gear formed in the sleeves 3.
Note, recently there is a tendency that grease having a low flowing property is used as the lubricant to prevent leakage.
The grease is caused to adhere on the inner surface of the sleeves 3 like a doughnut by the centrifugal force produced by the rotation the rotary shafts 1 and does not flow down and keeps the adhered state as it is even if the rotation of the rotary shafts 1 stops. Further, the grease other than that located in the vicinity of the portion where the teeth are meshed does not move and keeps the state that it adheres to the same position while the rotary shafts 1 rotate.
Since the conventional flexible gear coupling is arranged as described above, although a less amount of a lubricant leaks, since the lubricant has a low flowing property, the circulation of the lubricant at the portion where teeth are meshed with the lubricant at the portion other than the above cannot be almost expected. Therefore, since it is only a part of the lubricant located in the vicinity of tooth surfaces that contributes to lubrication, there is a problem that an efficiency of using the lubricant is lowered and the lubricant must be entirely replaced even if it is partially deteriorated.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to solve the above problem and has as its object the provision of a flexible gear coupling capable of forcibly circulating the lubricant.
With the above object in view, the present invention resides in a flexible gear coupling arranged such that a pair of external gears provided with pinions are crowned in order that when a pair of internal gears disposed along the same axis of sleeves are meshed with the external gears, the external gears can move in the axial direction of the internal gears by a predetermined amount as well as incline toward the axial direction of the internal gears at a predetermined angle. A lubricant is filled in the vicinity of the portion where the internal gears are meshed with the external gears. A rotational force is transmitted from a first rotary shaft fixed to one of the pinions to a second rotary shaft fixed to the other of the pinions. The flexible gear coupling comprises stirring members each composed of an elastic body and having a fixing portion fixed to the sleeve in the sleeve and movable portions capable of being moved in the inner peripheral direction of the sleeve by a centrifugal force caused by the rotation of each of the rotary shafts and disposed at a position where the lubricant exists.
The stirring member may be formed to a comb shape and fixed along the inner surface of the sleeve.
A flexible gear coupling may also be arranged such that a pair of external gears provided with pinions are crowned in order that when a pair of internal gears disposed along the same axis of sleeves are meshed with the external gears, the external gears can move in the axial direction of the internal gears by a predetermined amount as well as incline toward the axial direction of the internal gears at a predetermined angle, a lubricant is filled in the vicinity of the portion where the internal gears are meshed with the external gears, and a rotational force is transmitted from a first rotary shaft fixed to one of the pinions to a second rotary shaft fixed to the other of the pinions, the flexible gear coupling comprises stirring members each composed of an elastic body and having a fixing portion fixed to the sleeve in the sleeve and movable portions capable of being moved by an inertial force caused by the change of an acceleration produced by the rotation of each of the rotary shafts and disposed at a position where the lubricant exists.
Also, a flexible gear coupling may be arranged such that a pair of external gears provided with pinions are crowned in order that when a pair of internal gears disposed along the same axis of sleeves are meshed with the external gears, the external gears can move in the axial direction of the internal gears by a predetermined amount as well as incline toward the axial direction of the internal gears at a predetermined angle, a lubricant is filled in the vicinity of the portion where the internal gears are meshed with the external gears, and a rotational force is transmitted from a first rotary shaft fixed to one of the pinions to a second rotary shaft fixed to the other of the pinions, the flexible gear coupling comprises stirring members each having a fixing portion fixed to the pinion in the sleeve and abutting portions extending from the fixing portion in the direction of the inner periphery of the sleeve and disposed at a position where the lubricant exists.
The abutting portions of the stirring member may be inclined at a predetermined angle in the direction where the internal gear is meshed with the external gear.
The abutting portions of the stirring member are alternately inclined at a predetermined angle in the direction where the internal gear is meshed with the external gear and the direction opposite to the above direction.
According to the present invention, the lubricant is forcibly moved because the movable portions are moved by the change of the rotational speed of each of the rotary shafts by the provision of the stirring members each composed of an elastic body and having a fixing portion fixed to the sleeve in the sleeve and movable portions capable of being moved in the inner peripheral direction of the sleeve by a centrifugal force caused by the rotation of each of the rotary shafts and disposed at a position where the lubricant exists.
Also, since the stirring member is formed to a comb shape and fixed along the inner periphery of the sleeve, the flexible gear coupling can be easily made in addition to the operation.
The lubricant is forcibly moved because the movable portions are moved by the change of an acceleration by the provision of the stirring members each composed of an elastic body and having a fixing portion fixed to the sleeve in the sleeve and movable portions capable of being moved by an inertial force caused by the change of an acceleration produced by the rotation of each of the rotary shafts and disposed at a position where the lubricant exists.
The lubricant is forcibly moved by the abutting portions when the pinion moves in the axial direction of the sleeve and when the pinion inclines toward the axial direction at a predetermined angle by the provision of the stirring members each having a fixing portion fixed to the pinion in the sleeve and abutting portions extending from the fixing portion in the direction of the inner periphery of the sleeve and disposed at a position where the lubricant exists.
The movement of the lubricant is further accelerated because the lubricant is stirred by the abutting portions when the pinion moves or inclines by the arrangement that the abutting portions of the stirring member are inclined at a predetermined angle in the direction where the internal gear is meshed with the external gear.
According to another aspect of the present invention, the movement of the lubricant is further accelerated because the lubricant is stirred by the abutting portions when the pinion moves or inclines by the arrangement that the abutting portions of the stirring member are alternately inclined at a predetermined angle in the direction where the internal gear is meshed with the external gear and the direction opposite to the above direction.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more readily apparent form the following detailed description of the preferred embodiments taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a cross sectional view of the main portion of a first embodiment of the present invention;
FIG. 2 is a perspective view showing a stirring member of FIG. 1 when it is developed;
FIG. 3 is a cross sectional view showing the main portion of a second embodiment;
FIG. 4 is a cross sectional view showing the main portion of a third embodiment;
FIG. 5 is a cross sectional view showing the main portion of a fourth embodiment;
FIG. 6 is a cross sectional view showing the main portion of a fifth embodiment;
FIG. 7 is a side elevational view showing a stirring member of FIG. 6;
FIG. 8 is a cross sectional view showing the main portion of a seventh embodiment;
FIG. 9 is a cross sectional view showing the main portion of a eighth embodiment; and
FIG. 10 is a front elevational view partly in cross section, of a prior art flexible gear coupling.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of the present invention will be described below with reference to drawings. FIG. 1 is a cross sectional view showing the main portion of the first embodiment. FIG. 2 is a perspective view of a stirring member of FIG. 1. In FIG. 1 and FIG. 2, numerals 1-7 denote the same components as those of prior art. Numeral 8 denotes a lubricant filled in the vicinity of the portion where the teeth 2a of an external gear are meshed with the teeth 3a of an internal gear, and grease having a low flowing property is generally used to prevent leakage.
Numeral 9 denotes the stirring member composed of an elastic body and having a fixing portion 9a fixed to a sleeve 3 in the sleeve 3 and the stirring member 9 also has comb-shaped movable portions 9b. Further, the movable portions 9b are disposed at a position where the lubricant 8 exists and arranged to be able to move in the inner peripheral direction of the sleeve 3 by the centrifugal force produced by the rotation of the a rotary shaft 1. Note, the stirring member 9 is composed of the elastic body such as metal, plastic or the like formed to the comb shape and the comb portion thereof is bent at a predetermined angle.
Next, the operation of the device will be described. In FIG. 1. a pinion 2 and the sleeve 3 are integrally rotated by the rotation of the rotary shaft 1. When the sleeve 3 rotates, the movable portions 9b of the stirring member 9 are deflected and moved toward the inner peripheral direction of the sleeve 3 as shown by an arrow 10 by a centrifugal force. Then, the lubricant 8 existing between the sleeve 3 and the movable portions 9b is pushed out in the direction of an arrow 11 by the movement of the movable portions 9b and fed in the direction of the teeth 3a of the internal gear.
When the rotary shaft 1 stops or the rotational speed thereof is lowered, the movable portions 9b move in the direction for enabling it to return to its original position. With this movement, the lubricant 8 in the vicinity of the sleeve 3 and the movable portions 9b is sucked therebetween. At the time, a slight amount of the lubricant 8 is returned in the direction opposite to that of the arrow 11. Since the movement of the movable portions 9b is repeated, however, the lubricant 8 existing between a center plate 5 and the teeth 3a gradually circulates as shown by an arrow 12.
With the above operation, the lubricant 8 in the vicinity of the portion where both teeth 2a and teeth 3a are meshed each other is mixed with the lubricant 8 circulating in the direction of the arrow 12 by the rotation of the rotary shaft 1, and as a time elapses, the entire lubricant 8 is gradually mixed.
As described above, since the lubricant 8 at respective portions circulates while being mixed and can be effectively used as a whole, the life of the lubricant 8 can be greatly extended.
FIG. 3 is a cross sectional view snowing the main portion of a second embodiment. In FIG. 3, numeral 13 denotes a spacer interposed between a sleeve 3 and a stirring member 9 to adjust the height of the stirring member 9 so that a lubricant 8 can circulate well. Note, when the spacer 13 is composed of a non-metal material, the wear of the stirring member 9 and movable portions 9b can be prevented when they come into contact with each other.
FIG. 4 is a cross sectional view showing the main portion of a third embodiment. In FIG. 4, numeral 14 denotes a stirring member similar to that of the stirring member 9 shown in FIG. 1, and the stirring member 14 is fixed in a direction reverse to that of the stirring member 9, that is, a fixing portion 14a is fixed to a sleeve 3 and movable portions 14b are disposed in the direction opposite to the portion where both teeth 2a and teeth 3a are meshed each other. Note, the movable portions 14b are disposed at a position where the lubricant 8 exists.
In the above arrangement, when the movable portions 14b move in the direction of an arrow 15 by a centrifugal force, the lubricant 8 existing between the sleeve 3 and the movable portions 14b are pushed out in the direction of an arrow 16 and circulates similarly to the case of FIG. 1.
FIG. 5 is a cross sectional view showing the main portion of a fourth embodiment. In FIG. 5, numeral 17 denotes a stirring member composed of a plate-shaped elastic body and having a fixing portion 17a fixed to the side of the center plate 5 of a sleeve 3 and movable portions 17b disposed in the direction where teeth 2a are meshed with teeth 3a. Further, the movable portions 17b are disposed at a position where a lubricant 8 exists. Note, a plurality of the stirring members 17 are disposed at a predetermined interval in the peripheral direction of a sleeve 3 and deflected in a peripheral direction by an inertial force caused by the change of an acceleration produced by the rotation of the sleeve 3 and move the lubricant 8 in the direction of an arrow 78.
With the above arrangement, since the lubricant 8 in the vicinity of the portion where the teeth 2a are meshed with the teeth 3a are moved by the stirring member 14 as the sleeve 3 rotates, the entire lubricant 8 is gradually mixed. Consequently, since the lubricant 8 can be effectively used as a whole, the life of the lubricant 8 can be greatly extended.
FIG. 6 is a cross-sectional view sowing the main portion of a fifth embodiment. FIG. 7 is a side elevational view showing a stirring member of FIG. 6. In FIG. 6 and FIG. 7, numeral 19 denotes a stirring member having an fixing portion 19a fixed to an end of a pinion 2 and comb-shaped abutting portions 19b as shown in FIG. 7 radially extending in the direction of the inner peripheral surface of a sleeve 3 and the abutting portions 19b are located at a position where a lubricant 8 exists.
In the arrangement of FIG. 6, the lubricant 8 can be moved by the movement of the pinion 2 to a position 22 or a position 23 in the axial direction of the sleeve 3 as shown by arrows 20 and 21. Since the entire lubricant 8 is gradually mixed by this arrangement, the lubricant 8 can be effectively used as a whole. As a result, the life of the lubricant 8 can be greatly extended.
Although the stirring member 19 fixed to the end of the pinion 2 is described in FIG. 6, the same advantage can be expected when the stirring member 19 is pressed against the pinion 2 by an axis end nut 6.
FIG. 8 is a cross sectional view showing the main portion of a seventh embodiment. In FIG. 8, numeral 24 denotes a stirring member having a fixing portion 24a fixed to an end of a pinion 2 and comb-shaped abutting portions 24b similar to those of FIG. 7, and the abutting portions 24b are formed to incline at a predetermined angle in the direction where the teeth 3a of an internal gear are meshed with the teeth 2a of an external gear 3a. Note, the abutting portions 24b are located at a position where a lubricant 8 exists.
When the pinion 2 and a sleeve 3 move relatively to each other in the arrangement of FIG. 8, since the abutting portions 24b stir the lubricant 8 in the direction of an arrow 25, the lubricant 8 is moved and gradually mixed as a whole. As a result, the life of the lubricant 8 can be greatly extended.
FIG. 9 is a cross sectional view showing the main portion of a eighth embodiment. In FIG. 9, numeral 26 denotes a stirring member having a fixing portion 26a fixed to an end of a pinion 2 and comb-shaped abutting portions 26b which are similar to those of FIG. 7 and alternately inclined at a predetermined angle in the direction where the teeth 3a of an internal gear is meshed with the teeth 2a of an external gear and the direction opposite to the above direction. The abutting portions 26a are disposed at a position where a lubricant 8 exists.
When the pinion 2 and a sleeve 3 move relatively to each other in the arrangement of FIG. 9, since the abutting portions 24b which are alternately disposed in opposite directions, respectively stir the lubricant 8 in the direction of an arrows 27 and 28, the lubricant 8 is moved and gradually mixed as a whole. As a result, the life of the lubricant 8 can be greatly extended.
As has been described above, according to the present invention, the lubricant is forcibly moved because the movable portions are moved by the change of the rotational speed of each of the rotary shafts by the provision of the stirring members each composed of an elastic body and having a fixing portion fixed to the sleeve in the sleeve and movable portions capable of being moved in the inner peripheral direction of the sleeve by a centrifugal force caused by the rotation of each of the rotary shafts and disposed at a position where the lubricant exists. As a result, since the entire lubricant circulates while being mixed and can be effectively used as a whole, the life of the lubricant can be expanded.
Also, according to the present invention, since the stirring member is formed to a comb shape and fixed along the inner periphery of the sleeve, the flexible gear coupling can be easily made.
In another embodiment of the present invention, the lubricant is forcibly moved because the movable portions are moved by the change of an acceleration by the provision of the stirring members each composed of an elastic body and having a fixing portion fixed to the sleeve in the sleeve and movable portions capable of being moved by an inertial force caused by the change of an acceleration produced by the rotation of each of the rotary shafts and disposed at a position where the lubricant exists. Therefore, since the entire lubricant circulates while being mixed and can be effectively used as a whole, the life of the lubricant can be expanded.
Also according to the present invention, the lubricant is forcibly moved by the abutting portions when the pinion moves in the axial direction of the sleeve and when the pinion inclines toward the axial direction at a predetermined angle by the provision of the stirring members each having a fixing portion fixed to the pinion in the sleeve and abutting portions extending from the fixing portion in the direction of the inner periphery of the sleeve and disposed at a position where the lubricant exists. Therefore, the entire lubricant circulates while being mixed and can be effectively used as a whole, so that the life of the lubricant can be expanded.
The movement of the lubricant can be further accelerated because the lubricant is stirred by the abutting portions When the pinion relatively moves or inclines with respect to the sleeve by the arrangement that the abutting portions of the stirring member are inclined at a predetermined angle in the direction where the internal gear is meshed with the external gear.
The movement of the lubricant can be further accelerated because the lubricant is stirred by the abutting portions when the pinion relatively moves or inclines with respect to the sleeve by the arrangement that the abutting portions of the stirring member are alternately inclined at a predetermined angle in the direction where the internal gear is meshed with the external gear.
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A flexible gear coupling which stirs the enclosed lubricant to extend the life of the lubricant. A stirring device is made of elastic material and has a first part which is fixed either to a sleeve or a pinion and a movable part which is moved by centrifugal force. The movable portion moves in the inner peripheral direction of the sleeve when the rotary shaft moves the gears. The movable portion is positioned within the enclosed lubricant. When the speed of the rotary shaft changes, the movable portion changes position and also moves the lubricant so as to gradually mix the lubricant.
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FIELD OF THE INVENTION
The present invention relates in general to wellbore operations and more particularly to a method of isolating zones in a wellbore having a slotted liner.
BACKGROUND
In many well completions a casing is run into the well after it is drilled. Cement is then pumped into the annulus between the casing and the wellbore wall. The casing and cement is then perforated at the desired formation. By perforating the cemented and sealed casing, isolation of the desired zone is maintained.
A significant number of wells are completed with perforated liners without any cement to bond the liner to the wellbore. The annulus between the liner and the wall of the wellbore may then be left empty or packed with gravel. Although slotted liners serve a purpose, they do not provide zonal isolation and permit fluid to flow in the annulus along the length of the liner. Typically, at some point in the well's life, it is desired to provide zonal isolation in the well for selective treatment of a zone or to prevent encroachment of an undesired fluid.
Therefore, it is a desire to provide a system and method for placing a substantially circumferential seal about a perforated liner. It is a still further desire to provide a method of creating zonal isolation about a perforated liner that is cost effective.
SUMMARY OF THE INVENTION
Methods of forming a seal circumferentially about a liner having pre-formed openings that is positioned in a wellbore are provided. In one embodiment of the invention the method includes the steps of creating an aperture through the slotted liner at the region and pumping a sealing fluid through the aperture and circumferentially about the liner to form a sealing plug in the annulus between the slotted liner and the wellbore.
The aperture may be larger in size than the pre-formed openings. The aperture may be created by expanding one or more of the pre-formed openings or by creating a new aperture. The aperture may be created by a perforating gun or by drilling. The sealing fluid may be thixotropic in nature and/or a swellable material to facilitate placement through aperture while forming a suitable sealing plug where desired.
In some embodiments of the invention, the method may include conveying a sealing applicator into the liner. The seal applicator may include one or more reservoirs for carrying fluids such as, but not limited to the sealing fluid, spacing fluids, and triggering agents. The seal applicator may include a mechanism, such as a pressure reservoir or pump for energizing the sealing fluid for injection through the aperture.
The foregoing has outlined 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
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:
FIG. 1 is a schematic side view of an embodiment of the sealing method of the present invention; and
FIG. 2 is a further view of the sealing method illustrated in FIG. 1 .
DETAILED DESCRIPTION
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.
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.
FIG. 1 is a schematic side view of an embodiment of the sealing method of the present invention, generally denoted by the numeral 10 . A portion of a wellbore 12 is completed with a slotted liner 14 . Slotted liner 14 includes a plurality of openings 16 formed along its length. As used herein, slotted liner 14 includes any liner or screen that has openings 16 formed therethrough prior to hanging the tubular in the wellbore. Examples of slotted liners 14 include slotted, perforated, or predrilled liners, or a screen or a pre-packed screen. The annulus 18 between slotted liner 14 and the wall 20 of wellbore 12 may be substantially empty or packed with sand or gravel.
It is desired to seal annulus 18 in a region 22 . In the illustrated embodiment it is desired to seal annulus 18 due to water entry 23 . In the first step of sealing method 10 , a perforating apparatus 24 is positioned within slotted liner 14 proximate region 22 via conveyance 26 . Perforating apparatus 24 may include, but is not limited to, perforating guns, drilling mechanisms or cutting mechanisms. Conveyance 26 may be tubing, a wireline or a slickline.
In the second step of method 10 , perforating apparatus 24 is activated to create one or more apertures 28 . Each aperture 28 is larger than the pre-existing openings 16 . Aperture 28 may be a new opening formed through liner 14 or the expansion of an existing opening 16 . The formation of one or more apertures 28 is critical for the placement of a sealing fluid sufficient to obtain a desired sealing plug circumferentially about liner 14 .
Referring now to FIG. 2 , aperture 28 has been created through liner 14 for forming sealing plug 32 circumferentially about liner 14 . To form sealing plug 32 , sealing fluid 34 must be suitable for injecting through aperture 28 and for setting into a sealing plug within region 22 . Thus, it is desired that sealing fluid 34 be thixotropic in nature so that it will set and become substantially “self-supporting” relatively quickly. It may further be desired for sealing fluid 34 to be a swellable material, so as to seal aperture 28 and openings 16 in region 22 . The swellable property further facilitates sealing between wellbore 12 and liner 14 . It may further be desired for sealing fluid 34 to have a sufficiently high gel strength so as to remain where placed, yet allow for a degree of gravity-induced flow to the lower portion of region 22 , for example in horizontal wellbores. It is noted that sealing fluid 34 may include one or more of the desired properties. It is further noted, and will be recognized with the following description of the method, that sealing plug 32 may be formed in stages or by one or more sealing fluids 34 . For example, a first sealing fluid 34 being primarily thixotropic in nature may be injected through aperture 28 into region 22 and then followed with a second swellable sealing fluid 34 . The swellable sealing fluid 34 may be followed by a triggering agent. It may also be desired to inject spacing fluids, such as water or drilling fluid, after one or more sealing fluid injections.
Examples of suitable sealing fluids 34 include, without limitation, foamed cements; unfoamed cements containing smectic clays such as bentonite and attapulgite, unfoamed cements containing welan gum, aluminum and/or iron sulphate, and/or calcium sulfate as thixotropy agents, thermosetting polymers such as epoxy, vinylester, phenolic and polyester resins, and cross-linking polymer gels (possibly with an added thixotrope).
Swellable sealing fluid 34 swells from an unexpanded state to an expanded state when it comes into contact with or absorbs a triggering fluid. The selection of a triggering fluid depends on the selection of the swellable material, and vice versa, as well as the wellbore environment and operation. The triggering fluid may be present naturally in wellbore 12 , present in the formation surrounding wellbore 12 and produced into the wellbore, or be injected into wellbore 12 and region 22 , such as from the surface through tubulars or a downhole seal applicator 30 .
Examples of suitable swellable sealing fluids 34 and their corresponding triggering fluids (listed in parenthetical) include, without limitation: ethylene-propylene-copolymer rubber (hydrocarbon oil); ethylene-propylene-diene terpolymer rubber (hydrocarbon oil); butyl rubber (hydrocarbon oil); haloginated butyl rubber (hydrocarbon oil); brominated butyl rubber (hydrocarbon oil); chlorinated butyl rubber (hydrocarbon oil); chlorinated polyethylene (hydrocarbon oil); starch-polyacrylate acid graft copolymer (water); polyvinyl alcohol cyclic acid anhydride graft copolymer (water); isobutylene maleic anhydride (water); acrylic acid type polymers (water); vinylacetate-acrylate copolymer (water); polyethylene oxide polymers (water); carboxymethyl celluclose type polymers (water); starch-polyacrylonitrile graft copolymers (water); highly swelling clay minerals, i.e. sodium bentonite, (water); styrene butadiene (hydrocarbon); ethylene propylene monomer rubber (hydrocarbon); natural rubber (hydrocarbon); ethylene propylene diene monomer rubber (hydrocarbon); ethylene vinyl acetate rubber (hydrocarbon); hydrogenised acrylonitrile-butadiene rubber (hydrocarbon); acrylonitrile butadiene rubber (hydrocarbon); isoprene rubber (hydrocarbon); chloroprene rubber (hydrocarbon); and polynorbornene (hydrocarbon).
In the embodiment illustrated in FIG. 2 , conveyance 26 carries both seal applicator 30 and perforating apparatus 24 to facilitate a single trip into the well to create sealing plug 32 circumferentially about liner 14 . By providing sealing fluid 34 via seal applicator 30 positioned downhole, the Theological requirements of fluid 34 are reduced and it allows for downhole mixing of two-part fluids or the like, for example, epoxy resins, which can set rapidly in region 22 .
Seal applicator 30 may include one or more reservoirs carrying fluids and/or pumping means. For example, applicator 30 may include a reservoir carrying sealing fluid 34 and a reservoir carrying a triggering agent fluid for causing sealing fluid 34 to swell. In various embodiments, each reservoir may include a fluid for staging injections to form sealing plug 32 . Sealing applicator 30 may further include aids, such as a source of heat or radiation, to trigger or aid the setting of sealing plug 32 .
After aperture 28 is formed, conveyance 26 is run into liner 14 positioning seal applicator 30 proximate aperture 28 and region 22 . Seal applicator 30 is actuated injecting sealing fluid 34 , as shown by the arrows, through aperture 28 into annulus 18 circumferentially about liner 14 within region 22 . In the described embodiment, sealing fluid 34 sets to become substantially self-supporting sealing plug 32 . Further, sealing fluid 34 contacts a triggering agent, that is present in region 22 or injected via conveyance 26 or seal applicator 30 , causing fluid 34 to swell further sealing aperture 28 and openings 16 .
From the foregoing detailed description of specific embodiments of the invention, it should be apparent that a system and method for placing a annular seal about a slotted liner in a wellbore that is novel 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.
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A method of forming a seal circumferentially about a liner having pre-formed openings that is positioned in a wellbore includes the steps of running a perforating device and a seal applicator into the slotted liner, the seal applicator carrying a sealing fluid and a pumping mechanism, creating an aperture through the slotted liner at the region by activating the perforating device and pumping the sealing fluid from the seal applicator through the aperture and circumferentially about the liner to form a sealing plug in the annulus between the slotted liner and the wellbore.
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FIELD OF THE INVENTION
[0001] This invention pertains to floor structures having sound attenuation properties, and more specifically it pertains to a floor structure having vibration dampers incorporated therein.
BACKGROUND OF THE INVENTION
[0002] At the present time, the National Building Code of Canada asks for a sound attenuation of 50 decibels through the walls separating apartments in a multi-apartment residential building. This standard is now under review, however. The Canada Mortgage and Housing Corporation for example, recently published sound attenuation objectives of over 55 decibels through walls and hard floors separating residential apartments, and over 65 decibels through carpet-covered floors. These objectives apply to sounds originating away from the floor, referred to as airborne sounds, and sound originating from the floor surface, referred to as impact sounds.
[0003] While several known floor structures can meet the requirement for airborne sound attenuation, the objective for impact sound attenuation has been a serious challenge in the construction industry.
[0004] The only prior art found disclosing a floor structure for minimizing impact noise transmission is the U.S. Pat. No. 3,270,475 issued to M. J. Kodaras on Sep. 6, 1966. This structure comprises a base layer made of low density material, fastened to the floor joists. Spaced-apart nailing strips are laid on the base layer perpendicularly to the floor joists and are retained to the base layer by spacer strips which are nailed to the base layer. The spacer strips have bevelled edges and define with the base layer spaced-apart dovetail slots in which the nailing strips are held without nail. The top flooring strips are nailed to the nailing strips with the nails not traversing the nailing strips. As the nails which secure the flooring strips to the nailing strips are completely isolated from the joists, there is no direct transmission of sound energy to the joists.
[0005] Although this document does not mention specific impact sound attenuation measurements, it is believed that this type of floor structure has great merits. This particular floor structure, however, is difficult and expensive to build by modern-day construction practices. It is believed that this difficulty constitutes a main reason, basically, why this method has not enjoyed a lasting commercial success.
[0006] Also, there is a trend in the construction industry to use 24 inch joist spacings as opposed to the long lasting standard of 16 inch spacings. The larger spacing requires more rigid floor and sub-floor layers. This trend motivates builders to combine rigidity and sound transmission attenuation performances in building systems.
[0007] As such, there is a need in the construction industry for a floor structure having acceptable sound attenuation characteristics without imposing a burden on existing construction trends and practices.
SUMMARY OF THE INVENTION
[0008] In the present invention, however, there is provided a floor structure that is compatible with modern-day construction practices with a joist spacing of 24 inches. The floor structure according to the present invention has an airborne sound attenuation of 65 decibels and an impact sound attenuation of 56 decibels. These sound transmission measurements were confirmed by the Acoustic Institute of the National Research Council of Canada.
[0009] More specifically, the present invention comprises a floor structure having spaced-apart floor joists, a base layer fastened to the joists, a resilient layer laid over the base layer, and a top layer mounted over the resilient layer. The top layer has a stiffness that is much greater than a stiffness of the base layer. The top layer is fastened to the base layer by wood screws which are placed substantially along a median between two adjacent floor joists, and each wood screw has a threaded portion extending simultaneously in both the top layer and the base layer.
[0010] The installation of the wood screws through both the top and the base layers causes a backlash in the advance of the screws upon entering the base layer, thereby causing the occurrence of a larger gap between the top layer and the base layer as compared with an installation using nails for example. The threaded portions of the screws being engaged simultaneously in both the top layer and the base layer act as spacers between the top layer and the base layer. The larger gap relaxes a pressure on the foam layer to reduce a transmission of sound and noise energy between the top layer and the joists.
[0011] In another aspect of the present invention, the top layer is made of balsam fir boards having a thickness of about 2 inches, and the base layer is made of oriented fibre boards having a thickness of ¾ inch. The balsam fir boards have a width of 24 inches, a length of 16 feet, and tongue-and-groove edges. The floor structure according to the present invention is very strong as compared with common floor structures, and is particularly appropriate for use with low-deflection flooring surfaces such as ceramic tiles.
[0012] This brief summary has been provided so that the nature of the invention may be understood quickly. A more complete understanding of the invention can be obtained by reference to the following detailed description of the preferred embodiment thereof in connection with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] One embodiment of the present invention is illustrated in the accompanying drawings, in which like numerals denote like parts throughout the several views, and in which:
[0014] FIG. 1 is a perspective view of a floor structure according to the preferred embodiment of the present invention;
[0015] FIG. 2 is a perspective view of a low-density wood board used in the floor structure according to the preferred embodiment;
[0016] FIG. 3 is a schematic cross-section view of the preferred floor structure illustrating a general concept of a sound attenuating joint between floor layers in the preferred floor structure;
[0017] FIG. 4 illustrates the tip of a common wood screw;
[0018] FIGS. 5 and 6 illustrate two common floor structures of the prior art;
[0019] FIG. 7 is a cross-section view of the floor structure according to the preferred embodiment;
[0020] FIG. 8 is a table illustrating sound attenuation properties of the preferred floor structure as compared with floor structures of the prior art;
[0021] FIG. 9 is a cross-section view through the floor structure at a fastening point, with a fastener partly installed;
[0022] FIG. 10 is a cross-section view through the floor structure at a fastening point, with the fastener fully inserted through the floor layers, as seen in circle 10 , in FIG. 7 ;
[0023] FIG. 11 is a cross-section view of the preferred floor structure at a fastening point, in a loaded condition, with the gap between the layers shown in an exaggerated mode.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will be described in details herein one specific embodiment of a floor structure with improved sound attenuation properties. 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 embodiment illustrated and described. For example, precise dimensions are used herein for convenience only to provide a better understanding of the structure of the present invention. Such dimensions should not be considered as being absolute and limiting.
[0025] Referring to FIGS. 1 and 2 , the preferred floor structure comprises floor joists 20 spaced 24 inches apart. A base layer 22 , is fastened to thejoist using nails or screws in any usual way. The base layer is made of plywood sheets or OSB™ (Oriented Strand Board) panels, having a thickness of ⅝ or ¾ inch, and more preferably ¾ inch.
[0026] A second layer 24 made of resilient material is laid on the base layer 22 . The second layer is made of foam sheeting, geo-textile, rubber, felt or a similar material and has a thickness of about ⅛ inch. This second layer 24 is fastened to the base layer 22 in a conventional way, with staples for example. For economical reasons, the second layer 24 in the preferred embodiment is made of foam sheeting and is referred to herein as the foam layer 24 for convenience. The purpose of this second layer 24 is to prevent hard contact region or direct contact point between the base layer 22 and the top layer 26 .
[0027] The top layer 26 is laid on the foam layer 24 , and is fastened to the base layer 22 with wood screws 28 extending along medians 30 between adjacent joists 20 such that there is no direct transmission of sound energy from the top layer to the joists.
[0028] The top layer 28 is made of wood boards 32 having a thickness of 2 inches; a width of 24 inches and a length of 8 to 16 feet. The wood boards 32 are made of balsam fir and have a tongue-and-groove profile along their edges. The fir boards 32 are made of three plies with a different fibre alignment in the middle ply, as it is customary in plywood boards. This type of wood board is described in Applicant's Canadian patent application #2,434,248, filed on Jul. 3, 2003.
[0029] The two inch thick fir boards 32 have a moment of inertia which is about 32 times greater than a ⅝ inch sheet, and about 18 times greater than a ¾ inch panel (proportional to the cube of the thickness). The stiffness of the fir boards 32 is therefore greater than the stiffness of the base layer 22 by about the same proportions.
[0030] The principal contributing feature to obtain the sound attenuation properties of the floor structure according to the preferred embodiment of the present invention will now be explained while making reference to FIGS. 3 and 4 . This feature is explained briefly using FIGS. 3 and 4 , and in greater details when making references to FIGS. 9, 10 , and 11 .
[0031] In FIGS. 3 and 4 , the screws 28 that are used to fasten the balsam fir boards 32 to the base layer 22 are three-inch common wood screws having threaded portions of about two inches long. In the installed position the threaded portion of each screw extends in both the balsam fir board 32 and in the base layer 22 . Because of the nature of these screws 28 , and its relatively blunt tip 34 , the pressure on the screw 28 when exiting the balsam fir board 32 and entering the base layer 22 causes a thread backlash to occur, as the tip 34 of the screw digs into the surface of the base layer 22 . This pressure also causes the base layer 22 to move away from the top layer 26 before the screw 28 can resume its advance into the base layer 22 .
[0032] It will be appreciated that because of the engagement of the threaded portion in both the fir board 32 and the base layer 22 , the screw cannot pull the base layer 22 against the fir board 32 at the end of its insertion. The screw segment ‘A’ traversing the foam layer 24 remains in compression to retain the top layer 26 at a distance from the base layer 22 .
[0033] The combination of the thread backlash, the foam layer 24 and the long threaded portion of the screw 28 , causes the occurrence of a joint 36 that has spacing and vibration-absorbing properties as illustrated schematically in FIG. 3 . For visual description purposes, the spacer 38 represents the thread backlash or gap ‘A’ between the top layer 26 and the base layer 22 , and the spring 40 represents the flexibility of the base layer 22 relative to the top layer 26 .
[0034] Because of this type of joint 36 , the base layer 22 is pre-stressed at every screw 28 . Under no load condition, the base layer 22 springs back straight and pushes the top layer 26 upward, to release a compression in the foam layer 24 . Because of this type of joint 36 , it is believed that an impact force on the floor surface is partly absorbed by the deflection 42 in the base layer 22 . It is also believed that a load on the top layer 26 is partly absorbed by a deflection 42 in the base layer 22 before a pressure is applied to the foam layer 24 in a region 44 above each joist 20 for example.
[0035] It is believed that sound transmission is effected primarily along these regions 44 above each joist 20 when the floor is loaded. It is also believed that the relaxation of pressure on the foam layer 24 due to the thread backlash or gap ‘A’ in each joint 36 contributes significantly to obtain the sound attenuation properties observed in the floor structure according to the preferred embodiment.
[0036] The sound attenuation properties referred to herein will be better understood when making reference to FIGS. 5-8 . In FIG. 5 , there is illustrated a floor structure made of floor joists 20 that are spaced 16 inches apart. Spaces between the joists 20 are partly filled with fibre-glass insulation 50 . The floor portion is made of two layers of plywood sheets or OSB™ boards 52 laid over each other. Two layers of gypsum boards 54 are suspended to the joists 20 by suspension mouldings 56 , which are common in the industry. The gypsum boards 54 constitute a ceiling for the apartment below the floor structure. The sound attenuation properties of this structure has been found to be 57 dB for airborne sounds and 50 dB for impact sounds, as shown in FIG. 8 .
[0037] Another common type of floor structure, as illustrated in FIG. 6 , has a 1- 1 / 2 inch thick cement slab 60 laid over a base layer 62 made of ⅝ or ¾ inch thick plywood sheets or OSB™ boards. The floor joists 20 are also spaced at 16 inches, and the insulation and ceiling arrangements are the same as in the first-described example. The sound attenuation characteristics of this second common floor structure has been found to be 69 dB for airborne sounds and 44 dB for impact sounds. The high density of this type of structure does not allow for wide span between joists.
[0038] Tests on the floor structure according to the preferred embodiment, however, have demonstrated that the sound attenuation properties of this preferred structure are 65 dB for airborne sounds and 56 dB for impact sounds. It will be appreciated that the sound attenuation properties of the floor structure according to the preferred embodiment exceeds the proposed requirement of 55 dB for both sound sources. It will also be appreciated that the high stiffness and relative low density of the floor structure according to the preferred embodiment allow for wide span of 24 inches or more between joists.
[0039] Referring now to FIGS. 9-11 , the formation of screw joint 36 will be explained in greater details. As mentioned, a common 3-inch wood screw 28 has two inches of threads. When this screw is inserted in the fir board 32 , whether it is inserted at right angle with the surface of the fir board 32 , or at a slight angle in the tongue of the fir board 32 , there is always a substantial portion of the thread length which remains engaged into the fir board 32 . The tip 34 of a common wood screw 28 , as shown in FIG. 4 , does not have much axial grip or pull in a wood surface. The tip 34 normally extends to a length ‘B’ of about 0.050 to 0.080 inch. When the screw 28 reaches the surface of the base layer 22 , the tip 34 drills into the surface of the base layer 22 for a few degrees or even a full turn or more before the thread starts pulling itself into the OSB™ or plywood layer 22 .
[0040] During this initial drilling of the surface of the OSB™ or plywood layer 22 , the engagement of the thread into the fir board 32 causes the screw 28 to continue to advance at a constant rate of speed. Consequently, a pressure is applied on the tip 34 of the screw and against the base layer 22 .
[0041] Because the stiffness of the fir board 32 is much greater than the base layer 22 , the base layer 22 is caused to move away from the fir board 32 , one or few thousands of an inch or maybe more. When the screw 28 resumes its advance into the base layer 22 , a small gap ‘A’ remains between the base layer 22 and the fir board 32 .
[0042] Because of such screw backlash between the fir board 32 and the base layer 22 , and because the screw 28 has thread engagement in both the fir board 32 and the base layer 22 , the screw 28 constitutes a spacer for separating the fir board 32 from the base layer 22 . Such a spacer means is represented by a block-type spacer 38 in FIG. 3 . The gap ‘A’ define by this spacer 38 is perhaps very small but nonetheless contributes to relaxing a compression of the foam layer 24 to some extent. Such gap would not be formed in an installation using nails for example.
[0043] Because the fir boards 32 are much more rigid than the base layer 22 , a loading on the floor structure deflects the base layer 22 before the fir boards 32 , and before the fir boards 32 can apply a pressure on the foam layer 24 above the joists 20 , as indicated by the regions 44 . The base layer 22 acts as a shock absorber or a suspension system to support the fir boards 32 in a floating mode above the foam layer 24 and the joists 20 .
[0044] FIG. 11 illustrates in an exaggerated manner the gap ‘A’ caused by the screw backlash mentioned before, and an initial deflection of the base layer 22 , as in a leaf spring, when the floor structure is loaded. It is believed that such a suspension system contributes greatly to obtaining the sound attenuations properties described herein.
[0045] As to other manner of usage and operation of the present invention, the same should be apparent from the above description and accompanying drawings, and accordingly further discussion relative to the manner of usage and operation of the invention would be considered repetitious and is not provided.
[0046] While one embodiment of the floor structure according to the present invention has been illustrated and described herein above, it will be appreciated by those skilled in the art that various modifications, alternate constructions and equivalents may be employed without departing from the true spirit and scope of the invention. For example, it is known that similar advantageous results can be obtained with screws other than common wood screws, as long that their threaded portions extend simultaneously in the base layer and the fir boards. Therefore, the above description and the illustrations should not be construed as limiting the scope of the invention.
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The floor structure has a base layer fastened to floor joists, a resilient layer laid over the base layer, and a top layer mounted over the resilient layer. The top layer has a stiffness that is greater than a stiffness of the base layer. The top layer is fastened to the base layer by wood screws that are placed substantially along a median between two adjacent floor joists. Each screw has a threaded portion extending simultaneously in both the top and the base layers. The installation of screws through the top and the base layers causes a backlash in the advance of the screws upon entering the base layer, thereby causing the occurrence of a larger gap between the layers as compared with an installation using nails. The larger gap relaxes a pressure on the foam layer and reduces the transmission of sound energy to the joists.
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FIELD OF THE INVENTION
This invention relates to a utility package, and more specifically, to a utility package for installation on the bed of a pickup truck. The utility package includes an air compressor and related items as well as a tool compartment.
BACKGROUND OF THE INVENTION
The construction and tire servicing industries have long required mobility as an integral part of their businesses. Tradesmen are required to transport their tools to and from their place of work as well as between construction sites. Construction materials also must be moved from a place of purchase to a construction site. The tire servicing industry is frequently required to travel to service tires, particularly those used on large or off-the-road vehicles, as farm tractors. In these operations, equipment required to service tires, tires and wheels must be moved to the vehicle site.
As a consequence of these and other needs, extensive use of pickup trucks is made by both industries. Pickup trucks used by the construction industry may be owned by construction firms or, in many cases, are owned by the workers employed by the firm. For the purpose of transporting tools whether for construction or for tire servicing, it is conventional to employ tool boxes which are mounted in the bed of the pickup truck just behind the cab. Such tool boxes typically include a lower section which fits between the side walls of the truck bed and an upper section from which the lower section depends. The upper section is somewhat wider than the lower section and is supported by the upper surfaces of the sides of the bed of the pickup truck.
Additionally, it is frequently necessary to provide some sort of means for operating power tools at a construction site, particularly when electric power may not be available or when pneumatic power is required. Consequently, many construction workers own generators or air compressors which they transport to and from and between construction sites in the bed of their pickup truck. Where possible, to avoid the effort of off-loading a generator or an air compressor, they are simply left on the truck bed and the truck moved in sufficient proximity to the location where construction is occurring that electrical tools such as drills, saws, etc. or pneumatic tools such as nailers can respectively be connected to a generator or an air compressor. In tire servicing an air compressor is also required for the purpose of inflating tires as a remote site.
In some instances, electrical generators, air compressor series and/or tool boxes are made part of a permanent installation on a vehicle. While this works well for its intended purpose, if the useful life of the truck does not coincide with the useful life of the generator, air compressor or tool box, a substantial inconvenience arises when one or the other or more of these components require replacement.
Furthermore, when individual electrical generators or air compressors are carried in a bed of a truck, they must frequently be tied down while the truck is in motion to prevent shifting that could damage the bed of the truck or the air compressor or electrical generator or both. Not untypically, whatever restraints are used during transportation of such components are loosened or removed when the electrical generator or air compressor is in operation, requiring additional effort on the part of the user.
The present invention is directed to overcoming one or more of the above problems.
SUMMARY OF THE INVENTION
It is the principal object of the invention to provide a new and improved utility package for installation in the bed of a pickup truck. More particularly, it is an object of the invention to provide a utility package containing an air compressor and a tool compartment.
An exemplary embodiment of the invention achieves the foregoing objects in a structure including a frame having a relatively narrow, lower vertical section of a width narrower than the interior spacing between the sides of the bed of the pickup while substantially spanning the entire distance between those sides. The frame has a relatively wide, upper section of a width greater than the interior spacing between the sides and no greater than about the distance between the exterior of the sides and adapted to be supported on the tops of the sides of the pickup truck bed. At least one elongated pressure vessel is located within the vertical section and a housing is mounted on the horizontal section oppositely of the vertical section and extends to opposite ends of the horizontal section. The housing has access openings at the respective ends of the horizontal section. A closure is provided for each of the access openings and is mounted on the housing for movement between positions opening and closing the associated access opening. An air compressor is mounted on the frame between the access openings and a motor or an engine is located on the frame between the access openings and connected to the air compressor to drive the same. A tool box is located in the vertical section adjacent one end of the horizontal section and above the pressure vessel to be accessible through the housing at the one end and at least one hose reel is mounted in the vertical section adjacent the other end of the horizontal section and is accessible through the housing at the other end of the horizontal section.
In a preferred embodiment, the frame is generally T-shaped. In a highly preferred embodiment, the pressure vessel is elongated in the horizontal direction.
In a highly preferred embodiment, the housing is divided into two housing sections, each mounted on the horizontal section oppositely of the vertical section with each housing located at a respective end of the horizontal section.
In a preferred embodiment, the tool box is an upwardly opening tool box.
In a preferred embodiment, the tool box is a rectangular container having an open upper end surrounded by depending sidewalls and having a bottom wall just above the pressure vessel. The side walls and the bottom walls are disposed within the vertical section and the open upper end is disposed in the horizontal section and covered by one of the housings.
In a highly preferred embodiment, a fluid reservoir is located in the vertical section and interposed between the pressure vessel and the air compressor.
In one embodiment the pressure vessel has a length less than the width of the vertical section. A mounting bracket is located within the vertical section adjacent an end of the pressure vessel and the hose reels are mounted on the mounting bracket.
In one embodiment, one end of the horizontal section includes a generally horizontal, tool-receiving surface with tool retaining means mounted on the upper side of the tool receiving surface.
Preferably, the tool retaining means comprise a plurality of upwardly directed projections and even more preferably, the projections are rods.
In a highly preferred embodiment, there are a plurality of the pressure vessels in generally side-by-side, parallel relation defining a generally horizontal plane.
The invention further contemplates a cover panel extending between the housing sections and covering the air compressor and the motor or engine.
In one embodiment of the invention, at least one exterior light is mounted on the exterior of at least one of the housings.
In a preferred embodiment of the invention, at least one interior light is mounted on the interior of one of the housings.
In a highly preferred embodiment of the invention, a control panel is mounted in the housing section containing the hose reels.
Other objects and advantages will become apparent from the following specification taken in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a utility package made according to the invention;
FIG. 2 is an exploded view of the utility package;
FIG. 3 is a rear elevation of the utility package;
FIG. 4 is a side elevation of the utility package; and
FIG. 5 is a view similar to FIG. 3 but of a modified embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, an exemplary embodiment of a utility package for installation in the bed of a pickup truck includes a frame, generally designated 10. The frame, as best seen in FIG. 2, is generally T-shaped and includes a lower, vertical section 12 which has a width or end-to-end dimension that is just slightly less than the interior dimension between the sides of a conventional pickup truck. This dimension is marked W1 in FIG. 3. The top of the frame 10 includes a generally horizontal section 14. It has a width or an end-to-end dimension W2 (FIG. 2) that is greater than the distance between the interior sides of the pickup truck bed and approximately equal to the distance between the exterior of the sides of the pickup truck bed. The top to bottom dimension of the vertical section 12 is such that when the package is installed in the bed of a pickup truck, the end sections 16,18 of the horizontal section 14 will rest on the upper surfaces of the sides of the bed of the pickup truck. Conventional means may be utilized to secure the frame 10 to the bed of the pickup truck. Typically hooks or bolts that extend into pre-existing openings in the upper sides of the bed of the pickup truck are used.
The vertical section 12 includes two lower, spaced frame members 20 (FIG. 2) which are parallel to one another and which may be formed of channel or angle iron or the like. At each end of the frame members 20, cross members 22 are located and interconnect the frame members 20. An intermediate cross member 24 may also be employed. Again, the cross members 22 and 24 may be formed of angle iron or channel.
An air storage reservoir, generally designated 26, is located in the vertical section 12. The air reservoir 26 is made up of two, side-by-side, generally parallel, elongated pressure vessels 28 held together by a pair of spaced combination straps and mounting brackets 30. The combination straps and mounting brackets 30 surround the pressure vessels 28 and include feet 32 on both ends which are secured to the frame members 20, preferably by threaded fasteners.
It is noted that through the use of plural pressure vessels in side-by-side relation and in a common horizontal plane, the vertical profile of the air reservoir 26 may be minimized for compactness.
It should also be noted, particularly in FIGS. 1 and 3, that the air reservoir 26, though horizontally elongated, does not have a length equal to the dimension W1. This leaves room for a mounting bracket 34 which extends between the frame members 20 and is secured thereto by any suitable means, typically by a weldment. The mounting bracket 34, in turn, mounts to conventional hose reels 36,38 adjacent the end 18 of the horizontal section 14. To provide flexibility in supplying air to an air operated tool or the like, the two hose reels 36 and 38 are used and one hose reel will be, for example, provided with a half inch hose while the other may be provided with a 3/8" hose of shorter length. To suit this end, the hose reel 36 may be made smaller than the hose reel 38 to receive the smaller diameter, shorter pneumatic hose.
Turning now to the upper, horizontal section, the same is defined by spaced frame members 40 that are located above the frame members 20 and are generally parallel thereto. The end sections 16,18 interconnect respective ends of the frame members 40 and desirably, two cross members 42,44 divide the horizontal section 14 approximately into thirds. In a preferred embodiment, with the reservoir 26 installed within the vertical section 12, the combination straps and mounting brackets 30 will be disposed to be within that part of the horizontal section 14 delineated by the cross members 42 and 44. A hydraulic reservoir 46 is located in the vertical section 12 between the cross members 40 and 44 and secured, as by threaded fasteners, to the combination straps and support brackets 30. It should be noted that in the embodiment of the invention shown in FIG. 5, the hydraulic reservoir 46 may be dispensed with.
An air compressor unit, generally designated 48, has its base 50 partially nested within the vertical section 12 by being secured to mounting brackets 52 located on the upper side of the hydraulic reservoir 46. The air compressor unit 48 preferably is a model SHD-60A available from Stellar Industries, Inc. of Gamer, Iowa. Typically, it will include a four cylinder air compressor 54 driven by a hydraulic motor 56. The unit will also include a heat exchanger 58 which serves as an oil cooler for hydraulic fluid and a fan 60 which may be driven by an electrical motor (not shown) for forcing air through the oil cooler 58. Make up fluid for the hydraulic circuit including the motor 56 and oil cooler 58 is stored in the reservoir 46.
Mounted on the upper side of the horizontal section 14 and oppositely of the vertical section 12 is a housing, generally designated 62. The housing 62 in turn is made up of two housing sections 64 and 68, the former being at the end section 18 and the latter at the end section 16 of the horizontal section 14. Thus, the air compressor unit 48 is nested between the housing sections 64 and 68 as illustrated in FIGS. 1 and 3, for example.
The housing sections 64 and 68 serve to provide secure, tool storage areas. To this end, a rectangular, upwardly opening tool box 70 is located within the vertical section 12 adjacent the end 16. The tool box 70 includes vertical sides 72 and a bottom 74. The same is supported by the cross members 42,44 and has its bottom 74 located just above the upper surface of the air reservoir 26. The housing section 68 is located at the end 16 and includes vertical side walls 76 and 78 which are ever so slightly trapezoidal, a top wall 80 and a rear wall 82 facing the air compressor unit 48. As a consequence, a generally vertical access opening 82 is defined by the top 80, the side walls 76 and 78, and a cross member 84 interconnecting the sides 76 and 78 at their lower extremities. Thus, the tool box 70 is accessible through the housing section 68.
A slidable, stowable door 86, of conventional construction is adapted to be received on rails (not shown) on the interior of the housing section 68 just below the top 80. When located on the rails, the compartment door is in a stowed, open position. The same may be moved forwardly and pivoted downwardly in a conventional fashion to close the access opening 82. A lock of conventional construction, shown somewhat schematically at 88, may be provided to lock the door 86 in its closed position.
If desired, one or more shelves (not shown) may be located within the housing section 68 along with, for example, a compartment light for illuminating the interior of the housing section 68.
The housing section 64 is constructed generally similarly to the housing section 68 to include a rear panel 90, opposed side panels 92 and 94, a top panel 96, and a cross member (not shown). A door 86 with a lock 88 identical to the construction employed with the housing section 68 is also utilized.
As seen in the various figures, exterior floodlights 98 may be mounted on the upper wall 96 of the housing section 64. For that matter, similar floodlights could be mounted on the upper wall 80 of the housing compartment 68.
As best seen in FIGS. 2 and 4, the rear wall 90 of the housing compartment 64 is provided with a lighting fixture 100 which may be utilized to illuminate the interior of the housing section 64.
Referring specifically to FIG. 4, the interior of the housing section 64 is illustrated and desirably includes a shelf 102 located just above the larger one of the hose reels 38. To one side of the hose reels 36 and 38, a control panel 104 may be provided. Electrical switches 106 may be used to control, for example, the operation of a power takeoff on the engine of the pickup truck to which the package is mounted for providing hydraulic fluid under pressure to the hydraulic motor 56 (FIG. 2) to drive the air compressor unit 48. Switches 106 may also be employed to illuminate the interior light 100 or the exterior floodlights 98.
Indicator lights 108 for the various control functions may also be located on the control panel 104.
In some instances, an engine driven air compressor may be employed as seen in FIG. 5. In such a case, there is no need for the hydraulic reservoir 46 and an air compressor such as the air compressor 54 may be mounted directly on top of the air reservoir 26, utilizing the combination straps and mounting brackets 30. In such a case, an internal combustion engine 110, either diesel or gasoline, will typically be mounted on the frame members 40 between the cross members 42 and 44 and connected to the compressor as, for example, by a v-belt 112. In this case, one of the switches 106 may be utilized to operate an electrical starter for the internal combustion engine utilizing power supplied by the vehicular electrical system of the pickup truck on which the package is installed or, if desired, by an auxiliary battery contained within the package itself.
To further enhance the tool storage capability, the end section 18 of the horizontal section 14 may include a horizontal plate 120 adjacent the access opening 78 of the housing section 64. The plate 120 is located just forwardly of the hose reels 36,38 so as not to interfere with their operation and includes several upwardly extending projections 122 which may be in the form of steel rods welded to the plate 120. Various items may be impaled on the rods 122 for storage. For example, sockets for socket wrenches may be located on the rods 122. Alternatively, other items having an aperture extending through them may be stored on the rods 122. For example, a staple gun can be stored on the rods 122 by locating one of the rods 122 through the hand receiving section thereof. Other examples will readily occur to those skilled in the art.
The assembly is completed by cover plates, not all of which are shown. For example, a cover plate 110 extends between the top walls 80 and 96 of the housing sections 64 and 68 to provide a cover for the air compressor unit 48. Side panels 112 may be located on the ends of the vertical section. Similar panels (not shown) may be located on the long sides of the vertical section 12. Perforated panels may be utilized to extend between the frame members 40 and the cover plate 110 as well as the side wall 76,78,92,94 of the housing section to prevent access to the air compressor unit 48. It is to be noted that such panels should, however, be perforated or otherwise allow the free flow of air to assure proper operation of the oil cooler 58 or an internal combustion engine contained in the space if that option is used.
Finally, if desired, lifting eyes (not shown) may be located on the upper walls 80,96 of the housing section 64,68 to assist in the installation and removal of the package from the bed of a pickup truck.
From the foregoing, it will be appreciated that a utility package made according to the invention provides a means for both providing pneumatic power on site at remote construction or tire servicing locations, as well as for the storage of tools that may be used by workers at such sites. Because the same is mounted in a pickup truck, transportation of the various items is facilitated and yet, there is no requirement that the air compressor be periodically tied down or loosened from the bed of the pickup truck as is the case with individual units.
The provision of the hose reels within the unit provide a convenient means of storing the hoses when not in use. The use of two hose reels allows the use of one relatively large reel and one relatively small reel to minimize expense. The smaller reel may be used to store small diameter, short length of hose as might be in a tire inflating operation while the larger reel provides for the storage of an additional length of hose to assure that the hose may reach the point of use of a pneumatic tool to which the hose may be connected. Thus, a truly versatile utility package is provided.
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A utility package for installation in the bed of a pickup truck includes a frame (10) having a relatively narrow, lower vertical section (12) of a width W1 narrower than the interior spacing between the sides of the pickup truck bed while substantially spanning the entire interior distance between such sides and a relatively wide, upper horizontal section (14) of a width greater than the interior spacing between the sides and no greater than about the distance between the exteriors of the sides and adapted to be supported on the tops of the sides. An elongated pressure vessel (26) is located within the vertical section (12) and a pair of upright housing sections (64,68) are mounted on the horizontal section (14) oppositely of the vertical section (12). The housing section (64,68) have access openings (78) at respective ends (16,18) of the horizontal section (14). An air compressor unit (48) is mounted on the frame between the housing section (64,68) and a tool box (70) is located in the vertical section (12) adjacent one end (16) and above the pressure vessel (26) to be accessible through the housing section (68). At least one hose reel (36,38) is mounted in the vertical section adjacent the other end (18) of the horizontal section (14) and is accessible through the housing section (64) at the end (18) of the horizontal section (14).
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PRIORITY CLAIM
[0001] This application claims the benefit of previously filed U.S. Provisional Patent Application entitled “COMBINATION CAM LOCK WITH IMPROVED COMBINATION CHANGE MODE,” assigned U.S. Ser. No. 60/859,268, filed Nov. 15, 2006, and which is incorporated herein by reference for all purposes.
FIELD OF THE INVENTION
[0002] The present subject matter relates to bi-modal operable locks, namely combination and key operated locks. More particularly, the present subject matter relates to resettable combination locks where knowledge of a current combination as well as possession of a key lock operating key are required to reset the lock combination.
BACKGROUND OF THE INVENTION
[0003] Combination and key operated locks have been previously provided in the art and may be employed in a variety of situations to secure enclosed areas or containers. Non-limiting examples may include lockers, rooms, lock boxes, desk drawers, electrical panels, and other similar enclosures. Such locks are convenient from the standpoint that access may be had to a secured item or area by either entering a combination such as by way of manually rotating combination setting elements associated with the lock or by inserting a key into the lock.
[0004] Prior United States patents include reference to prior combination and key operated locks. For example, U.S. Pat. No. 6,539,761 to Yang is entitled “Padlock by combining key-operated lock and combination lock” and relates to a padlock which includes a lock body; a shackle operatively locked in or unlocked from the lock body; a key-operated locking device formed in the lock body for operatively unlocking the shackle for unlocking the padlock by using a key, and a combination locking device juxtapositionally formed in the lock body for operatively unlocking the shackle for unlocking the padlock merely by dialing the combination to an unlocking number. U.S. Pat. No. 6,708,534 to Ruan is entitled “Padlock” and relates to a padlock that comprises a shackle, a lock body, a lock cylinder assembly disposed at the middle portion in the lock body, and a combination lock assembly. Such padlock can be operated by either the key or the cipher. Also provided is a padlock having an interchangeable lock cylinder assembly.
[0005] Another prior patent is U.S. Pat. No. 6,792,778 by Chen, entitled “Combination lock” and relates to a combination lock comprising a tumbler wheel assembly, a backup locking assembly comprising a keyhole, a shaft, and an inner projection having a half circular section, a pivot assembly having a dog and an engagement member, a push button secured to the pivot assembly, a U-shaped shackle pivotably fastened at the lock housing, and an L-shaped resilient member. A correct combination of tumblers and a subsequent pressing of the push button will disengage the dog from a slot at one leg of the shackle and thus exert an elastic force of the resilient member on the leg for pushing the leg out of engagement with the lock. Should either the combination be forgotten or the combination be changed by another person, a turning of the shaft about 90 degrees by inserting a key into the keyhole will turn the projection and the engaged engagement member for releasing the dog.
[0006] U.S. Pat. No. 6,997,023 to Huang is entitled “Combined combination lock and padlock” and relates to a combined combination lock and padlock comprising a second shackle receiving hole including an inside slot at one leg of a shackle of steel rope for receiving a spring depressible block, a tumbler wheel assembly, a key turning assembly, a pivot assembly, a push button, and a U-shaped shackle. A correct combination of tumblers and a subsequent pressing of the push button will disengage a dog with the slot and thus expansion of the block will push the leg out of engagement with the lock. As also stated in U.S. Pat. No. 6,792,778 by Chen, should either the combination be forgotten or the combination be changed by another person, a turning of the shaft about 90 degrees by inserting a key into the keyhole will turn the projection and the engaged engagement member for releasing the dog.
[0007] U.S. Pat. No. 7,104,092 to Yu is entitled “Security lock with dual locking means” and concerns a security lock that can be unlocked by the owner of the security lock by dialing an unlocking number or by authorized security personals with a general key. The security lock mainly contains: a lock body, a plugging device, a controlling device, a securing mechanism, a restriction device, a first locking device and a second locking means. The lock body has a first channel and a second channel therein. The plugging device is pluggable into the first channel. The controlling device is slidably secured within the second channel. The securing mechanism is for securing or releasing the plugging device. The restriction device is slidably deposed within the second channel against the controlling device for controlling movement thereof. The first locking device is formed in the lock body for being engaged with or disengaged from the restriction device. The second locking device is formed in the lock body for rotating the restriction device to be disengaged from the first locking device.
[0008] U.S. Pat. No. 7,121,123, also to Yu, is entitled “Padlock” and concerns a padlock which comprises a lock body, a shackle, a combination locking device and a key locking device. The shackle is movable relative to the lock body between a locked position and an unlocked position. The combination and key locking devices are installed within the lock body respectively for controlling movements of the shackle. Additionally, the combination locking device has a frame for receiving a first end of the shackle and a combination unit connected to the frame, which is movable when the combination unit is unlock whereby a second end of the shackle is movable to the unlock position. Furthermore, the key locking device comprises a block unit for locking the first end of the shackle and a key unit connected to the block unit, which is movable when the key unit is unlocked by a key.
[0009] Depending on the particular use to which the foregoing general types of locks may be applied, it may be convenient or necessary to be able to change the combination for the lock.
[0010] In an exemplary known lock structure 100 as illustrated in present FIGS. 1 and 2 , desired access may be had by either inserting a key into the lock or by entering a combination (such as by way of manually rotating combination setting elements). In order to change the combination in the exemplary known combination and key operated locks as illustrated herein in FIGS. 1 and 2 , the currently configured combination must be used to unlock the assembly, with the combination thereafter changed. If the combination is known, the combination may be changed by use of a set screw 110 ( FIG. 1 ) that may be rotated 90° to engage an actuator 112 ( FIG. 2 ) to place the lock in a combination change mode. The combination cannot be changed with possession of a physical unlocking key. Set screw 110 is independent of a dead bolt mechanism that locks the panel cylinder 106 against the cam lock housing as well as independent of the keyplug 104 . In this known arrangement, if the combination is not known and a user tries to change the combination using set screw 110 , set screw 110 will partially rotate but will not allow the combination to be changed. In normal lock operation, the combination may be entered manually and the lock opened by actuation of button 102 .
[0011] In light of these recognized deficiencies, there exists a need for a manual combination and key lock operated lock that provides an improved mechanism for resetting the manual combination.
[0012] While various implementations of combination and key operated locks have been developed, no design has emerged that generally encompasses all of the desired characteristics as hereafter presented in accordance with the present subject matter.
SUMMARY OF THE INVENTION
[0013] In view of the recognized features encountered in the prior art and addressed by the present subject matter, improved apparatus and methodology for permitting reset of a manually enterable lock combination in a manual or physical key operable cam lock have been developed.
[0014] In an exemplary configuration and practice of the present subject matter, possession of an appropriately keyed physical key is required to reset a manually enterable combination.
[0015] In one of its simpler forms, insertion and operation of a physical key together with entry of a previously configured manually enterable combination allows resetting of the manual enterable combination.
[0016] Another positive aspect of the present type of subject matter is that either a physical key or manually entered combination may be used to operate the lock.
[0017] In accordance with aspects of certain embodiments of the present subject matter, corresponding methodologies and devices are provided to prevent operation of a lock of the present subject matter due to forced rotation of the keyplug by foreign objects.
[0018] One present exemplary embodiment relates to a combination cam lock, comprising a manually operable lock portion, a key lock portion, and a combination change portion. Such manually operable lock portion is preferably configured to enable lock operation upon presentation thereto of a predetermined manual entry combination. Such key lock portion is preferably configured to enable lock operation upon actuation with a physical key, independently of any presentation of any manually entered combination to the manually operable lock portion. Still further, such combination change portion is preferably configured to permit resetting of the predetermined manual entry combination upon both presentation of the predetermined manual entry combination and actuation of the key lock portion with a physical key.
[0019] In a present exemplary method of operating a combination cam lock, a combination cam lock is provided having a manually operable combination entry portion operable to open the cam lock upon manual entry of a predetermined combination, and an independently operable physical key operable portion operable to open the cam lock upon rotation of the physical key to a first position thereof. Further in such exemplary method, manual entry is made of the predetermined combination to the manually operable portion so as to unlock the cam lock. Also, a physical key is inserted into the key operable portion, and thereafter such physical key is rotated to a position beyond the first position thereof. Further thereafter, manual entry components of the manually operable combination entry portion may be selectively repositioned, with the result that the predetermined combination may be reset to a new predetermined combination.
[0020] In yet another present exemplary methodology, a method of operating a combination cam lock may preferably comprise providing a combination cam lock having a manually operable combination entry portion operable to open the cam lock upon manual entry of a predetermined combination, and an independently operable physical key operable portion operable to open the cam lock upon rotation of the physical key to a first position, with both such portions contained within a housing; manually entering the predetermined combination to the manually operable portion so as to unlock the cam lock; inserting a physical key into the key operable portion, and rotating the physical key to the first position thereof; removing the physical key from the key operable portion; and selectively repositioning manual entry components of the manually operable combination entry portion. With practice of such methodology, the predetermined combination may be reset to a new predetermined combination.
[0021] Additional objects and advantages of the present subject matter are set forth in, or will be apparent to, those of ordinary skill in the art from the detailed description herein. Also, it should be further appreciated that modifications and variations to the specifically illustrated, referred and discussed features, elements, and steps hereof may be practiced in various embodiments and uses of the present subject matter without departing from the spirit and scope of the subject matter. Variations may include, but are not limited to, substitution of equivalent means, features, or steps for those illustrated, referenced, or discussed, and the functional, operational, or positional reversal of various parts, features, steps, or the like.
[0022] Still further, it is to be understood that different embodiments, as well as different presently preferred embodiments, of the present subject matter may include various combinations or configurations of presently disclosed features, steps, or elements, or their equivalents (including combinations of features, parts, or steps or configurations thereof not expressly shown in the figures or stated in the detailed description of such figures).
[0023] Additional embodiments of the present subject matter, not necessarily expressed in the summarized section, may include and incorporate various combinations of aspects of features, components, or steps referenced in the summarized objects above, and/or other features, components, or steps as otherwise discussed in this application. Those of ordinary skill in the art will better appreciate the features and aspects of such embodiments, and others, upon review of the remainder of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] A full and enabling disclosure of the present subject matter, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0025] FIG. 1 illustrates a known resettable combination and key operable lock structure;
[0026] FIG. 2 illustrates a partially broken away view of the known lock structure of FIG. 1 ;
[0027] FIG. 3 illustrates a generally front perspective view of a combination and key operable cam lock incorporating features of the present subject matter;
[0028] FIG. 4 illustrates a generally front perspective view (in at least partial breakaway view) of a combination and key operable cam lock incorporating features of the present subject matter;
[0029] FIG. 5 illustrates a generally rear perspective view (also in at least partial breakaway view) of a combination and key operable cam lock incorporating features of the present subject matter, as otherwise seen in present FIG. 4 ;
[0030] FIG. 6 is a perspective view of a combination and key lock illustrating possible unintended operation;
[0031] FIG. 7 illustrates a generally front perspective view (in at least partial breakaway view) of a combination and key lock incorporating features of an additional exemplary embodiment of the present subject matter, including features prohibiting unintended lock operation;
[0032] FIG. 8 illustrates a generally rear and side perspective view (also in at least partial breakaway view) of a combination and key lock incorporating features of an additional exemplary embodiment of the present subject matter including features prohibiting unintended lock operation, as otherwise seen in present FIG. 7 ;
[0033] FIG. 9 illustrates a partially exploded view of another exemplary embodiment of the present subject matter; and
[0034] FIG. 10 illustrates a partial see-through view of a portion of the exemplary embodiment illustrated in FIG. 9 .
[0035] Repeat use of reference characters throughout the present specification and appended drawings is intended to represent same or analogous features, elements, or steps of the present subject matter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] As discussed in the Summary of the Invention section, the present subject matter is particularly concerned with an improved methodology for permitting reset of a manually enterable lock combination in a manual combination or physical key operated cam lock.
[0037] Selected combinations of aspects of the disclosed technology correspond to a plurality of different embodiments of the present subject matter. It should be noted that each of the exemplary embodiments presented and discussed herein should not insinuate limitations of the present subject matter. Features or steps illustrated or described as part of one embodiment may be used in combination with aspects of another embodiment to yield yet further embodiments. Additionally, certain features may be interchanged with similar devices or features not expressly mentioned which perform the same or similar function.
[0038] Referring now to the drawings, FIGS. 1 and 2 (each respectively marked as “Prior Art”) illustrate a known resettable combination and key operable lock structure 100 and a partially broken away view of the lock structure, respectively, as previously described. Such known configuration requires knowledge of the previously set manually enterable lock combination before the combination can be reset regardless of possession of a physical unlocking key. Depending upon the use to which the lock is applied, as previously described, it may not be preferable for possessors of the manually enterable combination to be able to change the combination simply by operation of set screw 110 .
[0039] Reference will now be made in detail to presently preferred exemplary embodiments of the subject combination cam lock.
[0040] With reference to FIG. 3 , there is illustrated a perspective view of a combination and key operable cam lock 300 incorporating features of the present subject matter and illustrating a fully assembled device. As may be seen, cam lock housing 360 contains therein a keyplug 310 . Cam lock housing 360 may be secured to an item to be protected by way of panel cylinder 362 .
[0041] FIGS. 4 and 5 , respectively, illustrate front and rear perspective breakaway views of a cam lock 300 constructed in accordance with a first exemplary embodiment of the present subject matter. In accordance with the present subject matter, knowledge of the previously assigned combination as well as possession of a lock operating key are required to change the combination. The lock operating key may be individually keyed to cam lock 300 or may be a master key for use with a series of similar cam locks. In either circumstance, the key or the combination respectively may be used individually to unlock the assembly.
[0042] In accordance with the present subject matter, in order to change the lock combination, insertion of a correct key into keyplug 310 together with knowledge of the current combination is required. As a correct key is inserted into keyplug 310 and rotated 90° clockwise (CW), keyplug 310 turns inside the inner cylinder 320 that encapsulates keyplug 310 and activates a lock plate 340 . Activation of lock plate 340 releases cam lock housing 360 from panel cylinder 362 , thereby unlocking the assembly and allowing the assembly to be rotated 90° CW to an unlatched position.
[0043] Detent actuator 370 ( FIGS. 4 and 6 ) prevents inner cylinder 320 from rotating when keyplug 310 is rotated to the unlocked position. In the unlocked position, and if the combination is known and the correct key is inserted into the keyplug 310 and rotated an additional 90° CW, the keyplug 310 rotation stop engages the inner cylinder 320 which rotates inside the cam lock housing 360 with a cam action 322 ( FIG. 6 ) to place the assembly in a combination change mode.
[0044] When keyplug 310 and the combination are in a locked position, it could be possible to partially rotate keyplug 310 by inserting a foreign object into keyplug 310 . Even though such activity would be unauthorized (i.e., unintended under ordinary, authorized use) such partial rotation could permit the tumblers in keyplug 310 to engage inner cylinder 320 and to rotate the inner cylinder 320 and keyplug 310 towards the combination change mode position. Such rotation could engage and sufficiently activate lock plate 340 so as to disengage from panel cylinder 362 , thus unlocking the assembly.
[0045] With reference now to FIGS. 7 and 8 , it will be seen that, in accordance with an additional embodiment of the present subject matter, measures have been provided to address such potential unauthorized methodology for unintended access to the cam lock mechanism.
[0046] With specific and collective reference to FIGS. 7 and 8 , it will be observed that inner cylinder 320 has been formed with a cut out region 324 (see FIG. 7 ), and the cam lock housing 360 has been provided a protrusion 364 (see FIG. 8 ). The provision of cut out region 324 allows three of the five keyplug tumblers 312 , 314 , and 316 , to lock against the cam lock housing 360 instead of against the inner cylinder 320 . As will be understood by those of ordinary skill in the art, by such present arrangement, tumblers one and five (not visible in the drawing) will lock against inner cylinder 320 while tumblers 312 , 314 , and 316 will lock against protrusion 364 of cam lock housing 360 . Inner cylinder cut out 324 and cam lock housing protrusion 364 may be configured so as to allow inner cylinder 320 to rotate 90° CW and back 90° CounterClockwise (CCW). The inner cylinder cutout region 324 and the cam lock housing protrusion 364 are sufficient to prevent the keyplug and inner cylinder from being partially rotated with a foreign object toward combination change mode, thus maintaining the engagement between the lock plate 340 and the panel cylinder 362 and also maintaining the security of the cam lock assembly.
[0047] With reference to FIGS. 9 and 10 , a further exemplary embodiment of a combination cam lock generally 400 in accordance with the present subject matter is described. Such further second embodiment provides for resetting the combination of the combination cam lock generally 400 and still advantageously per present subject matter requires both knowledge of the current (or existing) combination and possession of a physical key.
[0048] With reference to FIG. 9 , it will be noticed that combination cam lock 400 includes a housing 360 ′ including a portion 320 ′ that has been redesigned to accept keyplug 310 ′ directly without having to provide an inner cylinder (such as inner cylinder 320 of FIGS. 4 and 5 ). Further, keyplug 310 ′, while otherwise generally equivalent to keyplug 310 of the previous embodiment, is provided with a through hole 402 that passes entirely through keyplug 310 ′. In the illustrated embodiment, through hole 402 passes through keyplug 310 ′ in approximate parallel alignment between a second and third tumbler. It should be appreciated that such positioning is exemplary only and may be varied depending on positional requirements with cam lock 400 , for given embodiments thereof. In other words, those of ordinary skill in the art may within the spirit and scope of the present subject matter selectively position such through hole 402 in accordance with the needs or desires of particular implementations.
[0049] With further reference to FIG. 9 , it will be seen that cam lock housing 360 ′ is provided with a side hole or opening 404 and a combination change mechanism opening 406 substantially aligned with side hole 404 . Such arrangement is configured so that when keyplug 310 ′ is in place within inner cylinder equivalent space 320 ′ of housing 360 ′, and the lock is unlocked by use of a physical key, keyplug 310 ′ may be rotated 90° from its normal locked position such that keyplug hole 402 , side hole 404 , and combination change mechanism opening 406 are in alignment with each other.
[0050] To reset the manual entry combination in the first embodiment of the present subject matter, the correct combination must be set so as to unlock the assembly and a key must be inserted into the keyplug and rotated 180° to activate the inner cylinder 320 ( FIGS. 4 and 5 ) and to place the assembly in “combination change mode”. In the present embodiment, the inner cylinder 320 per se has been eliminated and the assembly housing modified to directly accept keyplug 310 ′ ( FIG. 9 ). In accordance with such further embodiment of the present subject matter, the correct (i.e., existing) combination must be set to unlock the assembly and a key must be inserted into the keyplug 310 ′ and rotated 90° Clockwise to the unlocked position. Maximum keyplug rotation for such further embodiment is 90°.
[0051] With the key removed from keyplug 310 ′, a tool such as a large paper clip 420 may then be inserted into side hole 404 ( FIG. 9 ), and through through hole 402 of keyplug 310 ′, and then into combination change mechanism opening 406 that has been provided to expose the combination change mechanism illustrated generally within circle 410 of FIG. 10 . Pushing the combination change mechanism with the tool, allows the combination to be reset. Disengaging the tool from the combination change mechanism sets the new combination. The key may then be reinserted and rotated 90° Counterclockwise to lock the assembly.
[0052] It should be appreciated by those of ordinary skill in the art that the keyplug may be provided with any suitable number of tumblers and that the example here illustrated involving three of five tumblers is purely illustrative of the present subject matter, and that different numbers of tumblers (both total and protectively locked) may be alternatively practiced within the broader scope of present aspects of the present subject matter.
[0053] While the present subject matter has been described in detail with respect to specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.
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Disclosed are apparatus and methodology for providing a resettable manual entry combination and key operated cam lock. Methodologies are provided for enabling changing of the manual entry resettable combination given knowledge of the previous combination and possession of an operable key. In alternative embodiments, provisions are made to prohibit forced opening of the lock by way of the use of foreign objects.
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FIELD OF THE INVENTION
[0001] The invention relates to cosmetic materials and in particular to cosmetic materials used to improve the appearance of skin and reduce skin wrinkles.
BACKGROUND OF THE INVENTION
[0002] Numerous cosmetics exist for treatment and concealment of wrinkles. The problem of how to alleviate wrinkling and improve the health and appearance of wrinkled skin is ubiquitous and cosmetic methods for treatment of wrinkles are avidly sought.
[0003] U.S. Pat. No. 6,156,804, the disclosure of which is incorporated herein by reference, describes treating wrinkles and fine lines on the skin by topically treating the skin with a microdispersion of wax in a topical composition. U.S. Pat. No. 5,185,155, the disclosure of which is incorporated herein by reference, describes encapsulating hydrophobic material to form a dispersion of micro-encapsulates for use in cosmetic products.
SUMMARY OF THE INVENTION
[0004] An aspect of some embodiments of the present invention relates to providing a cosmetic material that reduces wrinkling and improves appearance of skin to which it is applied.
[0005] An aspect of some embodiments of the present invention relates to providing a cosmetic substance, which when applied to the skin forms a network of filaments of the cosmetic substance on the skin. The network anchors itself to the skin and to furrows of wrinkles in the skin. As a result of attraction between components of the cosmetic material from which the filaments are formed, the filaments tend to contract with substantial force. The network as a whole therefore tends to contract. Since the filaments of the network are anchored to the skin and furrows of wrinkles therein, the network functions to mechanically “pull out” wrinkle furrows in the skin, thereby smoothing the skin and drawing the skin taut.
[0006] An aspect of some embodiments of the present invention relates to providing a cosmetic substance, which when applied to the skin diffuses water by osmosis to blood vessels, interstitial fluid and cells in the skin and causes thereby the structure of the skin to swell and expand. The swelling tends to flatten out wrinkles and improve flow of blood and interstitial fluid in the skin that irrigates the skin with nutrients and removes metabolic waste materials from the skin.
[0007] An aspect of some embodiments of the present invention relates to providing a cosmetic substance that provides a peeling effect that detaches dead skin cells from the surface of the epidermis. When the cosmetic substance is removed from the skin, the detached dead skin cells are removed with the cosmetic substance.
[0008] In some embodiments of the present invention two or three of the aspects are present.
[0009] A cosmetic substance, in accordance with an embodiment of the present invention, comprises a composition of matter formed from water, hydrophilic silica particles and hydrophobic silica particles. In some embodiments of the invention a mass of hydrophilic particles in the composition is substantially greater than a mass of hydrophobic particles in the composition. For example, some embodiments of the present invention, may typically have mass ratios of hydrophilic to hydrophobic particles in a range from 6 to 20. Some embodiments may typically have mass ratios in a range from 3 to 10. Other mass ranges, in accordance with embodiments of the present invention are also possible. In some embodiments of the present invention, the composition takes a form of an aqueous emulsion. A majority of the hydrophilic particles in the emulsion remains in solution in the water and tends to form, with the water, a gel-like structure comprising relatively long filaments of hydrophilic particles to which water molecules adhere. Hydrophobic particles and a relatively small portion of the hydrophilic particles aggregate to form double layer shells that encapsulate pockets of air that are suspended in the water. The hydrophobic particles in a shell that encapsulates an air pocket are concentrated in an inner layer of the shell, which inner layer is in contact with the air in the air pocket. The hydrophilic particles in the shell are concentrated in an outer layer of the shell, which outer layer is in contact with the water. Optionally, additional hydrophilic particles are distributed in the water.
[0010] In some embodiments of the present invention, the cosmetic substance is powder-like and hereinafter is referred to as a powder. Particles that form the powder are droplets of water with hydrophilic particles in solution, each droplet encapsulated in a double layer shell having an inner layer comprising hydrophilic particles and an outer layer comprising hydrophobic particles. Most of the hydrophilic particles in the powder are dispersed in the water in the encapsulated water droplets and, as in the emulsion form of the cosmetic composition, tend to form with the water a gel-like structure comprising filaments of hydrophilic particles adhered with water molecules.
[0011] When the cosmetic substance, in either the emulsion or powder form, is rubbed into a region of skin, it forms a layer of the cosmetic substance on the surface of the skin. A portion of the hydrophilic particles in the layer migrate to and enter sweat gland ducts in the skin region, forming tendrils of hydrophilic particles that penetrate into the ducts. A portion of the hydrophobic particles migrate to and enter ducts of sebaceous glands located in hair follicles in the skin region, forming tendrils of hydrophobic particles that protrude into the hair follicles and ducts of their sebaceous glands. In particular, the hydrophilic and hydrophobic tendrils protrude into hair follicles and ducts of sweat glands and sebaceous glands in furrows of wrinkles in the skin region. Water in the cosmetic material diffuses by osmoses into interstitial fluid and cells in the skin.
[0012] As water leaves the cosmetic substance, the volume of the cosmetic substance contracts and the layer shrinks to a network of filaments on the skin. Each of the filaments is formed from a slurry of hydrophilic and hydrophobic particles in water. The hydrophilic and hydrophobic tendrils anchor the filaments to the skin region and wrinkle furrows therein.
[0013] As a result of the attraction of the hydrophilic particles to water and attraction of the hydrophobic particles to the hydrophilic particles and to water, the filaments tend to contract aggressively. It is noted that hydrophobic molecules do not generally repel water and are often attracted to water with greater force than they are attracted to each other. Hydrophobic effects evidenced by hydrophobic molecules generally result from attraction of water molecules to each other being greater than attraction of water to the hydrophobic molecules. The cosmetic filamentary network therefore tends to contract aggressively and thereby pulls out furrows of wrinkles in the skin and smoothes the skin.
[0014] The cosmetic substance optionally also functions as a peeling agent that tends to peel off dead skin cells from the epidermis. As a result of capillary action and attraction of hydrophilic and hydrophobic particles in the cosmetic substance to moisture and natural oils in the skin respectively, water and hydrophilic and/or hydrophobic particles in the cosmetic tend to penetrate between dead skin cells and the surface of the epidermis. If the skin is wet or moist, water and predominantly hydrophilic particles will tend to penetrate and concentrate between the dead skin cells and the epidermis. If the skin is oily, water and predominantly hydrophobic particles will tend to penetrate and concentrate between the dead skin cells and the epidermis. If the dead skin cells are dry, water in the cosmetic will tend to be absorbed by the dead skin cells resulting in their swelling. The penetration and concentration of the hydrophobic and/or hydrophilic between dead skin cells and the epidermis tends to pry up and dislodge the dead skin cells from the epidermis. Swelling of dry dead skin cells also tends to mechanically dislodge the dead skin cells from the epidermis. When the cosmetic substance is removed from the skin, the dislodged dead skin cells are removed with the cosmetic substance.
[0015] There is therefore provided in accordance with an embodiment of the present invention, an emulsion comprising: water; hydrophilic particles; and hydrophobic particles; wherein the hydrophilic and hydrophobic particles form shells encapsulating a gas that are suspended in the water, said shells comprising an external layer of hydrophilic particles and an internal layer of hydrophobic particles adjacent to the layer of hydrophilic particles. Optionally, hydrophilic particles are dispersed in the water and form with the water a gel-like structure having filaments of hydrophilic particles to which water molecules adhere.
[0016] In some embodiments of the present invention, the shells have a characteristic diameter in a range from about 1 micrometer to about 20 micrometers.
[0017] In some embodiments of the present invention, a relative concentration by weight of the hydrophobic particles in the emulsion is such that the emulsion does not tend to become a powder.
[0018] In some embodiments of the present invention, a concentration by weight of hydrophobic particles in the emulsion is between 0.5% and 1.8%.
[0019] In some embodiments of the present invention, hydrophobic particles have a characteristic specific surface greater than about 100 m 2 /g.
[0020] In some embodiments of the present invention, a relative concentration by weight of the hydrophilic particles in the emulsion is about equal to K phil /S phil where S phil is a characteristic specific surface of the hydrophilic particles and K phil is a constant having a value between about 20 m 2 /g and about 50 m 2 /g. Optionally, K phil has a value between about 30 m 2 /g and about 40 m 2 /g.
[0021] In some embodiments of the present invention, the hydrophilic particles have a characteristic specific surface greater than about 100 m 2 /g.
[0022] In some embodiments of the present invention, a characteristic diameter of the hydrophilic particles is between about 5 nm and about 150 nm.
[0023] In some embodiments of the present invention, the hydrophilic particles comprise oxide particles having surfaces covered with polar radicals. Optionally, the hydrophilic particles comprise a mix of hydrophilic particles, said mix comprising a first type of hydrophilic particles formed from particles based on a first oxide and at least one second type of hydrophilic particles formed from particles based on a second oxide different from the first oxide. Optionally, the polar radicals are selected from the group consisting of OH, CA 2 CO 3 , CUSO 4 and CASO 4 .
[0024] In some embodiments of the present invention, the hydrophobic particles comprise oxide particles having surfaces covered with non-polar radicals. Optionally, An emulsion according to claim 20 wherein the hydrophobic particles comprises a mix of hydrophobic particles, said mix comprising a first type of hydrophobic particles formed from particles based on a first oxide and at least one second type of hydrophobic particles formed from particles based on a second oxide different from the first oxide.
[0025] In some embodiments of the present invention, the oxide particles are selected from the group consisting of SiO 2 , Al 2 O 3 , TiO 2 , Fe 2 O 3 and MnO particles.
[0026] In some embodiments of the present invention, the gas is air.
[0027] In some embodiments of the present invention, the gas is ozone.
[0028] In some embodiments of the present invention, a substance beneficial for skin care is present in the water. Optionally, the substance is an oil. Optionally, the substance is vitamin A. Optionally, the substance is beta carotine.
[0029] There is further provided, in accordance with an embodiment of the present invention, a powder comprising: water; hydrophilic particles; and hydrophobic particles; wherein the water is encapsulated in shells comprising an external layer of hydrophobic particles and an internal layer of hydrophilic particles adjacent to the layer of hydrophobic particles. Optionally, hydrophilic particles are dispersed in solution in the encapsulated water and form with the water a gel-like structure having filaments of hydrophilic particles to which water molecules adhere.
[0030] In some embodiments of the present invention, the hydrophobic particles have a characteristic specific surface greater than about 100 m 2 /g.
[0031] In some embodiments of the present invention, a relative concentration C phil by weight of the hydrophilic particles in the powder satisfies an equation C phil =K phil /S phil where S phil is a characteristic specific surface of the hydrophilic particles and K phil is a constant having a value between about 20 m 2 /g and about 50 m 2 /g. Optionally, K phil has a value between about 30 m 2 /g and about 40 m 2 /g.
[0032] In some embodiments of the present invention, the hydrophilic particles have a specific surface greater than about 100 m 2 /g.
[0033] In some embodiments of the present invention, a characteristic diameter of hydrophilic particles is between about 5 nm and about 150 nm.
[0034] In some embodiments of the present invention, the shells have a characteristic average diameter in a range from about 1 micrometer to about 20 micrometers.
[0035] In some embodiments of the present invention, the hydrophilic particles comprise oxide particles having surfaces covered with non-polar radicals. Optionally, the hydrophilic particles comprise a mix of hydrophilic particles, said mix comprising a first type of hydrophilic particles formed from particles based on a first oxide and at least one second type of hydrophilic particles formed from particles based on a second oxide different from the first oxide. Optionally, the polar radicals are selected from the group consisting of OH, CA 2 CO 3 , CUSO 4 and CASO 4 .
[0036] In some embodiments of the present invention, the hydrophobic particles comprise oxide particles having surfaces covered with non-polar radicals. Optionally, the hydrophobic particles comprises a mix of hydrophobic particles, said mix comprising a first type of hydrophobic particles formed from particles based on a first oxide and at least one second type of hydrophobic particles formed from particles based on a second oxide different from the first oxide.
[0037] In some embodiments of the present invention, the oxide particles are selected from the group consisting of SiO 2 , Al 2 O 3 , TiO 2 , Fe 2 O 3 or MnO particles.
[0038] In some embodiments of the present invention, a substance beneficial for skin care is present in the water. Optionally, the substance is an oil. Optionally, the substance is vitamin A. Optionally, the substance is beta carotine.
[0039] There is also provided, in accordance with an embodiment of the present invention, a method of reducing wrinkling in a region of skin comprising: forming a layer of an emulsion according to an embodiment of the present invention on the region; and waiting a sufficient period of time so that a portion of the water from the emulsion is absorbed by the region and the volume of the layer shrinks so that the layer transforms into a network of strands on the region, which network is anchored to the skin by attraction of hydrophilic and hydrophobic particles to the skin and tends to contract as water is absorbed from the emulsion.
[0040] In some embodiments of the present invention, the method comprises applying water to the region of skin after the network is formed so that the network absorbs water and expands and subsequently releases water to the skin and contracts again.
[0041] In some embodiments of the present invention, the method comprises applying a substance comprising a component that is absorbed by the network and the skin to the region of skin after the network is formed so that the network absorbs the component and expands and subsequently releases the component to the skin and contracts again. Optionally, the component is an oil. Optionally, the component is vitamin A. Optionally, the component is beta carotine.
[0042] There is further provided in accordance with an embodiment of the present invention, A method of reducing wrinkling in a region of skin comprising: applying a powder in accordance with an embodiment of the present invention to the region so that shells in the powder rupture and release their water content and the released water, hydrophilic particles and hydrophobic particles in the ruptured cells form a layer on the region; and waiting a sufficient period of time so that at least portion of water in the layer is absorbed by the region and the volume of the layer shrinks so that the layer transforms into a network of strands on the region, which network is anchored to the skin by attraction of hydrophilic and hydrophobic particles to the skin and tends to contract as water is absorbed from the network.
[0043] In some embodiments of the present invention, the method comprises applying water to the region of skin after the network is formed so that the network absorbs water and expands and subsequently releases water to the skin and contracts again.
[0044] In some embodiments of the present invention, the method comprises applying a substance comprising a component that is absorbed by the network and the skin to the region of skin after the network is formed so that the network absorbs the component and expands and subsequently releases the component to the skin and contracts again. Optionally, the component is an oil. Optionally, the component is vitamin A. Optionally, the component is beta carotine.
[0045] There is further provided, in accordance with an embodiment of the present invention, A method of forming an aqueous emulsion in which encapsulated pockets of gas are suspended in water comprising: forming a solution of water and hydrophilic particles; adding a quantity of hydrophobic particles to the solution to form a mixture; causing the gas to be present in the mixture while causing the gas to cavitate so as to generate pockets of the gas in the mixture and wherein the quantity of hydrophobic particles added to the mixture is not sufficient to cause the cavitating mixture to form a powder.
[0046] There is further provided, in accordance with an embodiment of the present invention, a method of forming a powder comprising water, the method comprising: forming a solution of water and hydrophilic particles; adding a quantity of hydrophobic particles to the solution to form a mixture; causing the gas to cavitate so that droplets of the water are encapsulated in shells of hydrophilic and hydrophobic particles and wherein the amounts of hydrophobic and hydrophilic particles in the mixture are enough to form a sufficient number of shells so that substantially all the water in the mixture can be contained in encapsulated water droplets.
BRIEF DESCRIPTION OF FIGURES
[0047] Non-limiting examples of embodiments of the present invention are described below with reference to figures attached hereto. In the figures, identical structures, elements or parts that appear in more than one figure are generally labeled with a same numeral in all the figures in which they appear. Dimensions of components and features shown in the figures are chosen for convenience and clarity of presentation and are not necessarily shown to scale. The figures are listed below.
[0048] [0048]FIGS. 1A and 1B schematically show a cosmetic emulsion and details of its composition, in accordance with an embodiment of the present invention;
[0049] [0049]FIGS. 2A and 2B schematically show a cosmetic powder and details of its composition, in accordance with an embodiment of the present invention; and
[0050] FIGS. 3 A- 3 D schematically illustrate functioning of the cosmetic emulsion shown in FIG. 1 in ameliorating wrinkles in a region of skin to which the emulsion is applied, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0051] [0051]FIG. 1A schematically shows a cosmetic aqueous emulsion 20 , in accordance with an embodiment of the present invention. Cosmetic emulsion 20 comprises hydrophilic particles represented schematically by shaded circles 22 and hydrophobic particles represented by unshaded circles 24 suspended in water 26 . A number of hydrophilic particles 22 in emulsion 20 is optionally substantiality greater than a number of hydrophobic particles 24 in the emulsion.
[0052] A hydrophilic particle 22 , in accordance with an embodiment of the present invention, may be formed from an oxide particle which has its surface covered with polar radicals. Any of a large variety of different oxides may be used to form a hydrophilic particle, for example a hydrophilic particle may be formed from a silica (SiO 2 ), alumina (Al 2 O 3 ), titanium oxide TiO 2 , Fe 2 O 3 or MnO particle having its surface covered with polar radicals. The polar radicals are, preferably, hydroxyl radicals (i.e. OH), though other polar radicals such as Ca 2 CO 3 , CuSO 4 , CaSO 4 may also be used. A hydrophobic particle 24 , in accordance with an embodiment of the present invention, may be formed from an oxide particle having its surface covered with non-polar radicals, such as for example methyl radicals (i.e. CH 3 ). As in the case of a hydrophilic particle 22 , a hydrophobic particle 24 may be based on any one of a large variety of different oxide particles.
[0053] Hydrophilic particles 22 in emulsion 20 , in accordance with an embodiment of the present invention, may comprise hydrophilic particles of a same type, i.e. all based on a same type oxide particle, or a mix of different types of hydrophilic particles, in which each type is based on a different type oxide particle. Similarly, hydrophobic particles 24 in emulsion 20 may comprise a single type of hydrophobic particle based on a same type oxide particle, or comprise hydrophobic particles of different types.
[0054] Hydrophobic particles 24 and a relatively small portion of hydrophilic particles 22 aggregate to form double layer shells 28 that encapsulate pockets of air 30 , which are suspended in water 26 . A large proportion of hydrophilic particles 22 remains dispersed in water 26 , as is schematically shown in FIG. 1A. Details of structure of shells 28 that encapsulate air pockets 30 are shown in an enlarged, partially cutaway schematic of a shell 28 in FIG. 1B. An inner layer 32 of each shell 28 comprises hydrophobic particles 24 and an outer layer 34 of the shell comprises hydrophilic particles 22 . Whereas for simplicity of presentation, inner layer 32 of hydrophobic particles 24 is shown as a single layer of hydrophobic particles 24 , inner layer 32 may comprise a small plurality of layers of hydrophobic particles. Similarly, outer layer 34 , which is shown comprising a single layer of hydrophilic particles 22 , may comprise a plurality of layers of hydrophilic particles. For hydrophilic particles 22 having a same size as hydrophobic particles 24 , generally, the number of hydrophilic particles 22 in shell 28 is about equal to the number and hydrophobic particles 24 in the shell.
[0055] Hydrophilic particles 22 and hydrophobic particles 24 preferably have a specific surface (i.e. surface to mass ratio) that is greater than about 100 m 2 /g and preferably substantially greater. It is advantageous for hydrophilic and hydrophobic particles 22 and 24 to be as small as possible and to the extent that the specific surface of a particle is greater, the size of the particle is smaller. To the extent that the particles are smaller, the size of air pockets 30 tend to be smaller and a larger fraction of the total surface area of shells 28 encapsulating air pockets 30 contacts and interacts directly with the skin when cosmetic emulsion 20 is applied to the skin. Contact with the skin of a shell 28 of an air pocket 30 tends to rupture the shell, freeing hydrophilic and hydrophobic particles 22 and 24 in the shell to contact and interact with the skin. In addition, the smaller the size of hydrophilic particles 22 and hydrophobic particles 24 , the more easily do the particles flow into ducts of sweat glands and sebaceous glands in the skin, as described below.
[0056] It noted however, that hydrophilic and hydrophobic particles 22 and 24 should not be too small. As the size of hydrophilic and hydrophobic particles 22 and 24 is reduced and air pockets 30 become smaller, hydrophilic and hydrophobic particles 22 and 24 in shells 28 of the air pockets are more tightly bound to each other. It therefore becomes more difficult to rupture shells 28 and free hydrophilic and hydrophobic particles 22 and 24 that they comprise. As a result, activity of cosmetic emulsion 20 is restrained and its cosmetic efficacy reduced. Advantageously, diameters of air pockets 30 range from about 1 micrometer to about 20 micrometers. For air pockets 30 having diameters substantially smaller that about 1 micrometer, shells 28 of the air pockets are generally not ruptured easily enough. Air pockets 30 having diameters greater than about 20 micrometers are generally mechanically unstable. Diameters of hydrophilic and hydrophobic particles 22 and 24 range correspondingly from about 5 nm to about 150 nm.
[0057] Hydrophilic and hydrophobic silica particles having average specific surfaces in the ranges from about 100 m 2 /g to about 400 m 2 /g and from about 100 m 2 /g to about 280 m 2 /g. respectively are currently available commercially. For example, Degussa of Germany markets hydrophilic and hydrophobic particles having specific surfaces in the above noted range under the brand name AEROSIL. Cabot of the US also markets hydrophilic and hydrophobic silica particles that have specific surfaces in the above noted ranges under the brand name CAB-O-SIL. For the above noted specific surfaces, hydrophilic and hydrophobic particles in the commercially available products have diameters in a range from about 5 nm to about 150 nm.
[0058] Concentration of hydrophobic particles 24 in emulsion 20 controls an amount of air encapsulated in the emulsion and thereby the amount of water 26 per unit volume of the emulsion. As the amount of hydrophobic particles 24 in emulsion 20 increases, the amount of air trapped in the emulsion increases and the amount of water 26 per cubic centimeter of emulsion decreases. The inventors have determined that water content of emulsion 20 is advantageously between about 40% and about 70% by volume. Though water content of emulsion 20 can be less than 40% and greater than 70%, for water content less than 40% the emulsion tends to be too dry and for water content above 70% the emulsion tends to be too watery. The advantageous water content range corresponds to a concentration of hydrophobic particles 24 in emulsion 20 in a range from about 0.5% to about 1.5% by weight.
[0059] The concentration of hydrophobic particles 24 in emulsion 20 must generally be below a certain threshold concentration, hereinafter referred to as a “powder threshold”. Concentrations of hydrophobic particles greater than the powder threshold are generally not possible for the emulsion form of a cosmetic composition in accordance with an embodiment of the present invention and are characteristic of the powder form of a cosmetic composition in accordance with an embodiment of the present invention. Let C phob represent the relative concentration (not percent) by weight of hydrophobic particles 24 in emulsion 20 . The inventor has found that to maintain integrity and stability of emulsion 20 as an emulsion, concentration, C phob should satisfy a relation C phob ≦K phob /S phob , where S phob is a characteristic specific surface of the hydrophobic particles and K phob is a constant. For an emulsion, in accordance with an embodiment of the present invention, similar to emulsion 20 , for which hydrophilic and hydrophobic particles 22 and 24 are hydrophilic and hydrophobic silica particles, for which S phob ≅260 m 2 /g, and for substantially pure water, K phob has a value between about 4 m 2 /g and about 5 m 2 /g.
[0060] Concentration of hydrophilic particles in emulsion 20 determines viscosity of the emulsion and stability of the emulsion against deterioration by phase separation of its components. The inventor has determined that, in accordance with an embodiment of the present invention, the relative concentration by weight, “C phil ”, of the hydrophilic particles advantageously satisfies an equation C phil =K phil /S phil . In the equation for C phil , S phil is a specific surface of hydrophilic particles 22 and K phil is a constant. The inventor has determined that for hydrophilic silica particles having S phil ≅380 m 2 /g, K phil less than about 20 m 2 /g emulsion 20 is generally too watery, while for K phil greater than about 40 m 2 /g, the emulsion becomes very viscous and paste-like. Whereas, both a watery and a paste-like form of emulsion 20 can be advantageous, generally a value for K phil between about 20 m 2 /g and 40 m 2 /g is advisable. For a range for values for K phil between about 20 m 2 /g and about 40 m 2 /g, concentration by weight of hydrophilic particles 22 in emulsion 20 ranges from about 7% to about 11%.
[0061] The inventor has determined that different values of pH for cosmetic emulsions similar to emulsion 20 are advantageous for different skin types. For example, for normal skin that is neither too oily nor too dry, a pH between 5.2 and 5.5 can be advantageous. For oily skin, a pH about equal to 4 can be advantageous. The pH of emulsion 20 is determined by relative concentrations of hydrophilic particles 22 and hydrophobic particles 24 and/or by addition of appropriate ions, such as silver ions. Generally, if an Son is added to emulsion 20 , the ion concentration is a dominant factor in determining the pH of the emulsion.
[0062] To provide an example of how to produce an emulsion in accordance with an embodiment of the present invention similar to emulsion 20 , assume that it is desired to produce a kilogram of the emulsion and that particles 22 and 24 are hydrophilic and hydrophobic silica particles respectively. Assume that the specific surfaces of hydrophilic particles 22 is 380 m 2 /g and that K phil =38 m 2 /g so that the concentration C phil of hydrophilic particles by weight is about 0.1. Assume that S phob ≅380 m 2 /g and for a desired concentration of water 26 in emulsion 20 that concentration C phob of hydrophobic particles 24 should be about 0.01. Then, a kilogram of emulsion 20 should comprise about 10 g of hydrophobic particles 24 and about 100 g of hydrophilic particles 22 . A remainder of emulsion 20 , about 890 g, is highly purified water optionally having substances, for example vitamins or an antiseptic agent, beneficial for skin care dissolved or dispersed therein.
[0063] To produce emulsion 20 , 890 g of water and 100 g of hydrophilic particles 22 are mixed together for five to ten minutes in a DS-CH4000RM mixer sold by Shiangtai Machinery Industry of Japan having a 50 mm propeller rotating at about 500 rpm. Following mixing at 500 rpm, mixing continues for 10-15 minutes at about 1000 rpm and then for an additional period of 75-80 minutes at between about to about 2500 rpm. At the end of the additional mixing period of 75-80 minutes, 10 g of hydrophobic particles 24 are added to the mixture and the mixture is mixed for about 30 minutes at a mixing speed of about 1000 to about 1500 RPM. The mixing is then stopped and the resultant mixture of hydrophilic particles 22 , hydrophobic particles 24 and water is set aside for a period of about 24 hours, during which it is maintained at a constant temperature of about 20° C. and isolated from mechanical vibration and shock. During this “quiet” period extraneous gas bubbles introduced into the mixture during mixing are released and the mixture gels and matures into the emulsion.
[0064] It is noted that whereas FIG. 1 shows shells 28 in emulsion 20 encapsulating air pockets 30 , in accordance with an embodiment of the present invention, a formulation similar to emulsion 20 can be produced in which shells 28 encapsulate a gas or mixture of gases other than air. For example, a cosmetic formulation, in accordance with an embodiment of the present invention, can be formed in which shells 28 encapsulate ozone or some other gas or gas mixture that is beneficial for skin care. During manufacture of the emulsion a given desired gas or gas mixture is encapsulated in the emulsion, in accordance with an embodiment of the present invention, by bubbling or otherwise suffusing the mixture of water and particles from which the emulsion is being formed with the gas.
[0065] [0065]FIG. 2A schematically shows a cosmetic powder 50 , in accordance with an embodiment of the present invention. Cosmetic powder 50 comprises powder particles 52 each particle of which comprises a droplet of water 54 encapsulated in a double layer shell 56 of hydrophilic and hydrophobic silica particles 22 and 24 . Hydrophilic particles 22 form an inner layer 58 of shell 56 and hydrophobic particles 24 form an outer layer 60 of the shell. Hydrophilic particles 22 in solution in a water droplet 54 optionally, form with the water in the droplet a gel-structure comprising relatively long filaments (not shown) of hydrophilic particles to which water molecules are intimately adhered. Some details of structure of powder particles 52 are shown in an enlarged schematic, partial cutaway of a particle 52 in FIG. 2B.
[0066] Cosmetic powder 50 is produced similarly to the way in which emulsion 20 is produced by adding hydrophilic and hydrophobic particles 22 and 24 to water and mixing. A main factor in determining if the mixture becomes a cosmetic emulsion or a cosmetic powder, in accordance with an embodiment of the present invention, is an amount of hydrophobic particles 24 added to the water to make the mixture. As noted above, if the concentration of hydrophobic particles 24 is greater than a hydrophobic powder threshold for the mixture, the mixture will form a powder. For example, assume that the hydrophobic and hydrophilic particles 22 and 24 are hydrophobic and hydrophilic silica having specific surfaces respectively the same as the specific surfaces of the hydrophilic and hydrophobic particles used in the above example of formation of emulsion 20 . Then if C phob ≧K phob /S phob , where K phob has a value between about 4 m 2 /g and about 5 m 2 /g, the mixture will tend to form a powder. For such a concentration of hydrophobic particles, the mixture has enough hydrophobic particles to form surfaces of a sufficient number of shells 56 so that substantially all the water in the mixture is contained in encapsulated water droplets 54 .
[0067] By way of example, assume that a kilogram of a cosmetic powder similar to cosmetic powder 50 is to be formed, in accordance with an embodiment of the present invention, from hydrophilic and hydrophobic particles having the specific surfaces noted in the example described above for manufacturing cosmetic emulsion 20 . Further assume that K phob is equal to about 4.5 m 2 /g. To form the cosmetic powder, 882 g of water and about 100 g of hydrophilic particles 22 are mixed together for five to ten minutes in a DS-CH4000RM mixer having a 50 mm propeller rotating at about 500 rpm. Following mixing at 500 rpm, mixing continues for 10-15 minutes at about 1000 rpm and then for an additional period of 75-80 minutes at about 2500 rpm. At the end of the additional mixing period of 75-80 minutes, 18 g of hydrophobic particles are added to the mixture. The amount of hydrophobic silica added to the water is such that C phob ≧K phob /S phob , i.e. 18 g>1000 g(4.5 m 2 /g)/(280 m 2 /g)≅16. As a result, the mixture can be processed to produce a cosmetic powder rather than a cosmetic emulsion. Following addition of the hydrophobic particles the mixture is mixed for about 30 minutes at a mixing speed of about 3000 RPM. (The mixing speed for the powder is optionally substantially greater than the mixing speed of the emulsion in this stage of the manufacturing process.) The mixing is then stopped and the resultant mixture of hydrophilic silica particles 22 , hydrophobic silica particles 24 and water is set aside for a period of about 24 hours during which it is maintained at a constant temperature of about 20° C. and isolated from mechanical vibration and shock. During this 24-hour period the mixture becomes a powder.
[0068] It is noted that a cosmetic powder, in accordance with an embodiment of the present invention, similar to powder 50 can be produced in which the water encapsulated by shells 58 contains desired substances, such as vitamins and anti-aging compounds, beneficial to skin care. The substances are added to the water used in producing the powder prior to adding the hydrophilic particles to the water in the process of producing the powder. The added substances will generally change a powder threshold concentration of hydrophobic particles required to produce a stable cosmetic powder in accordance with an embodiment of the present invention.
[0069] An emulsion or powder, in accordance with an embodiment of the present invention, corresponding to an emulsion or powder comprising hydrophilic and hydrophobic silica particles can, as noted above, be formed from hydrophilic and hydrophobic particles based on oxides other than silica or on a mix of oxides. Quantities of the “other or mixed oxide” hydrophobic and hydrophilic particles in the corresponding emulsion or powder are quantities that provide substantially same total surface areas as surface areas provided by the quantities of hydrophilic and hydrophobic particles respectively comprised in the silica based emulsion or powder. Cosmetic emulsions and powders for which total surface areas of the other or mixed oxide hydrophobic and hydrophilic particles are different from total surface areas of the silica based hydrophilic and hydrophobic particles may also be formed, in accordance with embodiments of the present invention.
[0070] FIGS. 3 A- 3 D schematically show functioning of cosmetic emulsion 20 to improve appearance and relieve wrinkling in a region of skin 70 to which the emulsion is applied, in accordance with an embodiment of the present invention.
[0071] [0071]FIG. 3A schematically shows cosmetic emulsion 20 and skin 70 to which the emulsion is applied in a plan view when the emulsion is first applied to the skin. The region of skin 70 has wrinkle furrows indicated by shaded bands 74 , sweat gland ducts 76 and hair follicles 78 in which hairs 80 are located. Cosmetic emulsion 20 is applied to the region of skin 70 so that the emulsion forms a thin layer on the region indicated by a shaded area 19 . In accordance with an embodiment of the present invention, layer 19 of emulsion 20 is left on the skin for an application period of from about 3 to about 10 minutes.
[0072] [0072]FIG. 3B shows a cross-sectional view along a line A-A of layer 19 of cosmetic emulsion 20 and the region of skin 70 on which the emulsion is located shown in FIG. 3A. The cross sectional view shows a surface 72 of skin 70 and a wrinkle furrow 74 in the surface, in which a sweat gland duct 76 and a hair follicle 78 are located. A hair 80 is located in hair follicle 78 and the hair follicle has a sebaceous gland 83 having a duct 84 . A dead skin cell 86 to the right of sweat gland duct 76 adheres to surface 72 of skin 70 .
[0073] Hydrophilic particles 22 from emulsion 20 migrate to and enter sweat gland duct 76 and form a tendril 77 of hydrophilic particles in the sweat gland duct as a result of the relatively high concentration of water in the duct. Hydrophobic particles 24 migrate to hair follicle 78 and enter into sebaceous gland duct 84 forming a tendril 85 of the hydrophobic particles in the hair follicle and duct as a result of the relatively high concentration of natural body oil in the duct and hair follicle. Hydrophilic and hydrophobic tendrils 77 and 85 and similar tendrils in other regions (not shown) of skin 70 attach emulsion layer 19 to the skin.
[0074] Water and hydrophobic particles 24 also tend to concentrate between dead skin cell 86 and surface 72 of skin 70 as a result of capillary action and a relatively high concentration of oil that covers the dead skin cell. The hydrophobic particles 24 between dead skin cell 86 and skin surface 72 tend to “pry up” and dislodge the dead skin cell from the skin surface. Water 26 in emulsion 20 , which contacts skin 70 , tends to diffuse into cells, blood vessels and interstitial fluid (not shown) in the skin and swell the cells and blood vessels and increase volume of the interstitial fluid. The swelling of the cells and blood vessels and expansion of the interstitial fluid tends to puff out wrinkle furrows 74 . However, as a result of loss of water from cosmetic layer 19 to skin 70 , volume of the cosmetic emulsion layer shrinks.
[0075] [0075]FIG. 3C schematically shows a plan view of cosmetic layer 19 after its volume has shrunk from loss of water. As a result of shrinkage, voids 80 form in cosmetic layer 19 and the layer is transformed from a relatively homogeneous layer covering a continuous region of skin 70 to a network 82 of strands 84 covering the skin region. Network 82 is anchored to skin 70 by hydrophilic and hydrophobic tendrils 77 and 85 (FIG. 3B) that protrude respectively into sweat gland ducts 76 and hair follicles 78 in skin 70 . Each strand 84 contains aqueous slurry of filaments of hydrophilic particles 22 and adhered water molecules and hydrophobic particles 24 . As a result of attractive forces between the particles and between the particles and water in the slurry, each strand tends to contract along its length with substantial force as it loses water. The contractive forces generated by strands 84 in network 82 apply forces to wrinkle furrows 74 in skin 70 that tend to pull out and flatten the wrinkle furrows.
[0076] [0076]FIG. 3D schematically shows a cross section view of skin 70 and network 82 along line A-A shown in FIG. 3C which is the same line shown in FIG. 3A along which the cross-section view shown in FIG. 3B is taken. The cross-section view schematically shows the cosmetic affect of cosmetic emulsion 20 in ameliorating wrinkling in skin 70 during the application period of emulsion 20 to the skin. Wrinkle furrow 74 shown in FIG. 3B is substantially flattened in FIG. 3D. It is noted that in an experiment carried out by the inventor, depth of a relatively deep wrinkle furrow in a patient's skin was reduced by about 2 mm during an application period of a cosmetic emulsion similar to cosmetic emulsion 20 .
[0077] Also, as shown in FIG. 3D, during the application period a sufficient quantity of hydrophobic particles 24 and water have become lodged under dead skin cell 86 so that the skin cell is detached from surface 72 of skin 70 . When emulsion 20 is removed from skin 70 dead skin cell 86 is removed with the emulsion, leaving a fresher more vibrant looking region of skin where previously the dead skin cell was attached.
[0078] It is noted that network 82 of strands 84 adheres tenaciously to skin 70 . In some embodiments of the present invention after network 82 is formed, excess emulsion is removed from skin 70 so as to leave network 82 substantially in place. This may be accomplished for example by gentle washing of the skin with water. Network 82 is substantially invisible, or may be easily camouflaged with suitable makeup, and the inventors have found that it can remain in place for periods of hours after treatment. In accordance with an embodiment of the present invention, anti-wrinkling action of network 82 in the region of skin on which it is located is “resurrected” by simply applying water to the skin. Network 82 absorbs some of the applied water causing strands 84 to tend to relax and elongate, relaxing thereby tension on the skin. Subsequently, network 82 releases water into the skin, as a result of which, strands 84 will again tend to contract and flatten wrinkles in the skin.
[0079] In some embodiments of the present invention, anti-wrinkling action is resurrected by applying a suitable cream, such as a moisturizing cream or a nutritional cream such as a cream comprising vitamin A or beta-carotine, having a component that is absorbed by the network and subsequently released to the skin. The component of the cream absorbed by the network and released to the skin may be an oil and/or water.
[0080] A region of skin treated with an emulsion, in accordance with an embodiment of the present invention, similar to emulsion 20 can therefore reduce wrinkling and keep the region of skin looking fresh and vibrant for an extended period of time by periodically applying water to the treated skin.
[0081] The functioning of a cosmetic powder, in accordance with an embodiment of the present invention, similar to cosmetic powder 50 is similar to the functioning of cosmetic emulsion 20 described above. When the powder is applied to the skin, shells in the powder that encapsulate water rupture and release the water they contain. The water and hydrophilic and hydrophobic particle “debris” from the shells form a cosmetic layer on the skin similar to cosmetic layer 19 shown in FIGS. 3 A- 3 D.
[0082] The powder form of a cosmetic substance in accordance with an embodiment of the present invention however generally produces a thinner, less visible cosmetic layer on the skin than the emulsion form of the cosmetic substance. It is therefore generally more convenient for use as a cosmetic to maintain skin appearance when in public. For example a man or woman can conveniently carry the powder form of the cosmetic to freshen up his or her skin during a “powder break” to the bathroom during an evening out.
[0083] In the description and claims of the present application, each of the verbs, “comprise” “include” and “have”, and conjugates thereof, are used to indicate that the object or objects of the verb are not necessarily a complete listing of members, components, elements or parts of the subject or subjects of the verb.
[0084] The present invention has been described using detailed descriptions of embodiments thereof that are provided by way of example and are not intended to limit the scope of the invention. The described embodiments comprise different features, not all of which are required or present in all embodiments of the invention. Some embodiments of the present invention utilize only some of the features or possible combinations of the features. Variations of embodiments of the present invention that are described and embodiments of the present invention comprising different combinations of features noted in the described embodiments will occur to persons of the art. The scope of the invention is limited only by the following claims.
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An emulsion comprising: water; hydrophilic particles; and hydrophobic particles; wherein the hydrophilic and hydrophobic particles form shells encapsulating a gas that are suspended in the water, said shells comprising an external layer of hydrophilic particles and an internal layer of hydrophobic particles adjacent to the layer of hydrophilic particles.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
Embodiments of the present invention relate to an injection blow molding apparatus and method for forming molded articles.
2. Description of the Related Art
Injection blow molding (IBM) is a technique used for creating various containers such as plastic bottles for medication or other contents. The IBM process is performed with an IBM machine that first injection molds a resin into a plurality of parisons of desired shapes and then blow molds the parisons into the final molded articles.
An injection station of the IBM machine typically includes a split parison mold assembly that defines a plurality of cavities within which the parisons are formed. In the injection molding stage of the IBM process, the parison-forming surfaces of the split parison mold are heated to and/or cooled to different temperatures via a plurality of water lines foamed in the split parison mold near the parison-forming surfaces. The water lines may be supplied with water at different temperatures depending on the location of the water line relative to the neck or body of the parison being formed. Typically, a plurality of individual thermolators are required to control the temperature of water supplied to the various water lines in the parison mold and an operator is required to use a significant amount of discretion in making adjustments to the water temperature flowing through water lines at different locations along the body and/or neck of the parison during the injection blow molding process.
The operator discretion necessary to make certain parison mold designs function properly requires highly experienced IBM operators and can require significant trial and error in order to determine satisfactory operating parameters. Further, the complexity of manufacturing and operating split parison molds with multiple water lines formed therein can result in high capital costs, high operating costs, and high maintenance costs.
Thus, it would be desirable to have an injection molding system and/or process where IBM operator discretion is minimized, trial-and-error operation of the IBM operator is minimized, and mold tooling design, fabrication, replacement, and maintenance costs are minimized.
SUMMARY OF THE INVENTION
Some embodiments of the invention disclose an injection blow molding system for injection molding a resin into a plurality of parisons and blow molding the parisons into a plurality of molded articles. The injection blow molding system includes an injection station for injection molding the resin into the parisons, a blowing station for blow molding the parisons into the molded articles, and an indexing head for transferring the parisons from the injection station to the blowing station. The injection station includes first and second die sets shiftable between an open position and a closed position, a plurality of first individual body mold halves coupled to the first dies set and spaced apart from one another, and a plurality of second individual body mold halves coupled to the second die set and spaced apart from one another. Each of the first individual body mold halves has a corresponding second individual body mold half, and each pair of corresponding first and second individual body mold halves cooperatively defines the exterior shape of the body of one of the parisons.
Other embodiments of the invention disclose an injection blow molding system for injection molding a resin into a plurality of parisons and blow molding the parisons into a plurality of molded articles. The injection blow molding system includes an injection station for injection molding the resin into the parisons, a blowing station for blow molding the parisons into the molded articles, and an indexing head for transferring the parisons from the injection station to the blowing station. The injection station includes first and second die sets shiftable between an open position and a closed position, a plurality of first individual mold halves independently coupled to the first die set, and a plurality of second individual mold halves independently coupled to the second die set. Each of the first individual body mold halves has a corresponding second individual body mold half and each pair of corresponding first and second individual body mold halves cooperatively defines the exterior shape of the body of one of the parisons.
Some embodiments of the invention disclose an injection blow molding process. The injection blow molding process includes a step of injection molding a resin into a plurality of parisons at an injection station. The injection molding step includes the substeps of shifting first and second die sets of the injection molding station from an open position to a closed position and injecting the resin into a plurality of parison cavities cooperatively defined by first and second mold half assemblies coupled to the first and second die sets respectively. The first mold half assembly includes a plurality of first individual body mold halves independently coupled to the first die, and the second mold half assembly includes a plurality of second individual body mold halves independently coupled to the second die set. Each of the first individual body mold halves has a corresponding second individual body mold half for cooperatively defining the exterior shape of the body of one of the parisons. The injection blow molding process further includes a step of transferring the parisons from the injection station to a blowing station and a step of blow molding the parisons into molded articles at the blowing station.
BRIEF DESCRIPTION OF THE FIGURES
Embodiments of the present invention are described in detail below with reference to the attached drawing figures, wherein:
FIG. 1 is a block diagram of a system for producing blow molded articles, particularly illustrating an injection blow molding apparatus and systems for supplying resin and heat transfer fluid to an injection station of the injection blow molding apparatus;
FIG. 2 is a plan view of an injection blow molding apparatus, particularly illustrating the apparatus's injection station, blowing station, ejection station, and indexing head;
FIG. 3A is a side view of the injection station depicted in FIG. 1 , particularly illustrating the injection mold die sets, split injection mold assembly, and resin manifold assembly;
FIG. 3B is a side view of the blowing station depicted in FIG. 1 , particularly illustrating the blow mold die sets and split blow mold assembly;
FIG. 3C is a schematic side view of the ejection station depicted in FIG. 1 , particularly illustrating the stripper plate used to remove blow molded articles from the core rods of the indexing head;
FIG. 4 is an isometric view of an injection station configured in accordance with a first embodiment of the present invention, particularly illustrating the injection station in an open position with two die sets attached to a split parison mold assembly comprising monolithic neck mold halves and monolithic body mold halves forming a plurality of parison cavities;
FIG. 5 is an isometric view of the injection station of FIG. 4 in a closed position;
FIG. 6 is an isometric view of the injection station of FIG. 5 illustrating a plurality of heat transfer channels in phantom located within the die sets and the split parison mold assembly;
FIG. 7 is a side view of the injection station depicted in FIG. 5 , particularly illustrating the interaction between the heat transfer channels in the die sets and the heat transfer channels in the neck mold halves and also showing an absence of heat transfer channels in the body mold halves;
FIG. 8 is a top view of the injection station of FIG. 5 illustrating the heat transfer channels in phantom and includes arrows depicting the direction of flow of heat transfer fluid through the heat transfer channels from an inlet to an outlet thereof;
FIG. 9 is a cutaway front view of the injection station depicted in FIG. 5 , particularly illustrating the configuration of the heat transfer channels in the neck molds;
FIG. 10 is a fragmentary cross-sectional view of the heat transfer channels taken along line 10 - 10 in FIG. 7 , including arrows depicting the direction of flow of heat transfer fluid through the heat transfer channels in the die sets to the heat transfer channels in the neck mold halves;
FIG. 11 is an isometric view of the upper neck mold half of FIG. 4 illustrating the open-sided configuration of the contoured heat transfer channels, as well as the interlock seal recesses formed around the contoured channels;
FIG. 12 is cross-sectional side view of the injection station taken along line 12 - 12 in FIG. 9 ;
FIG. 13 is a cross-sectional side view of the injection station taken along line 13 - 13 in FIG. 9 ;
FIG. 14 is a fragmentary, cross-sectional, enlarged side view of the neck mold halves as illustrated in FIG. 14 , particularly illustrating how the portion of the heat transfer channel closest to the surface of the parison cavity is cooperatively defined by the neck mold halves and interlock insert halves;
FIG. 15 is a fragmentary, cross-sectional, enlarged front view of one of the heat transfer channels in one of the neck mold halves, illustrating relationships between a neck-forming surface and its corresponding contoured channel;
FIG. 16 is an isometric view of the injection station of FIG. 5 and illustrates a plurality of mechanical fasteners joining the split parison mold assembly with the die sets;
FIG. 17 is a side view of the injection station depicted in FIG. 5 , particularly illustrating the mechanical fasters joining the interlock insert halves, neck mold halves, and body mold halves together and to the first and second die sets, respectively;
FIG. 18 is a cutaway top view of the injection station depicted in FIG. 16 , particularly illustrating the spacing of the mechanical fasteners extending horizontally through the interlock insert halves, neck mold halves, and body mold halves;
FIG. 19 is a front view of the injection station depicted in FIG. 16 , particularly illustrating the spacing of the mechanical fasteners extending vertically through the first or second die set and portions of the split parison mold assembly;
FIG. 20 is an isometric view of an injection station configured in accordance with a second embodiment of the present invention, particularly illustrating the injection station in an open position with two die sets attached to a plurality of first or second individual mold halves, each individual mold half comprising an individual neck mold half and an individual body mold half forming one of the parison cavities;
FIG. 21 is an isometric view of the injection station of FIG. 20 in a closed position;
FIG. 22 is a front view of the injection station of FIG. 21 , particularly illustrating mechanical fasteners independently attaching each of the individual mold halves to the first or second die set; and
FIG. 23 is a cross-sectional side view of the injection station of FIG. 21 , particularly illustrating individual body mold halves and individual interlock inserts independently attached to the first or second die set.
The drawing figures do not limit the present invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.
DETAILED DESCRIPTION
The following detailed description of the invention references the accompanying drawings that illustrate specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of the present invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.
In this description, references to “one embodiment”, “an embodiment”, or “embodiments” mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to “one embodiment”, “an embodiment”, or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, act, etc. described in one embodiment may also be included in other embodiments, but is not necessarily included. Thus, the present technology can include a variety of combinations and/or integrations of the embodiments described herein.
An injection blow molding system 30 , as illustrated in FIGS. 1-23 , is configured for injection molding a resin into a plurality of parisons and blow molding the parisons into a plurality of molded articles. As illustrated in FIG. 1 , the injection blow molding system 30 may comprise: a resin source 32 , a resin feed system 34 , a heat transfer fluid source 36 , a temperature control system 38 comprising at least one temperature control unit 40 , and an injection blow molding (IBM) machine 42 .
The resin source 32 may be any apparatus for producing and/or storing resin suitable for being molded and hardened into one or more molded articles. For example, the resin provided at the resin source 32 may be polyolefin resin. The resin feed system 34 may be coupled in fluid-flow communication with the resin source 32 and configured to inject resin into cavities of a mold of the IBM machine 42 , as described below.
The heat transfer fluid source 36 may be any system capable of providing an amount of heat transfer fluid sufficient to supply the heat transfer fluid to desired portions of the IBM machine 42 in a desired quantity and for a desired length of time during an injection molding process. For example, the heat transfer fluid source 36 may be a water supply or a supply of any fluid of a sufficient viscosity to freely flow throughout desired portions of the IBM machine 42 . The heat transfer fluid may also have sufficient thermal characteristics to remain within a desired temperature range as it flows through the desired portions of the IBM machine 42 , as described in detail below.
The temperature control system 38 may comprise one or more of the temperature control units 40 (e.g., thermolators) coupled in fluid-flow communication with the heat transfer fluid source 36 and operable to control the temperature of the heat transfer fluid within a predetermined temperature range. In some embodiments, a plurality of the temperature control systems 38 and/or a plurality of the temperature control units 40 may be provided. However, in some embodiments, only one temperature control unit 40 is used to control the temperature of heat transfer fluid injected into the IBM machine 42 . The temperature control unit 40 may provide heat transfer fluid of a substantially uniform temperature to the desired portions of the IBM machine 42 , as described in detail below.
As illustrated in FIG. 2 , the IBM machine 42 may be configured for injection blow molding a plurality of parisons and/or molded articles. The IBM machine 42 may comprise an indexing head 44 , an injection station 46 , a blowing station 48 , and an ejection station 50 . The injection blow molding process performed with the IBM machine 42 may include inserting polyolefin resin at the injection station 46 to form the parisons while simultaneously passing a heat transfer fluid through heat transfer channels defined within the injection station 46 to regulate the temperature of the injection station 46 , as described below. The injection blow molding process may then include actuating the indexing head 44 to transfer the resulting parisons from the injection station 46 to the blowing station 48 to be blow molded into molded articles. Next, the molded articles may be transferred via the indexing head 44 to the ejection station 50 , where the parisons are then ejected from the IBM machine 42 . The injection blow molding process described herein may be performed repetitively by the IBM machine 42 . For example, the method steps described herein may be repeated at least 100, 1,000, or 10,000 consecutive times.
The indexing head 44 is configured for transferring the parisons from the injection station 46 to the blowing station 48 and then to the ejection station 50 . The indexing head 44 may comprise a face block 52 on one or more outward-facing sides thereof, one or more core rod retainer plates 56 attached to the face blocks 52 , and one or more core rods 54 attached to the core rod retainer plates 56 . Each of the core rods 54 may be spaced a distance apart from adjacent core rods 54 and may be shaped according to a desired interior shape of the parisons to be formed thereon. In one embodiment of the IBM machine 42 , the indexing head 44 may be configured to rotate the core rods 54 from the injection station 46 to the blowing station 48 and then to the ejection station 50 as directed by an operator or automated control devices (not shown). For example, the face blocks 52 may be arranged in a substantially triangular configuration with core rods 54 protruding from one or more sides of the triangular configuration, and the indexing head 44 may rotate approximately 120 degrees to move the core rods 54 on one side of the triangular configuration from the injection station 46 to the blowing station 48 . In some embodiments of the injection blow molding system 30 , the indexing head 44 may have core rods 54 protruding from each side, such that the injection station 46 , blowing station 48 , and ejection station 50 may each operate simultaneously on a different set of parisons or molded articles.
The injection station 46 may be configured for injection molding the resin into the parisons. Specifically, the injection blow molding process may comprise injection molding a resin into a plurality of parisons at the injection station 46 . As depicted in FIG. 1 , the injection station may be fluidly coupled with the resin source 32 , the resin feed system 34 , the heat transfer fluid source 36 , and the temperature control system 38 and/or unit 40 . The injection station 46 may comprise at least a portion of the resin feed system 34 , as illustrated in FIG. 4 . For example, the resin feed system 34 may comprise or be fluidly coupled with an injection manifold 58 and one or more nozzles 60 positioned and configured for injecting resin into the one or more parison cavities.
Referring again to FIG. 2 , the blowing station 48 may be configured for blow molding the parisons into the molded articles and the injection blow molding process may include the steps of transferring the parisons from the injection station 46 to the blowing station 48 and then blow molding the parisons formed at the injection station 46 into molded articles at the blowing station 48 .
As shown in FIG. 3B , the blowing station 48 may comprise an upper die shoe 62 , a lower die shoe 64 , an upper mold half 66 coupled to the upper die shoe 62 , and a lower mold half 68 coupled to the lower die shoe 64 . The upper die shoe 62 and/or the lower die shoe 64 may be movable toward and away from each other, moving the blowing station 48 between an open position and a closed position. For example, the upper die shoe 62 and its corresponding upper mold half 66 may move upward and downward on a blowing station guide pin 70 fixed relative to the lower die shoe 64 and/or the lower mold half 68 .
As shown in FIGS. 2 and 3C , the ejection station 50 may comprise a stripper plate 72 or any other device configured for pushing, pulling, dumping, or otherwise stripping the parisons off of the core rods 54 once they have been blow molded. For example, once the indexing head 44 moves the molded articles from the blowing station 48 to the ejection station 50 , the stripper plate may be inserted adjacent to a top edge of the necks of the molded articles, between the necks and a center point of the indexing head 44 . Then the stripper plate 72 may be moved laterally away from the center point of the indexing head 44 , thus stripping the core rods 54 of the molded articles resting thereon.
In some embodiments of the IBM machine 42 described above, a conventional indexing head 44 , blowing station 48 , and/or ejection station 50 may be used. However, the injection station 46 disclosed herein may comprise a multitude of improvements over prior art injection stations. Referring now to FIGS. 3 a and 4 - 7 , in various embodiments of the IBM machine 42 described herein, the injection station 46 may comprise first and second die sets 74 , 76 , a split parison mold assembly 78 comprising first and second parison mold halves 80 , 82 coupled to the first and second die sets 74 , 76 respectively, and a plurality of heat transfer channels 84 (dashed lines in FIGS. 6 and 7 ) defined within the die sets 74 , 76 and/or the split parison mold assembly 78 for regulating a temperature of the parison forming surfaces of the split parison mold assembly 78 . The first and second parison mold halves 80 , 82 may also be referred to herein as first and second mold half assemblies. When the pair of first and second die sets 74 , 76 is shifted from an open position to a closed position, the first and second parison mold halves may cooperatively define one or more parison cavities 86 . In some embodiments of the injection station 46 , the first and/or second die sets 74 , 76 may slide along an injection station guide pin 88 when actuated between the open and closed positions.
The first and second die sets 74 , 76 (also referred to herein as upper and lower die sets of the injection station 46 ) may be formed of nickel plate or other die set materials known in the art. The die sets 74 , 76 may be shiftable between the open position and the closed position, as mentioned above. The injection blow molding process may therefore include a step of shifting the first and second die sets 74 , 76 of the injection molding station 46 from the open position to the closed position and from the closed position to the open position. At least one of the die sets 74 , 76 may be configured to actuate toward and away from the other of the die sets 74 , 76 . For example, the first die set 74 may move toward and away from the second die set 76 along the injection station guide pin 88 .
The first and second parison mold halves 80 , 82 of the split parison mold assembly 78 may be directly coupled to the first and second die sets 74 , 76 respectively. As used herein, the term “directly coupled” denotes connection of a first component to a second component in a manner such that at least a portion of the first and second components physically contact one another. The first parison mold half 80 may have a first parison cavity surface 90 ( FIG. 13 ) and the second parison mold half 82 may have a second parison cavity surface 92 ( FIG. 13 ). When the split parison mold assembly 78 is in the closed position, the first and second parison cavity surfaces 90 , 92 may define the one or more parison cavities 86 within which the resin is received. The resin feed system 34 may be coupled in fluid-flow communication with the parison cavities 86 and operable to inject the resin into the parison cavities 86 .
The injection blow molding process may include injection molding a polyolefin resin into a plurality of parisons at the injection station 46 . This injection molding process may comprise shifting the split parison mold assembly 78 from the open position to the closed position, then introducing or injecting the resin, such as polyolefin resin, into the parison cavities 86 cooperatively defined by the first and second parison cavity surfaces 90 , 92 of the split parison mold assembly 78 when the split parison mold assembly 78 is in the closed position. The resin fills the parison cavities 86 and may remain therein until it hardens to a point at which it can at least temporarily hold its shape when the split parison mold assembly 78 is opened. Then the die sets 74 , 76 may be shifted from the closed position to the open position and the parisons may be removed from the parison mold halves 80 , 82 while the die sets 74 , 76 are in the open position.
As perhaps best illustrated in FIGS. 13 and 14 , each of the parison cavity surfaces 90 , 92 may comprise a body-forming surface 94 , 96 for defining the exterior shape of the bodies of the parisons and a neck-forming surface 98 , 100 for defining the exterior shape of the necks of the parisons when the split parison mold 78 is in the closed position.
In various embodiments of the injection station 46 , the split parison mold assembly 78 may comprise first and second body mold halves 102 , 104 , first and second neck mold halves 106 , 108 , and first and second interlock insert halves 110 , 112 coupled to the first and second die sets 74 , 76 respectively. The neck-forming surfaces 98 , 100 ( FIG. 14 ) may be formed into the neck mold halves 106 , 108 and the body-forming surfaces 94 , 96 may be formed into the body mold halves 102 , 104 , respectively.
In some embodiments of the injection station 46 , the body mold halves 102 , 104 are each monolithic components having a plurality of the parison body-forming surfaces 94 , 96 formed therein via a molding or milling manufacturing process. As used herein, the term “monolithic” means formed of a single body or member; not of multiple bodies or members fastened together. The monolithic body mold halves 102 , 104 may be configured such that the first body mold half 102 and the second body mold half 104 cooperatively define the exterior shape of the bodies of at least two, at least four, or at least six of the parisons. In other embodiments of the injection station 46 , as described below, the body mold halves 102 , 104 may each comprise a plurality first body mold halves 102 and a plurality of second body mold halves 104 each independently coupled to one of the die sets 74 , 76 , with each first body mold half 102 and each corresponding second body mold half 104 comprising at least one body-forming surface 94 , 96 formed therein.
The first and second neck mold halves 106 , 108 can be directly coupled to the first and second die sets 74 , 76 respectively, and are disposed between the first and second body mold halves 102 , 104 and the first and second interlock inserts 110 , 112 respectively.
In some embodiments of the injection station 46 , the neck mold halves 106 , 108 are each monolithic components having a plurality of the parison neck-forming surfaces 98 , 100 formed therein via a molding or milling manufacturing process. The monolithic neck mold halves 106 , 108 may be configured such that the first neck mold half 106 and the second neck mold half 108 cooperatively define the exterior shape of the necks of at least two, at least four, or at least six of the parisons.
In other embodiments of the injection station 46 , as described below, the neck mold halves 106 , 108 may each comprise a plurality first neck mold halves 106 and a plurality of second neck mold halves 108 each independently coupled to one of the die sets 74 , 76 , with each first neck mold half 106 and each corresponding second neck mold half 108 comprising at least one neck-forming surface 98 , 100 formed therein.
The first and second interlock inserts 110 , 112 (also referred to herein as interlock insert halves) may be directly coupled to the first and second die sets 74 , 76 respectively, adjacent to the first and second neck mold halves 106 , 108 . The first and second neck mold halves 106 , 108 may be disposed between the first and second interlock inserts 110 , 112 and the first and second body mold halves 102 , 104 respectively. The interlock insert halves 110 , 112 along with the first and second neck mold halves 106 , 108 may cooperatively form at least a portion of the heat transfer channels 84 , as later described herein.
The heat transfer channels 84 , as illustrated in FIGS. 6-10 , are formed in the die sets 74 , 76 and/the parison mold halves 80 , 82 and are configured to receive the heat transfer fluid. For example, the heat transfer channels 84 may be configured to receive heat transfer fluid from the heat transfer fluid source 36 and pass the heat transfer fluid from heat transfer channels 84 defined within the first and second die sets 74 , 76 into heat transfer channels 84 defined within the first and second parison mold halves 80 , 82 respectively. Heat transfer fluid may be passed through the plurality of heat transfer channels 84 defined within the injection station 46 to regulate the temperature of at least a portion of the parison cavity surfaces 90 , 92 .
The heat transfer channels 84 may be coupled in fluid-flow communication with the heat transfer fluid source 36 and the temperature control system 38 . The temperature control system 38 may thus control the temperature of the heat transfer fluid fed into the heat transfer channels 84 . In some embodiments of the injection blow molding system 30 , there may be one or more temperature control systems 38 or temperature control units 40 , but only one of the temperature control units 40 may be associated with the injection station 46 and its heat transfer channels 84 . The injection molding process described herein may therefore further comprise passing the heat transfer fluid from a single temperature control unit 40 through all the heat transfer channels 84 defined within the injection station 46 . In some embodiments of the injection blow molding system 30 , all of the heat transfer fluid passed through the heat transfer channels 84 enters the injection station 46 at substantially the same temperature.
The injection station 46 may define one or more inlets 114 , 116 for receiving the heat transfer fluid from the temperature control unit 40 and one or more outlets 118 , 120 for allowing fluid to flow out of the heat transfer channels. In some embodiments of the injection blow molding system 30 , the injection station 46 may define no more than two inlets 114 , 116 for receiving the heat transfer fluid from the temperature control unit 40 into the heat transfer channels 84 . For example, each of the first and second die sets 74 , 76 may comprise only one inlet 114 , 116 , respectively, for receiving fluid to be passed through all of the heat transfer channels 84 defined with that die set and associated parison mold half.
As noted above, at least a portion of the heat transfer channels 84 may be defined within the first and second die sets 74 , 76 . Furthermore, at least a portion of the heat transfer channels 84 may be defined within the first and second parison mold halves 80 , 82 . For example, at least a portion of the heat transfer channels 84 may be defined within the first and second neck mold halves 106 , 108 of the first and second parison mold halves 80 , 82 . The heat transfer channels 84 defined within the first and second parison mold halves 80 , 82 may be connected in fluid-flow communication with at least a portion of the heat transfer fluid channels 84 defined within the first and second die sets 74 , 76 . For example, heat transfer fluid can be supplied to heat transfer channels 84 defined within the first and second parison mold halves 80 , 82 by heat transfer channels 84 defined within the first and second die sets 74 , 76 respectively.
As perhaps best illustrated in FIG. 8 , all of the heat transfer channels 84 defined within the first die set 74 may be connected in serial fluid-flow communication, and all of the heat transfer channels 84 defined within the second die set 76 may be connected in serial fluid-flow communication. As used herein, “serial fluid-flow communication” denotes the connection of multiple fluid carrying bodies or channels in a manner such that fluid flows sequentially through the multiple bodies or channels. The heat transfer channels 84 defined within each of the first and second die sets 74 , 76 may comprise a plurality of spaced-apart, substantially linear channels 122 . In some embodiments of the injection station 46 , each of the die sets may comprise a minimum of 2, 3, or 4 of the linear channels 122 and a maximum of 40, 20, or 8 of the linear channels 122 . Each of the linear channels 122 may have a length of at least 6, 12, or 16 inches and/or not more than 60, 48, or 36 inches. Furthermore, the linear channels 122 may extend substantially parallel to one another. The average lateral spacing between adjacent ones of the linear channels 122 may be at least 0.5, 0.75, 1.0, or 1.25 inches and/or not more than 8, 6, 4, or 2 inches. Furthermore, the average diameter of the linear channels 122 in the die sets 74 , 76 may be at least 0.05, 0.15, or 0.25 inches and/or not more than 3.0, 1.5, or 0.75 inches.
As mentioned above, the linear channels 122 may be coupled in serial fluid-flow communication with one another. For example, one or more crossing heat transfer channels 124 may be positioned proximate one or more ends of the linear channels 122 and may provide fluid communication between adjacent ones of the linear channels 122 . For example, the linear channels 122 and the crossing channels 124 may cooperatively define heat transfer channels that snake back and forth laterally across each of the die sets 74 , 76 . For example, the heat transfer fluid may travel in a first direction through a first one of the linear channels 122 , enter a first one of the crossing channels 124 or a first portion of one of the crossing channels 124 , and then flow in a second, opposite direction through a second one of the linear channels 122 . In some embodiments of the injection station 46 , plugs 126 may be strategically placed throughout the linear channels 122 and/or the crossing channels 124 , thereby directing the flow of the heat transfer fluid, as illustrated in FIG. 8 . Furthermore, the plugs 126 may also be placed at or into each end of the linear and crossing channels 122 , 124 to prevent heat transfer fluid from entering or exiting at any locations other than the inlets 114 , 116 and outlets 118 , 120 .
At least a portion of the heat transfer channels 84 defined within the die sets 74 , 76 connect the heat transfer channels 84 defined within the parison mold halves 80 , 82 in serial fluid-flow communication with one another. As illustrated in FIG. 10 , the parison mold halves 80 , 82 may each define at least two spaced-apart heat transfer channels, referred to herein as mold half channels 128 . The mold half channels 128 may be formed in the body mold halves 102 , 104 and/or the neck mold halves 106 , 108 , as later described herein. Specifically, the first and second die sets 74 , 76 may each comprise at least one connecting heat transfer channel or one connecting portion of one of the linear channels that provides fluid communication between the mold half channels 128 . For example, the mold half channels 128 may each have an inlet end 130 and an outlet end 132 in fluid communication with at least one of the linear channels 122 in the die sets. The linear channel 122 may have one of the plugs 126 placed therein between the inlet end 130 and the outlet end 132 of one of the mold half channels 128 to redirect the heat transfer fluid into that mold half channel 128 . The space between adjacent ones of the plugs 126 within the linear channels 122 in fluid communication with the mold half channels 128 may be referred to herein as a connecting portion or a connecting heat transfer channel 134 , because it fluidly connects the outlet end 130 of one mold half channel 128 with the inlet end 132 of another mold half channel 128 , as illustrated in FIG. 10 .
The inlet end 130 and the outlet end 132 of the mold half channels 128 may each be fluidly connected with the at least one of the linear channels 122 via extension channels 136 . In some embodiments of the injection station 46 , the extension channels 136 may extend downward from and substantially perpendicular to at least one of the linear channels 122 .
In some embodiments of the injection station 46 , the total volume of the heat transfer channels 84 may be at least 10, 20, or 40 cubic inches and/or not more than 500, 250, or 100 cubic inches. Additionally, the total volume of the heat transfer channels 84 defined within the first and second die sets 74 , 76 may be at least 5, 15 or 30 cubic inches and/or not more than 400, 200, or 80 cubic inches. The total volume of the heat transfer channels 84 defined within the first and second parison mold halves 80 , 82 may be at least 1, 3, or 5 cubic inches and/or not more than 100, 50, or 20 cubic inches. The total volume of the heat transfer channels 84 defined within the first and second body mold halves 102 , 104 may be less than 30, 15, or 5 cubic inches, and the total volume of the heat transfer channels 84 defined within the first and second neck mold halves 106 , 108 may be at least 1, 3, or 5 cubic inches and/or not more than 100, 50, or 20 cubic inches.
The ratio of the total volume of the heat transfer channels 84 defined within the die sets 74 , 76 to the total volume of heat transfer channels 84 defined in the split parison mold assembly 78 may be at least 1:1, 2.5:1, or 3.5:1 and/or not more than 20:1, 12:1, or 8:1. The ratio of the total volume of the heat transfer channels 84 defined within the die sets 74 , 76 to the total volume of heat transfer channels 84 defined in the body mold halves 102 , 104 may be at least 1:1. Thus, less than 50, 30, 25, 15, or 10 percent of the total volume of the heat transfer channels 84 in the injection station 46 may be defined within the body mold halves 102 , 104 . For example, in some embodiments of the injection station 46 none of the heat transfer channels 84 are defined within the body mold halves 102 , 104 . In various embodiments of the injection station 46 , at least 50, 60, or 70 percent of the total volume of the heat transfer channels 84 is located in heat transfer channels that are spaced more than 1, 3, or 5 inches from the parison cavity surfaces 90 , 92 .
In some embodiments of the injection station 46 , at least 20, 30, 50, or 70 percent and/or not more than 98, 95, or 90 percent of the total volume of the heat transfer channels 84 is defined within the die sets 74 , 76 . In some embodiments of the injection station 46 , at least 2, 5, or 10 percent and/or not more than 80, 50, or 30 percent of the total volume of the heat transfer channels 84 is defined within the split parison mold assembly 78 . In some embodiments of the injection station 46 , at least 2, 5, or 10 percent and/or not more than 80, 50, or 30 percent of the total volume of the heat transfer channels 84 may be defined within the neck mold halves 106 , 108 .
It may be desirable for the body-forming surfaces 94 , 96 of the parison molds 80 , 82 to stay within target temperature ranges during the injection molding process. In some embodiments of the injection station 46 , the target surface temperature of the body-forming surfaces (i.e., the target body surface temperature) may be at least 190, 200, or 205° F. and/or not more than 230, 220, or 215° F.
During the injection molding, while the resin is received in the parison cavities 86 , the surface temperature of at least 70, 80, or 90 percent of the total surface area of the body-forming surfaces 94 , 96 of the split parison mold assembly 78 may be maintained at or within 20, 10, or 5° F. of the target body surface temperature. For example, a target body surface temperature may be 210° F., and during the injection molding, the temperature of at least 90 percent of the total surface area of the body-forming surfaces 94 , 96 may be maintained between 205 and 215° F.
During the injection molding, the temperature of at least 70, 80, or 90 percent of the total surface area of the neck-forming surfaces 98 , 100 may be maintained within 20, 10, or 5° F. of a target neck surface temperature. For example, the temperature of at least 70, 80, or 90 percent of the total surface area of the neck-forming surfaces 98 , 100 may be maintained within a range having a minimum of 50 or 75° F. and a maximum of 150 or 175° F. In some embodiments of the injection station 46 , the target neck surface temperature may be at least 10, 25, or 50° F. less than the target body surface temperature. For example, if the target neck surface temperature is in the range of 50 to 175° F. then the target body surface temperature may be in the range of 190 to 230° F. In one example embodiment of the injection station 46 , the target body surface temperature may be 210° F., and the target neck surface temperature may be at least 25° F. less than the target body surface temperature.
In some embodiments of the injection station 46 , at least 75, 90, or 100 volume percent of the heat transfer fluid introduced into the heat transfer channels 84 is introduced at an inlet temperature that is at or within 20, 10, or 5° F. of a target inlet temperature. The target inlet temperature may be at least 40, 50, or 60° F. and/or not more than 150, 100, or 90° F. The temperature of the heat transfer fluid may be controlled in a single temperature control unit 40 (e.g., thermolator) prior to introducing the heat transfer fluid into the heat transfer channels 84 .
In certain embodiments, the neck mold halves 106 , 108 may be coupled to the die sets 74 , 76 independently of the body mold halves 102 , 104 . A first insulating gap 138 may be defined between at least a portion of the first body mold half 102 and the first neck mold half 106 , and a second insulating gap 140 may be defined between at least a portion of the second body mold half 104 and the second neck mold half 108 .
As noted above, at least a portion of the heat transfer channels 84 may be defined within the first and second neck mold halves 106 , 108 . For example, at least some of the spaced-apart heat transfer channels or mold half channels 128 may be partially or entirely defined within the first and second neck mold halves 106 , 108 . In some embodiments of the injection station 46 , at least a portion of the heat transfer channels 84 defined within the first and second neck mold halves 106 , 108 may be spaced at least 0.05, 0.1, or 0.15 inches and/or not more than 2, 1, or 0.5 inches from the neck-forming surfaces 98 , 100 . In some embodiments of the injection station 46 , all of the heat transfer channels 84 that are spaced less than 1 inch from the first and second parison cavity surfaces 90 , 92 are defined within the neck mold halves 106 , 108 .
The heat transfer channels 84 defined in the first and second neck mold halves 106 , 108 may include a plurality of contoured channels 142 associated with the neck-forming surfaces 98 , 100 . As perhaps best shown in FIG. 15 , the curvature of the contoured channels 142 may substantially correspond to the curvature of the necks of the parisons to be formed at the injection station 46 . Specifically, the contoured heat transfer channels 142 may include an inner face 144 having a shape that substantially corresponds to the shape of the neck-forming surface 98 , 100 with which it is associated.
As illustrated in FIGS. 14 and 15 , the curvature of each of the contoured heat transfer channels 142 may be substantially concentric with the curvature of the neck of the parison with which it is associated and the neck-forming surface 98 , 100 with which it is associated. The inner face 144 of the contoured heat transfer channel 142 may have an arcuate shape. The inner face 144 of the contoured heat transfer channel 142 may also be spaced from the neck-forming surface 98 , 100 with which it is associated by a distance S (as illustrated in FIG. 15 ), which may be at least 0.05, 0.1, or 0.15 inches and/or not more than 2, 1, or 0.5 inches. The inner face 144 of the contoured heat transfer channel 142 may have a radius of curvature r 1 that is at least 0.25, 0.5, 0.75, or 1 inch and/or not more than 5, 3, or 2. Furthermore, the inner face 144 of the contoured heat transfer channel 142 may extend through an angle θ (as illustrated in FIG. 15 ) that is at least 90, 120, or 140 degrees and/or not more than 175 or 180 degrees. The radius of the neck-forming surface 98 , 100 is denoted by r 2 in FIG. 15 . The length of each of the contoured channels 142 may be at least 1, 1.25, or 1.5 inches and/or not more than 10, 8, or 5 inches.
At least one of the contoured channels 142 may be located between and fluidly connected to a supply channel 146 and a return channel 148 , with the supply channel 146 extending to the inlet end 130 and the return channel 148 extending to the outlet end 132 of the mold half channels 128 . The supply and return channels 146 , 148 may extend from the contoured heat transfer channel 142 in a direction that is generally away from the neck-forming surface 98 , 100 with which the contoured heat transfer channel 142 is associated. The supply and return channels 146 , 148 may be substantially linear and/or parallel with each other and connected to generally opposite ends of the contoured heat transfer channel 142 . The supply and return channels 146 , 148 may also be substantially perpendicular relative to the linear channels 122 in the die sets 74 , 76 .
In some embodiments of the injection station 46 , the first and second interlock inserts 110 , 112 may be disposed adjacent the first and second neck mold halves 106 , 108 respectively, such that at least a portion of the contoured channels 142 are cooperatively defined by the interlock inserts 110 , 112 and the neck mold halves 106 , 108 , as illustrated in FIGS. 13-14 . For example, the contoured channels 142 may be milled into a front face of the neck mold halves 106 , 108 , and then the first and second interlock inserts 110 , 112 may be attached to the front face of the first and second neck mold halves 106 , 108 respectively, thereby cooperatively forming the contoured channels 142 .
An interlock seal 150 may be placed around a periphery of each of the contoured channels 142 at the front face of the neck mold halves 106 , 108 , such that the interlock seal 150 is disposed between the neck mold halves 106 , 108 and their corresponding interlock inserts 110 , 112 . The interlock seal 150 may be a gasket, sealant, or any other sealing device configured to prevent heat transfer fluid from leaking between the front face of the neck mold halves 106 , 108 and the interlock inserts 110 , 112 .
As shown in FIG. 9 , the injection station 46 may further comprise a plurality of first and second sealing members 152 , 154 . The first and second sealing members may be gaskets, sealant, or any other sealing device configured to prevent heat transfer fluid from leaking between the inlet ends 130 and outlet ends 132 of the mold half channels 128 and the extension channels 136 fluidly connecting the linear channels 122 with the mold half channels 128 . Each of the first sealing members 152 may be disposed between the first die set 74 and the first parison mold half 80 proximate a location where one of the heat transfer channels 84 of the first die set 74 connects in fluid-flow communication with one of the heat transfer channels 84 in the first parison mold half 80 . Each of the second sealing members 154 may be disposed between the second die set 76 and the second parison mold half 82 proximate a location where one of the heat transfer channels 84 in the second die set 76 connects in fluid-flow communication with one of the heat transfer channels 84 defined in the second parison mold half 82 .
Each component of the split parison mold assembly 78 may be directly attached to its corresponding die set 74 , 76 . In some embodiments of the injection station 46 , various components may be independently attached to the die sets 74 , 76 . Specifically, the first and second body mold halves 102 , 104 , first and second neck mold halves 106 , 108 , and first and second interlock insert halves 110 , 112 may each be directly and independently coupled to the first or second die sets 74 , 76 , respectively. Therefore, the body mold halves 102 , 104 , neck mold halves 106 , 108 , and interlock insert halves 110 , 112 may each be independently disconnected from the die sets 74 , 76 without removing any of the other components.
As illustrated in FIGS. 16-19 , a plurality of male threaded members may couple the first and second interlock inserts, neck mold halves, and body mold halves to one another and/or to the first and second die sets, respectively. For example, the first and second monolithic neck mold halves may be directly coupled to the first and second die sets respectively, and the first and second body mold halves may be directly coupled to the first and second die sets respectively. The coupling of these components may be accomplished using a plurality of mechanical fasteners 156 .
For example, in the embodiments illustrated in FIGS. 16-19 , the mechanical fasteners 156 comprise a plurality of vertically-extending male threaded members extending through the first and second die sets 74 , 76 and into either one of the interlock insert halves 110 , 112 or one of the body mold halves 102 , 104 . In FIGS. 16-19 , the mechanical fasteners 156 also include a plurality of horizontally-extending male threaded members extending through the first or second interlock insert halves 110 , 112 , then through the first or second neck mold halves 106 , 108 , respectively, and into the first or second body mold halves 102 , 104 respectively.
FIGS. 4-19 illustrate an injection station 46 with the first and a second parison mold halves 80 , 82 , each comprising one monolithic body mold half, one monolithic neck mold half, and one monolithic interlocking insert half. However, in alternative embodiments illustrated in FIGS. 20-23 , a plurality of first individual mold halves 158 and a plurality of second individual mold halves 160 are each independently attached to their respective die sets 74 , 76 in a spaced-apart configuration. As used herein, the term “independently coupled” denotes connection of a first component to a second component in a manner such that disconnection and removal of the first component from the second component does not require disconnection of any fasteners other than the fasteners that contact and connect both the first or second components.
In this configuration, each of the first individual mold halves 158 has a corresponding one of the second individual mold halves 160 with which it cooperates to define a single one of the parison cavities 86 . In certain embodiments, each of the first individual mold halves 158 are horizontally-spaced from one another to thereby form first gaps 174 therebetween, and each of the second individual mold halves 160 are horizontally-spaced from one another to thereby form second gaps 176 therebetween.
Advantageously, no horizontally-extending fasteners are used or required to couple the first individual mold halves 158 to one another or to couple the second individual mold halves 160 to one another, since they are each independently attached to their respective die sets 74 , 76 . Specifically, each of the first individual mold halves 158 may be coupled to the first die set 74 by one or more vertically-extending mounting fasteners 156 , and each of the second individual mold halves 160 may be coupled to the second die set 76 by one or more vertically-extending mounting fasteners 156 . The vertically-extending mounting fasteners may each include a male threaded portion. In this embodiment of the injection station 46 , vertically-extending mounting fasteners may be the only means used to couple the first and second individual mold halves 158 , 160 to the first and second die sets 74 , 76 , respectively.
The plurality of first and second mold halves 158 , 160 may each comprise a first and second individual body mold half 162 , 164 , a first and second individual neck mold half 166 , 168 , and a first and second individual interlocking insert half 170 , 172 respectively. Specifically, the first and second body mold halves 102 , 104 may each comprise a plurality of first and second individual body mold halves 162 , 164 , each directly and independently coupled to the first or second die set 74 , 76 respectively and each configured to define at least a portion of the exterior shape of the body of only one of the parisons. Furthermore, the first and second neck mold halves 106 , 108 may each comprise a plurality of first and second individual neck mold halves 166 , 168 , each directly and independently coupled to the first or second die set 74 , 76 respectively and each configured to define at least a portion of the exterior shape of the neck of only one of the parisons. Also, the first and second interlocking insert halves 110 , 112 may each comprise a plurality of first and second individual interlocking insert halves 170 , 172 each directly and independently coupled to the first or second die set 74 , 76 respectively. The individual body mold halves 162 , 164 may each be spaced apart from one another, the individual neck mold halves 166 , 168 may each be spaced apart from one another, and/or the individual interlocking insert halves 170 , 172 may each be spaced apart from one another.
Each of the first individual body mold halves 162 may have a corresponding second individual body mold half 164 , and each of the first individual neck mold halves 166 may have a corresponding second neck mold half 168 . Each pair of corresponding first and second individual body mold halves 162 , 164 may cooperatively defines the exterior shape of the body of one of the parisons, and each pair of corresponding first and second individual neck mold halves 166 , 168 may cooperatively define the exterior shape of the neck of one of the parisons. In some embodiments, the split parison mold of the injection station 46 may comprise at least two, four, or six of the first individual body mold halves 162 , 164 and at least two, four, or six of the second individual body mold halves 166 , 168 .
The individual first and second neck mold halves 166 , 168 may each have one of the mold half channels 128 formed therein and in fluid-flow communication with the heat transfer channels 84 in the first or second die set 74 , 76 . For example, heat transfer fluid may flow from a first mold half channel in one individual first neck mold half to a second mold half channel in an adjacent individual first neck mold half via a connecting portion of one of the linear channels 122 or via one of the connecting heat transfer channels 134 in the first die set 74 .
The injection molding process performed with the injection station 46 embodiment illustrated in FIGS. 20-23 is identical to the process performed with embodiments having primarily monolithic components, as in FIGS. 4-19 . For example, the injection molding process may comprise moving the split parison mold assembly 78 from the open to the closed position, with the core rods 54 disposed within the parison cavities 86 , then injecting resin into the plurality of parison cavities 86 . Simultaneously, the heat transfer fluid may be passed through the heat transfer channels 84 throughout the injection station 46 .
In some alternative embodiments of the injection station 46 , at least some components of the first and second parison mold halves 80 , 82 may be monolithic while other components are comprised of a plurality of individual components. For example, the first and second body mold halves 102 , 104 may each be monolithic components while the first and second neck mold halves 106 , 108 may comprise a plurality of first individual neck mold halves 166 and a plurality of second individual neck mold halves 168 .
In split parison mold configurations described above where at least some of the components of the split parison mold assembly 78 are independently coupled with the die sets 74 , 76 and are not directly coupled with each other, the IBM machine 42 may be reconfigured to produce different shapes and sizes of parisons and/or molded articles. For example, in an injection blow molding process, a first group of parisons may be injection molded at the injection station 46 using a first split parison mold assembly to define the exterior shape of the first group of parisons. The first group of parisons may then be blow molded into a first group of molded articles at the blowing station 48 . Next, at least one component of the first split parison mold assembly may be replaced with another component, thus creating a second split parison mold assembly attached to the die sets. Then a second group of parisons may be injection molded at the injection station 46 using the second split parison mold assembly to define the exterior shape of the second group of parisons. The second group of parisons may then be blow molded into a second group of molded articles at the blowing station 48 . The first and second groups of parisons may have different exterior shapes.
In some embodiments, the same blowing station 48 may be used to blow mold both the first and second groups of parisons into the first and second groups of molded articles respectively. Alternatively, the step of blow molding the first group of parisons may utilize a first blow mold assembly, such as a first upper mold half and a first lower mold half, to define the external shape of the first group of molded articles. Then the injection blow molding process may further comprise replacing the first blow mold assembly or the first upper and lower mold halves, with a second blow mold assembly, such as a second upper mold half and a second lower mold half. The second blow mold assembly may have a substantially different configuration than the first blow mold assembly. The step of blow molding the second group of parisons may thus utilize the second blow mold assembly, or second upper and lower mold halves, to define the external shape of the second group of molded articles. The first and second groups of molded articles have substantially different configurations.
As described above, the injection molding of the first and second groups of parisons may include passing heat transfer fluid through the heat transfer channels 84 defined within the injection station 46 . The temperature of the heat transfer fluid introduced into the injection station 46 may be substantially the same during the injection molding of the first group of parisons and the second group of parisons.
This method of exchanging components of the split parison mold assembly 78 may be particularly useful in an initial design of the split parison mold and/or the blowing station 48 . For example, if the first group of molded articles exhibits at least one undesirable characteristic, the second parison mold assembly may be configured to eliminate the undesirable characteristic in the second group of molded articles. Then the second parson mold assembly may replace the first parison mold assembly on the die sets 74 , 76 . The undesirable characteristic may include excessive wall thickness, inadequate wall thickness, and/or non-uniform wall thickness.
The exchangeable first and second parison mold assemblies may present respective first and second parison neck-forming surfaces for defining the external shape of the necks of the parisons in the first and second groups of parisons respectively. Furthermore, the first and second parison mold assemblies may present respective first and second parison body-forming surfaces for defining the external shape of the bodies of the parisons in the first and second groups of parisons respectively.
During the injection molding of each of the first and second groups of parisons, the surface temperature of at least 70 percent of the total surface area of the first and second parison body-forming surfaces is maintained at a temperature within 20° F. of the target body surface temperature. For example, the target body surface temperature may be 210° F., or may be in any of the ranges disclosed herein for the target body surface temperature. In one embodiment, during the injection molding of each of the first and second groups of parisons, the surface temperature of at least 90 percent of the total surface area of the first and second parison body-forming surfaces may be maintained in the range of 205 to 215° F. Furthermore, during the injection molding of each of the first and second groups of parisons, the temperature of at least 90 percent of the total surface area of the parison neck-forming surfaces may be maintained between 75 and 150° F.
Although the invention has been described with reference to the preferred embodiment illustrated in the attached drawing figures, it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims.
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An injection blow molding (IBM) system and method for forming a plurality of parisons and molded articles. The IBM system includes an injection station having two die sets and a plurality of first and second body mold halves each attached to a respective die set. Each of the first body mold halves has a corresponding second body mold half with which it cooperatively defines a cavity for forming the exterior shape of the body of one of the parisons. The individual, independent attachment of the body mold halves to the die sets allows easy individual replacement of faulty or worn molds. Further, such an attachment configuration also permits the body mold halves connected to a common die set to be spaced from one another, so as to reduce thermal expansion problems and ease dimensional tolerances required for the width of the body mold halves.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to radar timing circuits and more particularly to precision swept delay circuits for expanded time ranging systems. It can be used to correct errors in a swept-delay clock for sampling radar, Time Domain Reflectometry (TDR) and laser systems.
2. Description of Related Art
High accuracy pulse-echo ranging systems, such as wideband and ultra-wideband pulsed radar, pulsed laser rangefinders, and time domain reflectometers, sweep a timing circuit across a range of delays. The timing circuit controls a receiver sampling gate such that when an echo signal coincides with the temporal location of the sampling gate, a sampled echo signal is obtained. The echo range is then determined from the timing circuit, so high accuracy timing is essential. A stroboscopic time expansion technique is employed, whereby the receiver sampling rate is set to a slightly lower rate than the transmit pulse rate to create a stroboscopic time expansion effect that expands the apparent output time by a large factor, such as 100,000. Expanded time allows vastly more accurate signal processing than possible with realtime systems.
A common approach to generate accurate swept timing employs two oscillators with frequencies F T and F R that are offset by a small amount F T −F R =Δ. In a ranging application, a transmit clock at frequency F T triggers transmit pulses, and a receive clock at frequency F R gates the echo pulses. If the receive clock is lower in frequency than the transmit clock by a small amount Δ, the phase of the receive clock will slip smoothly and linearly relative to the transmit clock such that one full cycle is slipped every 1/Δ seconds. Such a clock system forms a swept phase clock system. The term phase can also relate to time, since phase is another way to express time difference between the two clocks. Typical parameters are: transmit clock F T =2 MHz, receive clock F R =1.99999 MHz, frequency offset Δ=10 Hz, phase slip period=1/Δ=100 milliseconds, and a time expansion factor of F T /Δ=200,000. This two-oscillator technique was used in the 1960's in precision time-interval counters with sub-nanosecond resolution, and it appeared in a short-range radar in U.S. Pat. No. 4,132,991, “Method and Apparatus Utilizing Time-Expanded Pulse Sequences for Distance Measurement in a Radar,” by Wocher et al.
There are many influences that can affect the accuracy of the phase slip, including: (1) oscillator noise due to thermal and flicker effects, (2) transmit-to-receive clock cross-talk, and (3) thermal transients that typically do not track out between the two oscillators. The receive oscillator is typically locked to the offset frequency by a phase locked loop (PLL) circuit, which does a reasonable job when the offset frequency is above several hundred Hertz. Unfortunately, precision long range systems require extremely high accuracy, on the order of picoseconds, at offset frequencies on the order of 10 Hz. A PLL system cannot meet this requirement for the simple reason that the PLL loop response must be slower than 1/Δ, or typically slower than 100 ms, which is far too slow to control short term phase errors between the two clocks.
U.S. Pat. No. 6,404,288 to Bletz et al addresses the problems associated with controlling low offset frequencies by introducing three additional oscillators into a system further comprised of seven counters and two phase comparators, all to permit PLL control at higher offset frequencies than the final output offset frequency, which is obtained by frequency down-mixing. This system is too complex for many commercial applications and like the prior art, it does not control instantaneous voltage controlled oscillator (VCO) phase errors and crosstalk.
Swept timing can also be implemented using analog sweep techniques. Analog approaches to swept timing include: (1) an analog voltage ramp that drives a comparator, with the comparator reference voltage controlling the delay, or (2) a delay locked loop (DLL), wherein the delay, or phase, between transmit and receive clocks is measured and controlled with a feedback loop. Examples of DLL architectures are disclosed in U.S. Pat. No. 5,563,605, “Precision Digital Pulse Phase Generator” by the present inventor, Thomas Edward McEwan, and in U.S. Pat. No. 6,055,287 “Phase-Comparator-Less Delay Locked Loop”, also by the present inventor. The analog approaches are subject to component and temperature variations, and often require calibration during manufacture. There can also be accuracy limitations.
A radar timing system employing a direct digital synthesizer (DDS) is disclosed in U.S. patent application Ser. No. 11/351,924, “Direct Digital Synthesis Radar Timing System” by the present inventor. A DDS generates frequencies by digitally accumulating phase in a manner that directly emulates the definition of frequency. Frequency ω can be defined by a rate of change in phase φ or ω=φ/t, where t is time. Direct digital synthesis emulates this process by continually incrementing a digital phase value in discrete phase increments in a phase accumulator. It performs the accumulation in discrete time steps. The size of the discrete phase increment is set by a digital tuning word, and the discrete time steps are set by a DDS clock. Together, both define the synthesized frequency. This technique works well for low synthesized frequencies relative to the DDS clock frequency since a large number of small phase increments can be added in the phase accumulator to produce one full cycle spanning 0 to 2 π in phase, and a very smooth progression in phase can be realized. It does not work as well at higher frequencies that are required for radar.
In a radar system, a DDS drives a receive sampling gate at a frequency that is offset from a transmit pulse frequency to produce an expanded time sampled echo signal. The frequency offset generates a smoothly slipping phase between realtime received echoes and the sampling gate that stroboscopically expands the apparent time of the sampled echoes with an exemplary factor of 1-million and a range accuracy of 1-centimeter. The flexibility and repeatability of the digitally synthesized timing system is a quantum leap over analog prior art. However, the accuracy of currently available DDS chips is limited to about 0.05% of full scale range. Many applications require higher accuracy but cannot take advantage of the benefits of a DDS timing system due to limited accuracy.
A rate locked loop (RLL) timing system is disclosed in U.S. patent application Ser. No. 11/343,049, “Rate Locked Loop Radar Timing System” by the present inventor. An RLL regulates phase slip between two clock signals to provide precision timing for radar, TDR and laser ranging systems. A phase detector converts clock phase to voltage and the voltage is differentiated to provide a rate-of-change signal to a loop controller that precisely regulates the rate-of-phase change. The RLL controls a VCO to produce a constant, linear phase slip having phase errors below the time equivalent of 1-picosecond. However, the RLL lacks the repeatability and programmability of a digital timing system such as a DDS.
SUMMARY OF THE INVENTION
The present invention overcomes the limitations of the various analog and digital timing techniques used to generate a swept phase clock by employing an error correction feedback loop that reduces deviations from a constant sweep rate. Errors, i.e., deviations are detected and fed back to a phase corrector in a high gain feedback system.
A radar timing system having a constant sweep rate can be implemented with a direct digital synthesizer (DDS) that generates a receive clock that is offset from a transmit clock However, DDS timing errors can introduce 1 cm range error. A feedback error correction loop can reduce errors to less than 0.1 mm. The flexibility, repeatability and accuracy of an error-corrected DDS timing system can enable a new generation of highly accurate radar, laser and guided wave rangefinders.
The present invention provides an error-corrected swept phase timing system for expanded time radar that can include:
a clock generator for providing a first clock signal and a swept phase signal, a phase corrector including a control port for producing a second clock signal in response to the swept phase signal, a phase detector for producing a phase detector output proportional to the phase between the first and second clock signals, an error detector for producing an error signal proportional to phase errors between the transmit clock signal and the swept phase signal; and a controller coupled to the control port for producing a control signal proportional to the error signal, wherein the first and second clock signals provide error corrected radar timing.
The error detector can comprise a first differentiator for producing a first derivative signal from the phase signal and a second differentiator for producing an error signal from the first derivative signal. It can also comprise a reference ramp generator for producing a reference ramp signal and a differencing element for producing an error signal proportional to the difference between the reference ramp signal and the phase signal.
The clock generator can include a reference oscillator to provide the first clock signal and a voltage controlled oscillator (VCO) to provide the swept phase signal. It can also include a reference oscillator to provide the first clock signal and a phase sweep circuit responsive to a range ramp to provide the swept phase signal. It can further include reference oscillator and a digital counter to provide the first clock signal and a direct digital synthesizer (DDS) provide the swept phase signal. The phase detector can consist of a flip-flop and a lowpass filter, the second differentiator can consist of an AC coupling circuit and the second clock signal can be harmonically related to the first clock signal.
The present invention can be used in expanded time radar, laser, and TDR ranging systems having high stability, flexible programmability, excellent repeatability and manufacturability, and an uncorrected phase accuracy on the order of 0.004 degrees using, for example, currently available, low cost DDS chips. Applications include pulse echo rangefinders for tank level measurement, environmental monitoring, industrial and robotic controls, digital handwriting capture, imaging radars, vehicle backup and collision warning radars, and universal object/obstacle detection and ranging.
A beneficial embodiment of the present invention is to provide a precision radar timing system that generates a highly accurate and repeatable phase slip to produce accurate radar signal time expansions and corresponding ranging accuracies. A further beneficial embodiment is to provide precision radar timing that is digitally and rapidly programmable. An even further beneficial embodiment of the present invention is to provide precision radar timing system that is highly reproducible, inherently calibrated and highly accurate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of an error-corrected swept phase timing system of the present invention.
FIG. 2 a is a diagram of a two oscillator dock generator.
FIG. 2 b is a diagram of a single oscillator clock generator including a phase sweeper.
FIG. 2 c is a diagram of a DDS based clock generator.
FIG. 3 a is a diagram of a phase detector.
FIG. 3 b is a diagram of a phase detector for harmonically related clocks.
FIG. 4 is a diagram of a phase corrector.
FIG. 5 is a diagram of a derivative circuit and a controller.
FIG. 6 a is an error plot for a timing system without error correction (PRIOR ART).
FIG. 6 b is an error plot for a timing system with error correction.
FIG. 7 is a diagram of the present invention in a ranging system.
FIG. 8 is a diagram of an error-corrected swept phase timing system including an alternative error detector.
DETAILED DESCRIPTION OF THE INVENTION
A detailed description of the present invention is provided below with reference to the figures. While illustrative component values and circuit parameters are given, other embodiments can be constructed with other component values and circuit parameters. All U.S. patents and copending U.S. applications cited herein are herein incorporated by reference.
General Description
The present invention overcomes the accuracy limitations of a DDS based clock generator and other clock generators by correcting errors in phase slip on a continuous and instantaneous basis. A beneficial example embodiment, as disclosed herein, employs a phase detector coupled directly between radar transmit and receive clocks, rather than through counter chains that are customary in PLL circuits, to produce a voltage proportional to instantaneous phase. When the phase between the clocks slips at a constant rate, because of the frequency offset between them, the phase detector output is a linear voltage ramp that increases with increasing phase values between 0 and 2 π and then it resets to 0 at 2 π, i.e., at the phase wrap point. The voltage ramp repeats at the offset frequency Δ. The voltage ramp is differentiated by a derivative circuit to produce a constant voltage proportional to the slope of the ramp, which can be termed the derivative voltage. The derivative voltage is applied to another derivative circuit that strips away the constant voltage produced by the first derivative circuit and allows only deviations in voltage from the first derivative circuit to pass as an error signal. A feedback controller controls a phase corrector in response to the error signal with the effect that phase errors are reduced, i.e., corrected. The amount of correction is a function of loop gain. If the slip rate varies, i.e., deviates, the high gain feedback controller instantaneously corrects the deviations.
The second derivative circuit outputs deviations in the rate of phase change. For a perfectly linear phase sweep, the second derivative circuit produces a zero error signal. The rate of sweep sets the output level from the first derivative circuit. The second derivative circuit rejects this output level so the system is not directly influenced by the sweep rate itself. The system is responsive to deviations in rate of change in phase and not to phase itself or to rate of change in phase. Consequently, the overall loop functions as an error corrector. High accuracy swept timing can be realized with low accuracy sweep systems when they are combined with the error corrector. Error correctors can be cascaded for increased error reduction.
One example swept timing system is based on a DDS as discussed in the Related Art section. The accuracy of a DDS timing system is limited by residual phase errors related to the number of accumulator bits in the DDS, which can be fairly large, e.g., 34 bits, and by sine ROM and DAC bit width, which can be 10-14 bits. The least significant bits (LSBs) from the accumulator are truncated to match the bit width of the DAC. A DDS in combination with a sine ROM, a DAC, and a reconstruction filter can provide an offset clock frequency having sufficiently small phase increments for sampling type stroboscopic radars having a full scale range error of 0.05%. When combined with the error corrector of the present invention, accuracy can be reduced to less than 0.001%.
Specific Description
Turning now to the drawings, FIG. 1 illustrates an exemplary configuration of an error-corrected swept phase timing system 10 for expanded time radar of the present invention. A clock generator 12 provides a clock signal (CLK 1 ) on line 14 and a swept phase signal on line 16 . The swept phase signal is coupled to a phase corrector 32 that outputs a second clock signal (CLK 2 ) on line 20 . CLK 1 can be a transmit clock and CLK 2 can be a receive clock. The receive dock in a radar can be swept, but the transmit clock can be swept instead.
A phase detector 22 compares the phase between CLK 1 and CLK 2 and outputs a voltage V(φ) that is proportional to the CLK 1 -CLK 2 phase. Voltage V(φ) can have a ramp waveform, termed a phase ramp, when the CLK 1 -CLK 2 phase changes at a constant rate.
A first differentiator 24 differentiates V(φ)to produce a derivative voltage V′(φ) proportional to the rate-of-change in phase between CLK 1 and CLK 2 . Voltage V′(φ) is constant when V(φ) changes at a linear rate, representing a constant phase slip. A second differentiator 26 differentiates voltage V′(φ) to produce a second derivative voltage V″(φ). Voltage V″(φ) is an error signal representing deviations from a constant phase sweep rate. Controller 28 amplifies V″(φ) and produces a control voltage Vc proportional to V″(φ). Voltage Vc is applied as a negative feedback signal to a phase control port of phase corrector 32 , which controls the phase of CLK 2 relative to its input on line 16 .
Blocks 22 , 24 , 26 , and 28 , as shown in FIG. 1 , form a high gain, high bandwidth continuous-mode feedback loop. Since the loop contains phase detector 22 and derivative elements 24 and 26 , it controls a second derivative of phase, or deviations in rate-of-change in phase. Accordingly, the feedback loop controls, i.e., corrects, phase deviations from a constant sweep.
FIG. 2 a depicts an exemplary clock generator 12 having an independent reference oscillator 40 , which can be a quartz crystal oscillator that may be temperature compensated (TCXO) or ovenized for greater stability. Oscillator 40 operates at a frequency of Fref. VCO 42 produces a frequency that is offset frequency from Fref. The frequency offset causes the phase of oscillator 42 to slip relative to the phase of oscillator 40 , thereby producing a swept phase signal. A frequency control input adjusts the VCO frequency using a PLL or other control system. VCO 42 can be a quartz crystal oscillator with a varactor phase/frequency control element.
FIG. 2 b depicts another exemplary dock generator 12 based on a single oscillator 40 , which directly provides CLK 1 . The swept phase signal is provided by a phase sweeper 44 , which is coupled to the CLK 1 line. The phase sweeper sweeps its output phase on line 16 in response to a ramp voltage. The maximum phase sweep range is normally limited to less than ½ π, which is sufficient for radar.
FIG. 2 c depicts another exemplary clock generator 12 based on a single oscillator 40 , which provides CLK 1 on line 14 after division by N using counter 46 , where N can be an integer or an integer ratio. A DDS 48 is docked by oscillator 40 . The DDS produces an output frequency that is set by a digital tuning word. The tuning word can be set to cause the DDS to output a frequency that is offset from a sub-multiple of Fref. Filter 49 removes spurious frequency components from the DDS output and provides the swept phase signal on line 16 . Exemplary parameters for the CLK 1 frequency can be 2.000000 MHz and the swept phase signal frequency can be 1.999990 MHz. The difference frequency is 10 Hz and the swept phase signal slips at a smooth rate repeating at a 10 Hz rate. Once every 1/10 second, the phase of the CLK 1 and the swept phase signals align so there is zero phase between them for an instant.
FIG. 3 a is an exemplary phase detector 22 , as shown in FIG. 1 , that is based on a D-input latch (or flip-flop) 50 . Latch 50 is cleared by CLK 1 via edge coupling network 52 . After clearing, the next CLK 2 edge sets latch 50 so that the duty cycle of the Q output is proportional to the phase between CLK 1 and CLK 2 . Low pass filter 54 averages the duty cycle into a voltage V(φ) proportional to phase.
FIG. 3 b depicts a further example of a phase detector wherein the CLK 1 signal is frequency divided by an integer N in counter 56 , such that V(φ) is proportional to the phase between a sub-multiple of the CLK 1 frequency and the direct frequency of CLK 2 . Counter 56 output is CLK 1 ′ at a sub-multiple N of CLK 1 . When the CLK 1 ′ is at a logic 1, latch 50 remains cleared, and when CLK 1 ′ is at logic 0, the next trigger edge of CLK 2 sets Q high. Since CLK 2 occurs at a higher rate than CLK 1 ′, the Q output, which is also CLK 2 ′, ranges over less than 2 π. For N=4, the phase range is ¼ π, a desirable range for many ranging systems. Further details on this harmonic mode can be found in U.S. Pat. No. 6,072,427, “precision Radar Timebase Using Harmonically Related oscillators,” by Thomas E. McEwan, the applicant of the present invention. Two frequencies are harmonically related if one is a multiple of the other, or dose to a multiple of the other, i.e., offset by a small difference frequency from the harmonic frequency.
FIG. 4 is an exemplary phase corrector 32 that includes an RC network 66 coupled to a threshold element 68 , a logic gate. RC network 66 slows the swept phase signal risetime and voltage Vc on line 30 provides an offset voltage that is applied to the input of gate 68 . The exact time that gate 68 thresholds on its input is a function of its input offset voltage. Therefore the timing, i.e. the phase, of the swept phase CLK 2 signal on line 20 is controlled by Vc.
FIG. 5 is an exemplary implementation of differentiators 24 , 26 and controller 28 , as shown in FIG. 1 . Phase detector 22 output V(φ) is applied to differentiation capacitor 70 , also labeled d/dt, which is coupled to the input of a transimpedance amplifier that includes op amp 72 and feedback resistor 74 , forming, in combination with capacitor 70 , a classic differentiator. Diode 76 conducts during the phase wrap transition at the 2 π points, i.e., during the positive edges seen in V(φ) waveform 89 , and acts to speed settling to the next negative going ramp of V(φ). Op amp 72 outputs a substantially constant voltage V′(φ) proportional to the rate of change of V(φ).
Switch 78 is normally closed and couples V′(φ) to a second differentiation capacitor 80 , also labeled d/dt. Capacitor 80 differentiates V′(φ) and couples a derivative voltage V″(φ) to resistor 82 and op amp 84 . Capacitor 80 forms an AC coupled circuit. Voltage V″(φ) is an error signal representing deviations from a perfectly linear sweep. Op amp 84 is a control amplifier that greatly amplifies the error signal to provide a feedback control voltage Vc on line 30 to phase corrector 32 . Capacitors 75 , 86 define the control loop bandwidth. Capacitor 80 need not necessarily form a perfect differentiator; it functions to block the DC voltage level of V′(φ).
Switch 78 is opened by a pulse applied to the dashed S control line of FIG. 5 shortly before the phase wrap. Opening switch 78 blocks phase wrap glitches from coupling to the control op amp. Switch 78 closes shortly after the phase wrap. The S control pulse can be derived from V(φ). Phase wrap glitches can limit the timing accuracy. Switch 88 is normally open and can close in compliment to switch 78 . The closure of switch 88 resets the output of op amp 84 at the phase wrap point and then switch 88 opens to allow extremely large DC gain, which helps reduce phase errors. Exemplary op amps 72 , 84 are Texas Instruments, Inc. TLV274 and switches 78 , 88 are Motorola, Inc. CMOS analog switches 74HC4066.
FIG. 6 a (PRIOR ART) plots phase error between CLK 1 ′ and CLK 2 ′ for an actual timing system using harmonically related clocks and the phase comparator of FIG. 3 b . A DDS dock generator as depicted in FIG. 2 c is used. Errors are indicated as the temporal equivalent of 15 picoseconds per division across a sweep range of 154 ns. CLK 1 ′ is operated at 1.625 MHz and CLK 2 at 6.5 MHz in a harmonic system as described with reference to FIG. 3 b . Hence the sweep range is 1/6.5 MHz=154 ns, which corresponds to a phase range of ¼ π. Maximum errors are on the order of +/−60 picoseconds, or about +/−0.04% of full scale range.
FIG. 6 b is a plot of the phase error for the system of FIG. 6 a further including an exemplary error corrector as illustrated by the timing system 10 of FIG. 1 . Range marker 90 can correspond to zero range and range marker 92 can correspond to the maximum range for a rangefinder implementation. Errors between markers 90 , 92 are on the order of 1-picosecond, or less than 0.001% of full scale range.
FIG. 7 illustrates an exemplary pulse-echo rangefinder 100 incorporating timing error corrector 10 , as shown in FIG. 1 , of the present invention. Clock generator 12 couples a transmit dock signal TX CLK to transmitter 110 and, via phase corrector 32 , a receive clock signal RX CLK to receiver 112 . TX CLK triggers transmit pulses and transmitter 110 radiates corresponding radio or optical transmit pulses. Alternatively, transmitter 110 transmits electrical pulses along a conductor in a time domain reflectometer. Receiver 112 receives echo pulses produced by the transmitter. RX CLK gates the receiver, causing it to sample echoes at the instant of gating. Samples are output from the receiver on line 114 in expanded time as the phase of RX CLK slips relative to TX CLK. The samples on line 114 may occur on a pulse-by-pulse basis, one for each pulse of RX CLK, or the samples may be integrated to form an integrated output representing many RX CLK cycles. Receiver 112 can include processing, in which case the output on line 114 represents a processed output arising from samples taken at timing instants defined by RX CLK.
Phase ramp voltage V(φ) can be optionally coupled to receiver 114 via line 116 to control a variable gain amplifier to compensate echo versus range loss. Other uses for phase ramp voltage V(φ) include detecting the phase wraps at 2 π for generating reset pulses, generating switch control pulses for controller 28 , or for providing an analog indication of range. Blocks 22 , 24 , 26 , 28 and 32 form a timing error corrector, which provides precision timing for rangefinder system 100 . Transmitter 110 and receiver 112 may be fashioned to operate with a single radiator or lens, or in the case of TDR, may be coupled onto a single conductor, as known in the art.
FIG. 8 illustrates another exemplary approach to obtaining an error signal for error correction. Clock generator 12 , phase detector 22 , control 28 , phase corrector 32 , CLK 1 and CLK 2 are as described previously. Reference ramp generator 25 generates a voltage ramp that matches phase ramp V(φ). Reference ramp generator 25 can consist of an analog generator or a digital generator as can be provided by a counter and a digital-to-analog converter (DAC). The optional dashed line in FIG. 8 connecting phase detector 22 to reference ramp generator 25 can provide synchronization between the phase ramp V(φ) and reference ramp voltage Vr, so they both reset simultaneously. This connection may also provide amplitude regulation so both V(φ) and Vr match in peak-to-peak amplitude. Differencing element 23 subtracts Vr from V(φ) and outputs a difference voltage, i.e., an error signal to control 28 . Control 28 amplifies the error signal to produce a control voltage Vc at the phase control port of phase corrector 32 , which corrects sweep phase errors. Control 28 can be AC coupled to strip off any DC offset in the error signal and to control only the deviations.
Phase detector 22 , ramp generator 25 and differencing element 23 form an error detector. Similarly, referring to FIG. 1 , phase detector 22 , first differentiator 24 and second differentiator 26 form an error detector.
The use of the word “radar” herein refers to traditional electromagnetic radar that employs microwaves or millimeter waves, and it also refers to optical radar, i.e., laser rangefinders, as well as guided wave radar, wherein radar pulses are guided along a electromagnetic guide wire or other conductor, as in TDR. “Radar” includes monostatic and bistatic systems, as well as radars having a single antenna/transducer. The use of the phrase “offset frequency” generally refers to an offset frequency between 1 and 1000 Hz between transmit and receive clock signals. However, the scope of the invention also encompasses larger offsets as may be required in various applications. Changes and modifications in the specifically described embodiments, including changing to digital and software embodiments, can be carried out without departing from the scope of the invention which is intended to be limited only by the scope of the appended claims.
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A feedback loop corrects timing errors by reducing deviations from a constant radar sweep rate. Errors are detected and fed back to a phase corrector in a high gain feedback system. A precision radar rangefinder can be implemented with a direct digital synthesizer (DDS) that includes feedback error correction for reducing range errors by, for example, 100 times, or to 0.1 mm. An error-corrected DDS swept timing system can enable a new generation of highly flexible, repeatable and accurate radar, laser and guided wave rangefinders.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable
FEDERALLY SPONSORED RESEARCH
Not Applicable
SEQUENCE LISTING OR PROGRAM
Not Applicable
BACKGROUND OF THE INVENTION
Field of Invention
The present invention relates generally to a vertical takeoff and landing (VTOL) winged vehicle and, more particularly, to a ducted, single-axis, oblique-rotor, flying vehicle that is controlled predominately by vanes in vertical flight mode and a combination of vanes and aerodynamic surfaces when in horizontal, or a wing-lifting, flight mode.
Prior Art
Flying machines that can takeoff vertically and hover have been around for over a century. To date, the most practical configuration of these machines is the helicopter. Although there have been variations of the helicopter design, all have similar mechanisms. The reasons for the success of the helicopter is the light-weight structural configuration of the rotor system that allows for a low disc loading and the ability to auto-rotate in the event of engine failure.
The helicopter has several limitations, however, including speed and range, because of the rotor's direct exposure to the freestream airflow. Another limitation of the helicopter is the inherent danger of exposed main and tail rotor blades to ground personnel. Finally, noise and airframe vibration is synonymous with the helicopter.
Humans have trying to solve these problems and create a more esthetically pleasing form of the helicopter ever since its creation. An early design conceptualized a propeller housed in a shroud and used a minimum number of vanes for control. See U.S. Pat. No. 1,822,386 (Andersen). Other early designs tried to encapsulate a large rotor with vanes, above and below, to direct flow and provide control. See U.S. Pat. No. 2,777,649 (Williams). Later, single and multi-rotor platforms were studied. See U.S. Pat. No. 2,955,780 (Hulbert). Winged, tandem-rotor platforms were also proposed. See U.S. Pat. No. 2,968,453 (Bright). Piasecki Aircraft Corporation built several prototypes of the wingless, tandem-rotor platforms. They were controlled by using both vanes and differentially adjusting the collective pitch control between each rotor. See U.S. Pat. No. 3,184,183 (Piasecki). More recent designs of the VTOL aircraft have been around for decades without becoming practical. An example of this is the Moller Skycar. The design requires very high power to weight ratios and complex mechanical control systems. See U.S. Pat. No. 5,115,996 (Moller).
Work has continued on the tandem rotor platform vehicle in recent times. These configurations are proposed with wings and without, with gamboling rotors and a multitude of vane configurations. See U.S. Pat. No. 6,464,166 (Yoeli), U.S. Pat. No. 6,883,748 (Yoeli), U.S. Pat. No. 6,892,979 (Milde), U.S. Pat. No. 7,246,769 (Yoeli), U.S. Pat. No. 7,249,732 (Sanders), 2009/0084907 (Yoeli), 2010/0270419 (Yoeli), U.S. Pat. No. 7,857,253 (Yoeli), 2011/0049306 (Yoeli), 2011/0168834 (Yoeli), U.S. Pat. No. 8,651,432 (De Roche). These concepts may have merit for short range and endurance, however, the design is inherently inefficient for both lifting capacity and horizontal flight.
Another concept that has recently been proposed, because of advances in electric power storage and reduction in motor weight, is the use of multiple, small, electricly-powered rotors, either shrouded or un-shrouded, to provide lift and control. See US. Pat. Appl. No. 2011/0042509 (Bevirt). Their design proposes that multiple rotors be used to provide differential thrust to control the vehicle. There are at least two drawbacks to these designs. Firstly, the inherent propulsion efficiency of multiple, small fans, shrouds, and electric motors will be limited. Secondly, the whole vehicle must be rolled or pitched away from level in order to translate or compensate for wind near the ground. This coupling of orientation and translation has drawbacks if the vehicle is to be used for the transportation of packages to and from the ground.
Objects and Advantages
Point-to-point transportation of products and people have been dreamt about for centuries. The idea of stepping into a personal flying machine that can take someone directly to where they want to go, all while watching the world from above, is alluring. Recently, corporations have even set goals to autonomously deliver packages to individual residence from the air. The present state of the art in air vehicles has prohibited either of these visions from realization. There is currently inadequate infrastructure to safely direct the number of flying machines required for mass movements of everyday people and goods. There is also a lack of viable aircraft that can safely be flown from or into residential or commercial locations, much less, ones that can be done at a price people can afford. A flying machine that will someday make point-to-point transportation a reality will be controlled autonomously. These machines must be able to land in a multitude of locations across a densely populated area since current airports do not have the areal capacity to park all the vehicles of those visiting and inhabiting a city. Flight paths of vehicles will be in close proximity and precise navigation and control will be required to safely integrate into the congested airspace in both visual and instrument meteorological conditions.
Flying machines that takeoff and land vertically have evolved into two districted groups, those with relatively small, enclosed rotors or lift nozzles, such as the Joint Strike Fighter or Harrier, and those with large rotors, such as helicopters. The first group has very high disk loading or nozzle pressures and requires large power-to-weight ratios to achieve vertical flight. They need state-of-the-art, expensive, fuel inefficient engines that produce noise levels much beyond what are acceptable in residential or business communities. The second group of vehicles, the helicopter, can fly vertically on much lower-power and use relatively efficient engines; however, they require trained personnel to be in their vicinity because of the dangers from exposed rotors. Helicopters also have inherent limited range and speed capability. Hybrid vehicles, such as the Osprey or Eagle Eye, using tilt-rotor configurations, have been introduced and used in service but this configuration requires very expensive turbine engines and complex mechanical systems for them to fly safely. And, they still suffer from the dangers of exposed rotors.
Electric, multi-rotor, flying vehicles have recently been introduced to the public for entertainment or used as a photography platform. These machines have only become available because of the miniaturization of electronic components and improved battery technology. They can be made with propulsion redundancy if enough rotors are employed; however, this adds complexity and weight. This configuration still suffers from exposed rotors which can be dangerous if scaled to a size that is useful to carry cargo or people.
Accordingly, there are several objects and advantages of my invention. The vehicle's novel oblique rotor configuration with forward facing inlet is the simplest mechanical system that can provide efficient vertical lift and horizontal propulsion. Multiple rotors rarely provide additional redundancy since failure of any mechanical component in a rotor system general means loss of the vehicle. The bifurcating duct that integrates the invention's payload location and also separates the left and right vertical control vanes, provides an optimum configuration for tomorrow's transportation needs. This simple mechanical rotor system using a plurality of vanes in a redundant configuration produces a reliable vehicle using inexpensive servos for control. This configuration also allows the vehicle to decouple attitude and translational flight control so that it can translate in a level position or stay stationary in a slight unlevel attitude. This feature is needed for package pickup and delivery and provides advantages for weapons delivery. Another advantage of this configuration is that it has a medium disc loading which can be powered by a hybrid electric-internal combustion powerplant and will produce little noise compared to current turbine-powered machines. Also, the rotor is completely enclosed, disallowing inadvertent contact with people or property. This configuration, integrated with wings, allows this vehicle to have much greater range and endurance than either a helicopter or any other enclosed-rotor VTOL configuration. The novel rotor pitch control mechanism in this invention allows for this simple rotor configuration while maintaining triple redundant collective control. Also, the geometric configuration of the vane installation decouples the vane control servo from the vane while the vane is in the stowed position and still being loaded by aerodynamic forces.
SUMMARY OF INVENTION
The present invention is a winged VTOL aircraft of novel configuration that utilizes a single-axis rotor mounted at an oblique angle within a forward-facing, bifurcating duct, that is controlled by a plurality of servo driven vanes, producing a mechanically simple, redundantly controlled vehicle that can carry cargo, people, or otherwise, directly from point to point. The configuration uses sets of vanes to produce both moments and forces referenced around the vehicle's center of gravity, thereby, allowing the vehicle to translate in a level position, or stay stationary relative to the ground while at a slight pitch or roll attitude. This feature is very important for autonomous vehicles to accurately pick up and drop off payloads on unlevel terrain or in windy conditions. Other rotor vehicles require pitch or roll attitude to translate or compensate for wind. Complementing this vehicle's mechanically simple rotor system is a novel mechanism that collectively drives the pitch of the rotor blades by combining the input from three separate servos. Each servo can be controlled by redundant fight control systems.
The use of the multi-vane configuration in the present invention lends itself to control redundancy using a mechanically simple, single-axis rotor that other configurations don't have. This allows for the use of less reliable, commercial servos and actuators, thereby, improving safety at a lower cost. Using a triple-redundancy in the rotor pitch control system and using multiple parallel powerplants, the present invention could revolutionize package delivery and personal transportation. This configuration could also have large implications in military intelligence gathering and weapons delivery.
The vehicle described here has a ducted inlet that faces approximately forward. Two sets of vanes are employed to control the vehicle, one set for vertical and transition to horizontal flight, housed in the lower exit duct on the bottom of the vehicle, and the other, for horizontal flight, is located on the exit duct at the aft section of the vehicle. During the horizontal flight mode, the bottom exit nozzle is completely closed off by the vanes that have rotated to a position in-plane with the bottom of the vehicle. Conversely, when the vehicle is in vertical flight, and not in transition, the aft vanes are closed completely, sealing off the aft exit nozzle. The set of lower vanes for horizontal flight is broken up into longitudinal and lateral vanes. The longitudinal vanes control the vehicle's attitude in pitch, roll, yaw, and fine altitude adjustments as well as for-aft translation. The lateral vanes control pitch attitude, roll and yaw as well as lateral translation without needing to roll the vehicle away from level. When the vehicle is in transition to and in horizontal flight mode, roll is controlled by wing-mounted ailerons and yaw by rudders mounted on the vertical stabilizer. The preferred embodiment does not employ a horizontal stabilizer or external elevator for stability or control, however the present invention will work for any lifting surface configuration, including but not limited to, a conventional wing and aft tail, a canard and rear mounted wing, tandem wings, or a tri-surface configuration. The present invention can be powered by an internal combustion (IC) engine, turbine or otherwise, or plurality of engines, or use electric motors or other means to power the rotor. Multiple rotors could also be used along a single axis, although this complicates the configuration. A hybrid, internal combustion-electric powered vehicle using two independent electric power systems and one internal combustion engine is the preferred configuration, each with approximately the same power output capacity. The electric motors and the IC engine are used for takeoff and transition to the horizontal flight mode. The batteries are then charged using the electric motors as alternators. Landing is accomplished using all three systems. The aircraft is designed to require only the power from two of the three systems to maintain altitude during the vertical flight mode. Also, a differing quantity of electric motors could be used to drive the rotor system. Purely electric propulsion is also possible; however, it will suffer from a short range and endurance at the present time.
Rotor pitch control is achieved on the preferred configuration using three separate irreversible servos that are connected to a common plane that pivots about and translates along the rotor axis ( FIG. 28 ). The actual pitch input is that of the relative translation of a point created by the intersection of the servo attachments and the rotor spin axis. Each blade's pitch is adjusted in unison in proportion to a kind of averaging of the three input servos. This configuration allows for one or two control systems or actuator failures while still maintaining pitch controllability. Another possibility is to independently control pairs of blades through multiple concentric collective linkages. And still a final configuration is to use a fixed-pitch rotor.
These and other features and advantages of the present invention will be readily apparent to those of skill in the art from a review of the following detailed description along with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present invention showing the duct intake, rotor, wings, and cargo container.
FIG. 2 is a perspective view of the present invention showing the aft duct exit vanes, vertical stabilizer, wings and cargo container.
FIG. 3 is a side view of the present invention.
FIG. 4 is a sectional view of the present invention illustrating air flow, the rotor and powerplant placement, and lower and aft duct exits.
FIG. 5 is a front view of the present invention.
FIG. 6 is a plan view from the bottom of the present invention showing longitudinal and lateral vane placements and location of the cargo container.
FIG. 7 is a plan view from the above of the present invention.
FIG. 8 is an aft view of the present invention illustrating the aft duct exit and vane placements.
FIG. 9 is a perspective view of the control vanes, aerodynamic surface and rotor.
FIG. 10 is a sectional view of the left-hand-side longitudinal control vanes—neutral lift positions.
FIG. 11 is a sectional view of the left-hand-side longitudinal control vanes—reduced lift positions.
FIG. 12 is a sectional view of the left-hand-side longitudinal control vanes—increased lift positions.
FIG. 13 is a sectional view of the left-hand-side longitudinal control vanes—aft force (+F x ) positions.
FIG. 14 is a sectional view of the left-hand-side longitudinal control vanes—nose-down pitching moment (+M y ) positions.
FIG. 15 is a sectional view of the left-hand-side longitudinal control vanes—forward force (−F x ) positions.
FIG. 16 is a sectional view of the left-hand-side longitudinal control vanes—no force or moment, stowed for horizontal flight mode.
FIG. 17 is a sectional view of the horizontal control vanes—no force or moment, stowed for vertical flight mode.
FIG. 18 is a sectional view of the horizontal control vanes—partially open positions.
FIG. 19 is a sectional view of the horizontal control vanes—nose-down pitching moment (+M y ) positions.
FIG. 20 is a sectional view of the horizontal control vanes—nose-up pitching moment (−M y ) positions.
FIG. 21 is a sectional view of the horizontal control vanes—fully open positions.
FIG. 22 is a sectional view of the lateral control vanes—stowed positions for horizontal flight mode.
FIG. 23 is a sectional view of the lateral control vanes—neutral lift position.
FIG. 24 is a sectional view of the lateral control vanes—lateral force (+F y ) positions.
FIG. 25 is a sectional view of the lateral control vanes—reduced lift and pitch up positions.
FIG. 26 is a sectional view of the lateral control vanes—lateral force (+F y ) and roll force (−M x ) positions.
FIG. 27 is a sectional view of the lateral control vanes—increase lift force (−F z ) positions.
FIG. 28 is a side view of the voting rotor pitch control system—two-bladed rotor shown.
FIG. 29 is a side view of a stowed vane with on-center control linkage.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiment of the present invention is a ducted, single-rotor, vane-controlled, vertical takeoff and landing, autonomously controlled, hybrid-electric, winged, vehicle with triple-redundant propulsion and control systems. The plane of the rotor is fixed relative to the vehicle in a position inclined approximately halfway between the vehicle's longitudinal and vertical axis. The vehicle has two predominant flight modes, vertical and horizontal. It carries a cargo pod 11 , passenger compartment or otherwise between each vertical duct exit.
During vertical flight, lift is create by ingesting air into the inlet 17 , accelerating it across the rotor 401 , separating it at the bifurcation duct 15 and directing it downward through left-hand 201 and right-hand 203 vertical duct exits. Control in the vertical flight mode is achieved by using the vertical exit vanes to create forces and moments in all six degrees of freedom about the vehicle's center of gravity. The vanes are moved by servos that are directed by a plurality of flight computers or controllers. The vertical exit vanes are further broken down into longitudinal and lateral sets consisting of the left-hand longitudinal vanes 25 , left-hand lateral vanes 21 , the right-hand longitudinal vanes 27 , and the right-hand lateral vanes 23 . Longitudinal vanes are used to create longitudinal force, instantaneous lift change and moments to adjust the pitch, roll and yaw attitudes. Lateral vanes are used to create lateral force, instantaneous lift change and moments to adjust pitch, roll and yaw attitudes. Longitudinal and lateral forces are created on the vehicle by directing the flow of air away from vertically downward using a majority of the vanes. Since the center of gravity of the vehicle is above the plane of the vertical duct exit, moments will accompany any longitudinal or lateral force input unless local changes in lift occur simultaneously. Pitch, roll and yaw attitude is maintained or changed by balancing or modifying net moments that are created by all longitudinal and lateral vane forces and changes in local pressure distributions internal and external to the vehicle caused by deflecting said vanes in similar or opposing directions, in pairs or more. Vanes may move from partially deflected positions ( FIGS. 10 and 23 ) to those more aligned to the ducted airflow ( FIGS. 12 and 27 ), creating a local increase in lift.
Some possible longitudinal vane 25 positions of the left-hand vertical duct exit 201 are shown in FIGS. 10 through 16 . FIGS. 10 and 12 depict the vanes in neutral and net increased lift (−F z ) positions, respectively. FIG. 11 shows vane positions that produce balanced longitudinal forces while still decreasing local lift (+F z ), creating a left roll moment (+M x ) about the vehicle's center of gravity. To produce an aft force (+F x ), and lift distribution to offset a pitching moment, vanes can be positioned similarly to those shown in FIG. 13 . FIG. 14 shows vane positions that will produce a pitching moment about the vehicle's center of gravity without any net longitudinal force. To produce a forward force and translation of the vehicle with no pitch change, the vanes could be positioned as shown in FIG. 15 . This would initiate forward velocity and a translation to horizontal flight. FIG. 16 shows the vanes 25 in the left-hand lower exit duct fully close as they would be in the horizontal flight mode.
Lateral forces are generated by moving the left-hand lateral vanes 21 and right-hand lateral vanes 23 located in the left-hand vertical duct exit 201 and right-hand vertical duct exit 203 , respectively. Since the lateral vanes are located aft of the vehicle's center of gravity in the preferred embodiment, pitch attitude can be controlled by decreasing or increasing local lift forces through the deflection of vanes in opposite directions in pairs or more. FIG. 25 shows the defection of vanes to produce a decrease in local lift. This decrease would cause a nose-up pitching moment (−M y ) if other vanes on the vehicle were not adjusted. Alternatively, vane positions shown in FIG. 27 would cause a nose-down pitching moment (+M y ) if the lateral vanes were to move independently from all others. FIG. 23 shows lateral vane neutral positions, being able to be straightened for increase lift or opposed in pairs or more to decrease local lift. FIG. 24 will produce a net force to the vehicle's left-hand side (+F y ) while modifying the local lift distribution to balance any roll moments caused from the lateral load. Positioning vanes like those in FIG. 26 will produce a large lateral force (+F y ) and an associated rolling moment (−M y ). When the vehicle is in purely horizontal flight mode the vanes are rotated to completely block the airflow ( FIG. 22 ), redirecting air to the aft duct exit 205 .
To control the vehicle's pitch attitude in the horizontal flight mode, movable aft exit vanes 29 are deflected at the aft duct exit 205 . FIGS. 17 through 21 depicted the vanes in possible positions from stowed ( FIG. 17 ) to trimmed horizontal flight ( FIG. 21 ). FIG. 18 depicts the vane position in transition from vertical to horizontal or horizontal to vertical flight. FIGS. 19 and 20 show aft exit vane 29 positions producing pitch down (+M y ) and pitch up (−M y ) moments, respectively. Roll attitude is controlled by the three redundant left-hand ailerons 35 and three redundant right-hand ailerons 37 , mounted to the left wing 31 and right wing 33 , respectively. Yaw control is maintained by the three redundant rudders 53 mounted on the vertical stabilizer 51 .
Control of the vehicle in transition from vertical to horizontal, and horizontal to vertical flight is maintained by moving all the vanes and aerodynamic surfaces, together, in a similar manner as described above.
Figures and descriptions for producing forces and moments on the vehicle described here are considered building blocks and used to illustrate the method of control. Actual vane positioning may differ from those described here and will require other combinations that produce the forces and moments required to maintain vehicle control. This method of controlling the vehicle has many combinations of vane positions that will produce the same sets of net forces and moments, albeit, some more efficient than others. The control method described here, therefore, has redundant means of vehicle control in the event one or more vanes stop functioning properly, through the failure of a servo or complete control system. By dividing the vanes into dispersed groups and controlling each group of vanes using a separate control system, complete failure of one control system would not mean complete loss of control of the vehicle.
Addition embodiments of the vehicle are similar to what is described here but with the relocation of the lateral control vanes to near or forward of the vehicle's longitudinal center of gravity. Other possibilities include a differing number of vanes than are described here, but are still used in pairs or more to affect the lift distribution. An alternate embodiment may use vanes, movable or immovable, in addition to those at the vertical and aft duct exits to control airflow internal to the duct, in front of or aft of the rotor. An additional embodiment may have a different shape of the duct, duct exits, vanes or aerodynamic covers but that functions in a similar manor. The alternate embodiment may contain a duct inlet that changes sectional area as needed to improve propulsion efficiency or decrease aerodynamic drag. Still other embodiments may have different lifting surface configurations than described, including but not limited to, a conventional wing and aft tail, a canard and rear mounted wing, tandem wings, or a tri-surface configuration. A vertical stabilizer may also be in the form of vee-tail, multiple vertical stabilizers, inverted vee-tail, or otherwise, or be absent all together. Aerodynamic control surfaces described in present embodiment such as the ailerons and rudders may vary in quantity or may be in different form such as spoilers. Also, one or more elevators may be used, either fully moving or as part of stabilizer or canard.
When the vanes of the preferred embodiment are stowed in a position that blocks the duct exit, constant and varying aerodynamic forces are imposed on them ( FIG. 29 ). If conventional, reversing servos are used to actuate the vanes, power would be required to maintain position when under load. Energy would not only be wasted but servo would wear and their reliability reduced. To alleviate this issue, the preferred embodiment arranges the vane 25 , vane bell crank arm 133 , rotary actuator or servo 125 and servo bell crank arm 127 , so that when the vane is in the stowed position, the joint centers 137 and 135 between the control rod 123 and servo bell crank arm 127 and vane bell crank arm 133 are aligned along the servo output shaft 139 axis of rotation 129 . All servo and vanes in the preferred embodiment are arranged in a similar configuration to prevent aerodynamic or inertial forces from loading the servos when the vanes are stowed. Other embodiments may have differing geometric configurations of the servo or actuator connecting to the vane, but use the same principle of decoupling the rotation of the vane to servo when in the stowed position.
The preferred embodiment uses an internal combustion engine to power horizontal flight and to recharge the batteries of the electric propulsion systems. Take off, landing, and vertical flight is done using power from two electric motors and associated batteries and control units, and the internal combustion engine. This propulsion system 301 lends itself to redundancy if the power available from two of the three component systems is greater than the power needed to maintain altitude in vertical flight mode. Other possibilities include one or more engines of different type such as turboshafts or otherwise, either in concert with hybrid-electric systems or other propulsion types. Another embodiment may use one or more purely electric power plants using one or multiple electric motors or multiple electric windings within a single motor case. Multiple parallel powerplants not only work well for hybrid-electric propulsion systems but provide a means to implement redundant control systems.
The preferred embodiment uses a single rotor 401 consisting of primary components such as the hub 43 , six blades 41 , and spinner or hub cover 45 . Additional embodiment of the present invention may use a different number of blades 41 and may or may not implement the use of a spinner 45 to direct air around the hub and provide impact protection to the rotor mechanism.
Pitch control of the preferred embodiment of the present invention uses a mechanical voting system that allows averaging from three irreversible servo 89 or actuator inputs to drive the rotor blade 41 pitch positions ( FIG. 28 ). In the event one or more servos 89 or control systems stop functioning, the other servo or servos can drive the pitch system. FIG. 28 depicts a side view of the present invention's rotor system, showing only two of the six blades and associated linkages for clarity. Rotor blades 41 and control arms 103 have pitch positions controlled by movement of three irreversible servos 89 . The servos 89 are connected to a swivel plate 93 that pivots around a spherical bearing that is part of the slider 101 . The three servo connections define a plane that determines the position of the slider 101 along the rotor shaft 85 . The swivel plate 93 and the slider 101 do not rotate with the rotor shaft. Bearings 107 allow rotational isolation of the rotor shaft 85 and the slider 101 while still maintaining lateral continuity. The slider 101 is connected to a rotating collective fitting 91 through a rotational bearing 105 that is captured by a retaining clip 97 that resides in a machined groove. The rotational bearing 105 isolates the rotational movement of the collective fitting 91 to that of the slider 101 while still maintaining lateral and axial positioning. The collective fitting 91 translates along the rotor shaft and moves the each rotor link 87 the same axial distance the slider 101 moves. Each rotor link 87 is attached to a blade pitch arm 103 , which is rigidly attached to a blade. The rotor pitch arms 103 convert linear motion of the links 87 to rotation of the blade 41 about the blade pitch axis. A set of links 99 is attached between the collective fitting 91 and the rotor hub 43 . These maintain rotational position between the rotor head 43 and collective fitting 91 without impeding relative axial movement. Similarly, another set of links 109 attaches the swivel plate 93 to a rigid component on the airframe. These links 109 keep the swivel plate 93 from rotating with the rotor shaft 85 while still allowing the swivel plate to pivot freely about the its spherical bearing center. Another spherical bearing is required to attach the inner link 109 to the swivel plate 93 to allow independent rotation.
Other embodiments of the present invention may control the rotors pitch in a similar manner using different geometry and components but maintaining the ability to mechanically vote using a swivel plate 93 and multiple servos or actuators. The preferred embodiment uses three irreversible actuators to determine the swivel plate 93 orientation and position. Other embodiments of the present invention may use more than three reversible servos or actuators to vote and provide control redundancy to the rotor pitch system. A reversible servo or actuator is one that does not maintain position when power or commanded signal is lost. Still another embodiment of this invention is a system that contains multiple parallel pitch mechanisms that controls pairs of rotor blades attached opposite to each other on the rotor hub 43 . Each system is driven by a servo 89 , actuator or sets of either to independently control the pitch of pairs of rotor blades. For instants, a rotor hub containing six rotor blades could be controlled by three independent pitch mechanisms. Loads from the paired blades would be balanced across the rotor hub 43 even if they were commanded at different pitch angles from the other blade sets, or if they were inoperative.
The forgoing is considered as illustrative only to the principal of the invention. Further, since numerous changes and modification will occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described above, and accordingly, all suitable modifications and equivalents may be resorted to falling within the scope of the invention.
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The present invention is a winged VTOL aircraft of novel configuration that utilizes a single-axis rotor mounted at an oblique angle within a forward-facing, bifurcating duct, that is controlled by a plurality of servo driven vanes, producing a mechanically simple, redundantly controlled vehicle that can carry cargo, people, or otherwise, directly from point to point. The configuration uses sets of vanes to produce both moments and forces referenced around the vehicle's center of gravity, thereby, allowing the vehicle to translate in a level position, or stay stationary relative to the ground while at a slight pitch or roll attitude. This feature is very important for autonomous vehicles to accurately pick up and drop off payloads on unlevel terrain or in windy conditions. Other rotor vehicles require pitch or roll attitude to translate or compensate for wind. Complementing this vehicle's mechanically simple rotor system is a novel mechanism that collectively drives the pitch of the rotor blades by combining the input from three separate servos. Each servo can be controlled by redundant fight control systems.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/938,705, filed on May 18, 2007 and entitled “Method and apparatus for POLL SUFI and special value of HE field clarifications in a wireless communication system”, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method and apparatus for setting packet headers in a wireless communications system, and more particularly, to a method and apparatus for reducing overhead, and preventing a receiver from wrongly reassembling Service Data Units.
[0004] 2. Description of the Prior Art
[0005] The third generation (3G) mobile telecommunications system has adopted a Wideband Code Division Multiple Access (WCDMA) wireless air interface access method for a cellular network. WCDMA provides high frequency spectrum utilization, universal coverage, and high quality, high-speed multimedia data transmission. The WCDMA method also meets all kinds of QoS requirements simultaneously, providing diverse, flexible, two-way transmission services and better communication quality to reduce transmission interruption rates.
[0006] The access stratum of the 3G mobile telecommunications system comprises a radio resource control (RRC), radio link control (RLC), media access control (MAC), packet data convergence protocol (PDCP), broadcast/multicast control (BMC) and other sub-layers of different functions. The operations of the above-mentioned sub-layers are well known for those skilled in the art, and will not be further mentioned. A primary function of the RLC layer is providing different transmission quality processing, performing segmentation, reassembly, concatenation, padding, retransmission, sequence check, and duplication detection on transmitted data or control instructions based on different transmission quality requirements. The MAC layer can match packets received from different logic channels of the RLC layer to common, shared, or dedicated transport channels according to radio resource allocation commands of the RRC layer, for performing channel mapping, multiplexing, transport format selection, or random access control.
[0007] When the RLC layer operates in an acknowledged mode (AM), a header of an RLC PDU (Protocol Data Unit) comprises a two-bit HE (Header Extension Type) field utilized for indicating if the next octet is data or a Length Indicator (LI) and Extension (E) bit. The HE field has different values, and the corresponding description is as follows:
[0008] 1. “00”: The succeeding octet contains data.
[0009] 2. “01”: The succeeding octet contains LI and E bit.
[0010] 3. “10” and “11”: Reserved. PDUs with this coding represents that a protocol error is occurred, and the PDUs will be discarded.
[0011] In order to decrease overhead, the prior art can configure a “use of the special value of the HE field” mode to set “10” of the HE field to indicate that the succeeding octet contains data and the last octet of the corresponding PDU is the last octet of an SDU (Service Data Unit). In other words, in the “use of the special value of the HE field” mode, if a PDU carries either a complete SDU or a segment of a SDU, and the complete SDU or the segment of the SDU ends at the end of the PDU, the HE field of the PDU will be set to “10.” As a result, an extra PDU carrying the corresponding LI is not needed, to decrease overhead.
[0012] Therefore, after the “use of the special value of the HE field” mode is configured, if a HE field of a PDU equals “10”, it implies that there is no SDU concatenation inside the PDU. However, the condition for setting the HE field to the special value is incorrect in the prior art as follows: if the last octet of a PDU is the last octet of an SDU, and the “use of the special value of the HE field” has been configured by higher layers, set the HE field to indicate that the last octet of the PDU is the last octet of an SDU. In such a situation, even if there are concatenated SDUs inside the PDU, the prior art still sets the HE field of the PDU to indicate that the last octet of the PDU is the last octet of an SDU. In other words, the receiver will consider the concatenated SDUs as the same SDU, and reassemble the SDUs incorrectly.
[0013] In short, the prior art does not precisely specify the condition for setting the HE field to the special value, leading the receiver to wrongly reassemble the SDUs, and causing system malfunction.
SUMMARY OF THE INVENTION
[0014] According to the claimed invention, a method for setting a header, having a header extension type field, of a protocol data unit in a radio link control layer of a wireless communications system comprises configuring a “use of the special value of the header extension type field” mode, and setting the header extension type field to indicate that a last octet of the protocol data unit is a last octet of a service data unit when the last octet of the protocol data unit is the last octet of the service data unit and there is no concatenation of service data units inside the protocol data unit.
[0015] According to the claimed invention, a communications device for accurately setting a header, having a header extension type field, of a radio link control protocol data unit in a wireless communications system comprises a control circuit for realizing functions of the communications device, a processor installed in the control circuit, for executing a program code to command the control circuit, and a memory installed in the control circuit and coupled to the processor for storing the program code. The program code comprises configuring a “use of the special value of the header extension type field” mode, and setting the header extension type field to indicate that a last octet of the radio link control protocol data unit is a last octet of a service data unit when the last octet of the radio link control protocol data unit is the last octet of the service data unit and there is no concatenation of service data units inside the radio link control protocol data unit.
[0016] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a function block diagram of a wireless communications device.
[0018] FIG. 2 is a diagram of program code of FIG. 1 .
[0019] FIG. 3 is a flowchart of a process according to an embodiment of the present invention.
[0020] FIG. 4 is a schematic diagram of a wireless communications system.
DETAILED DESCRIPTION
[0021] Please refer to FIG. 4 , which illustrates a schematic diagram of a wireless communications system 1000 . The wireless communications system 1000 can be a 3G mobile telecommunications system, an LTE (long-term evolution) system or other mobile communications systems, and is briefly composed of a network and a plurality of UEs. In FIG. 4 , the network and the UEs are simply utilized for illustrating the structure of the wireless communications system 1000 . Practically, the network may comprise a plurality of base stations (Node Bs), radio network controllers and so on according to actual demands, and the UEs can be devices such as mobile phones, computer systems, etc.
[0022] Please refer to FIG. 1 , which is a functional block diagram of a wireless communications device 100 . The communications device 100 is utilized for realizing the network or the UEs in FIG. 4 . For the sake of brevity, FIG. 1 only shows an input device 102 , an output device 104 , a control circuit 106 , a central processing unit (CPU) 108 , a memory 110 , a program code 112 , and a transceiver 114 of the wireless communications device 100 . In the wireless communications device 100 , the control circuit 106 executes the program code 112 in the memory 110 through the CPU 108 , thereby controlling an operation of the wireless communications device 100 . The wireless communications device 100 can receive signals input by a user through the input device 102 , such as a keyboard, and can output images and sounds through the output device 104 , such as a monitor or speakers. The transceiver 114 is used to receive and transmit wireless signals, transmitting received signals to the control circuit 106 , and outputting signals generated by the control circuit 106 wirelessly. From a perspective of a communications protocol framework, the transceiver 114 can be seen as a first portion of a first layer, and the control circuit 106 can be utilized to realize functions of a second layer and a third layer.
[0023] Please continue to refer to FIG. 2 . FIG. 2 is a diagram of the program code 112 shown in FIG. 1 . The program code 112 comprises an application layer 200 , a Layer 3 interface 202 , and a Layer 2 interface 206 , and is coupled to a Layer 1 interface 218 . When a signal is transmitted, the Layer 2 interface 206 forms a plurality of SDUs 208 according to data outputted by the Layer 3 interface 202 , and stores the plurality of SDUs 208 in a buffer 212 . Then, based on the SDUs 208 stored in the buffer 212 , the Layer 2 interface 206 generates a plurality of PDUs 214 , and sends the plurality of PDUs 214 to a destination terminal through the Layer 1 interface 218 . In contrast, when a wireless signal is received, the signal is received through the Layer 1 interface 218 , then outputted as PDUs 214 to the Layer 2 interface 206 . The Layer 2 interface 206 restores the PDUs 214 to SDUs 208 and stores the SDUs 208 in the buffer 212 . Last, the Layer 2 interface 206 transmits the SDUs 208 stored in the buffer 212 to the Layer 3 interface 202 .
[0024] When the communications device 100 operates in AM, a header of a PDU 214 comprises a two-bit HE field utilized for indicating if the next octet is data or an LI and E bit. When the “use of the special value of the HE field” mode is configured, a reserved value of the HE field represents that the succeeding octet contains data and the last octet of the corresponding PDU is the last octet of an SDU. In such a situation, the embodiment of the present invention provides a header setting program code 220 , for accurately setting the value of the HE field.
[0025] Please refer to FIG. 3 , which illustrates a schematic diagram of a process 30 in accordance with an embodiment of the present invention. The process 30 is utilized for setting a header of a PDU in an RLC layer of the wireless communications system 1000 . The header comprises an HE field. The process 30 can be compiled into the header setting program code 220 , and comprises the following steps:
[0026] Step 300 : Start.
[0027] Step 302 : Configure a “use of the special value of the HE field” mode.
[0028] Step 304 : Set the HE field to indicate that a last octet of the PDU is a last octet of an SDU when the last octet of the PDU is the last octet of the SDU and there is no concatenation of SDUs inside the PDU.
[0029] Step 306 : End.
[0030] According to the process 30 , after the “use of the special value of the HE field” mode is configured, if the last octet of a PDU is the last octet of an SDU, and there is no SDU concatenation inside the PDU, the embodiment of the present invention sets the HE field of the PDU to indicate that the last octet of the PDU is the last octet of the SDU, e.g., setting the value of the HE field to [ 1 0 ]. In other words, after the “use of the special value of the HE field” mode is configured, if there is no SDU concatenation inside a PDU, and an SDU ends at the end of the PDU, the embodiment of the present invention will sets the HE field of the PDU to indicate that the last octet of the PDU is the last octet of the SDU. As a result, an extra PDU carrying the corresponding LI is not needed, so as to decrease overhead.
[0031] Therefore, via the process 30 , after the “use of the special value of the HE field” mode is configured, if the last octet of a PDU is the last octet of an SDU, and there is no SDU concatenation inside the PDU, the embodiment of the present invention sets the HE field of the PDU to indicate that the last octet of the PDU is the last octet of the SDU. Oppositely, if the last octet of a PDU is the last octet of an SDU while there are concatenated SDUs inside the PDU, the embodiment of the present invention will not set the HE field of the PDU to indicate that the last octet of the PDU is the last octet of the SDU. As a result, the receiver will not wrongly reassemble the SDUs.
[0032] In summary, after the “use of the special value of the HE field” mode is triggered, if the last octet of a PDU is the last octet of an SDU, and there is no SDU concatenation inside the PDU, the embodiment of the present invention can set the HE field of the PDU to indicate that the last octet of the PDU is the last octet of the SDU. As a result, the embodiment of the present invention can reduce overhead, and prevent the receiver from wrongly reassembling SDUs.
[0033] Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.
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A method for setting a header, having a header extension type field, of a protocol data unit in a radio link control layer of a wireless communications system includes configuring a “use of the special value of the header extension type field” mode, and setting the header extension type field to indicate that a last octet of the protocol data unit is a last octet of a service data unit when the last octet of the protocol data unit is the last octet of the service data unit and there is no concatenation of service data units inside the protocol data unit.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a composition for precious metal sintering from which a precious metal sinter for use in jewelry, ornaments, accessories, or the like can be obtained. More specifically, the present invention relates to: a composition for precious metal sintering; a process for producing the precious metal sinter; and the precious metal sinter. The composition for precious metal sintering can obtain a precious metal sinter even if the precious metal content per unit volume of the composition for precious metal sintering is reduced, which can reduce weight of the precious metal sinter.
[0003] 2. Description of the Prior Art
[0004] It is well known that there exists a composition for precious metal sintering (which may also be referred to as a precious metal clay-like composition or a precious metal plastic composition) containing a precious metal powder and an organic binder as fundamental components. The composition for precious metal sintering is heated-sintered after shaping into a prescribed shape and dried, and thereby the organic binder is removed by being decomposed, vaporized, combusted, or the like from the composition for precious metal sintering during firing. This induces cohesion of the particles of the precious metal powder to be sintered to each other, allowing the production of a desired precious metal sinter. Herein, the precious metal sinter obtained from the above-described composition for precious metal sintering is porous in itself and thus weighs less compared to a molded metal object produced by casting or the like (a weight reduction of up to about 40% is possible compared to a cast object). Accordingly, the precious metal sinter is suitable to be used for ornament to be put on (see, for example, Patent Documents 1 to 6).
[0005] On the other hand, reduction in weight of made objects in many fields has been studied and implemented. It is known that a reduction in weight of concrete products can be achieved by using concrete produced by arranging cement concrete around an aggregate so as to increase porosity, or by adding lightweight aggregate such as pearlite and vermiculite to cement mortar.
[0006] It has also been known that reduction in weight of various plastic products can be achieved by adding a lightweight filling material such as silicon dioxide (silica) to resin.
[0007] However, techniques for concrete products or plastic products are not applicable in the field of producing a precious metal sinter using the composition for precious metal sintering. This is because a concrete product is solidified by cement solidification (hydraulic reaction system) in which the aggregate is taken into a matrix. This is a fundamental reaction system completely different from that in producing a precious metal sinter where precious metal powder is sintered at high temperature. A plastic product is produced by solidifying resin. This is also a fundamental reaction system completely different from that in producing a precious metal sinter whereby precious metal powder is sintered at high temperature.
[0008] Further, pearlite, vermiculite, or the like is not applicable to precious metal sinter obtained from the composition for precious metal sintering, unless the pearlite, vermiculite, or the like is made into fine powder. However, pearlite, vermiculite, or the like cannot possibly be applicable to the production of the precious metal sinter because the fine powder thereof is expected to have a larger apparent density and also to cause loss of the unique precious metallic coloring of the precious metal sintered product.
[0009] Further, in case that the precious metal content per unit volume of the composition for precious metal sintering is greatly reduced by adding a large amount of the lightweight filling material, it is not clearly known whether or not a successful precious metal sinter can be obtained therefrom. Moreover, the addition of the lightweight filling material disadvantageously degrades recognition as a precious metal product, due to the precious metal sintered product having essentially in itself a visual (aesthetic) value such as color and luster unique to precious metal.
[0010] In the meantime, in the field of producing a product by casting or the like, a core mold is used for creating a hollow object in some cases. In producing a product having a s complicated shape such as an ornament, however, it is difficult to use a core mold.
[0011] A core mold is sometimes used for creating a hollow in obtaining a sinter from the composition for precious metal sintering. However, the shape of such a core mold is inevitably limited because the core mold is to be burned down during firing/sintering, resulting in violent gas generation due to combustion. For example, assume a case where cork is used as a core mold, and the composition for precious metal sintering with a thickness thereof reduced is attached (applied) to the entire surface of the cork. If the object to be sintered is small-sized or has a gas vent hole, there is no problem. However, if the object is completely coated and sealed, there is a problem that the sintered object becomes deformed owing to the pressure of the gas during firing/sintering.
[0012] If a composition for precious metal sintering containing a silver oxide powder is sintered, a porous sinter can be obtained because the silver oxide powder is decomposed during firing, generating oxygen gas. Therefore, there is a problem that an obtained sinter becomes deformed due to pressure of the oxygen gas releasing during firing/sintering as described above (see, for example, Patent Document 7).
[0013] [Patent Document 1] Japanese Patent No. 3867786
[0014] [Patent Document 2] Japanese Patent No. 3456644
[0015] [Patent Document 3] Japanese Patent No. 3248505
[0016] [Patent Document 4] Japanese Patent No. 3896181
[0017] [Patent Document 5] Japanese Patent Application Publication No. 2002-241802
[0018] [Patent Document 6] Japanese Patent Application Publication No. 2007-51331
[0019] [Patent Document 7] Japanese Patent Application Publication No. 2004-292894
SUMMARY OF THE INVENTION
[0020] The present invention has been made in an attempt to provide: a composition for precious metal sintering capable of obtaining a precious metal sinter even if the precious metal content per unit volume of the composition for precious metal sintering is reduced, and also capable of reducing the weight of the precious metal sinter object while maintaining a visual (aesthetic) value; a process for producing the precious metal sinter; and the precious metal sinter.
[0021] According to the first aspect of the present invention, a composition for precious metal sintering includes: a precious metal powder; an organic binder solution; and a hollow glass powder, and is suitable for manual shaping. The composition for precious metal sintering has a volume ratio of a bulk volume of the hollow glass powder in the range of 5 to 160% with respect to a total volume of the composition for precious metal sintering. The bulk volume of the hollow glass powder is measured in a state where the hollow glass powder exists independently without any other components.
[0022] The inventors have made intensive studies for solving the above-mentioned problems to finally find and achieve the present invention which provides a composition for precious metal sintering capable of obtaining a precious metal sinter even if the precious metal content per unit volume of the composition for precious metal sintering is reduced, and also capable of reducing the weight of the precious metal sinter while maintaining a visual (aesthetic) value, by mixing a hollow glass powder into the composition for precious metal sintering.
[0023] In the first aspect of the present invention, the composition for precious metal sintering can be handled similarly to a composition for precious metal sintering according to conventional technology but without decreasing ease of use and enables to obtain therefrom a precious metal sinter having much less weight while maintaining its visual value.
[0024] According to the second aspect of the present invention, a composition for precious metal sintering includes: a precious metal fundamental composition consisting of a 50 to 99 wt % of a precious metal powder and a 1 to 50 wt % of an organic binder solution; and a hollow glass powder contained in the precious metal fundamental composition, and is suitable for manual shaping. The composition for precious metal sintering has a volume ratio of a bulk volume of the hollow glass powder in the range of 5 to 160% with respect to a total volume of the composition for precious metal sintering. The bulk volume of the hollow glass powder is measured in a state where the hollow glass powder exists independently without any other components.
[0025] Also with a configuration as described above, the composition for precious metal sintering can be handled similarly to a conventional composition for precious metal sintering according to conventional technology without decreasing ease of handling and enables to obtain therefrom a precious metal sinter having much less weight while maintaining its visual value.
[0026] The terms “bulk volume” used in the first or second aspect of the present invention refer to the volume measured in such a way of, for example, putting a hollow glass powder into a measuring cylinder and measuring its volume with the scale of the measuring cylinder. The bulk volume thus includes a volume of the powder itself as well as that of interspace between particles of the powder and between a particle and the inside wall surface of the measuring cylinder. Therefore, the volume ratio of a bulk volume of the hollow glass powder in the range of 5 to 160% with respect to a total volume of the composition for precious metal sintering in which the bulk volume of the hollow glass powder is measured in a state where the hollow glass powder exists independently without any other components can be expressed by:
[0000] (a bulk volume of a hollow glass powder added/an actual volume of a total composition)×100=5 to 160%. The calculated result may exceed 100% because the “bulk volume” of the hollow glass powder added is used.
[0027] In general, when two different powders having different particle sizes from each other (for example, a precious metal powder and a hollow glass powder) are mixed together, a bulk volume of the mixed powder is smaller than a sum of respective bulk volumes of the two different powders. This is because, in the mixed powder, the smaller particle of one powder is crammed between larger particles of the other, which increases the bulk density of the mixed powder. Thus, in the present invention, an actual volume of an entire composition corresponds to an actual volume of the composition for precious metal sintering in which at least the precious metal powder, the hollow glass powder, and the organic binder solution are mixed together. Since the bulk volume of the added hollow glass powder is compared to the above actual volume, the bulk volume may exceed 100%.
[0028] Such a definition on the actual volume as above-mentioned has been made because the bulk density of the precious metal powder or the hollow glass powder varies according to a shape or a state thereof, and even if either one of a wt % or a vol % is used in the explanation, the actual desired conditions of the present invention cannot be clearly shown.
[0029] According to the third aspect, in the preferred embodiment of the present invention, the composition for precious metal sintering according to the first or second aspect includes the hollow glass powder having a mean particle diameter from 15 to 65 μm and the precious metal powder having a mean particle diameter from 1.0 to 20 μm, and is suitable for manual shaping.
[0030] The terms “mean particle diameter” of the precious metal powder used in the present invention are also referred to as an average grain diameter, an average particle diameter, a median diameter, a median size, or a 50% particle size; are typically represented as “D50”; and means a particle size corresponding to 50% of a cumulative distribution curve. More specifically, the mean particle diameter is a value of D50 of a particle size distribution obtained by using a laser diffraction-type particle size distribution measurement device with tri-laser scattered light detection mechanism (manufactured by Microtrac, Inc.) and setting measurement conditions thereof at “particle permeability: reflection” and “spherical/nonspherical: nonspherical”.
[0031] On the other hand, a definition of the terms “mean particle diameter” which describes the hollow glass powder of the present invention is the same as that of the precious metal powder previously explained. However, the measurement conditions of the laser diffraction-type particle size distribution measurement device with tri-laser scattered light detection mechanism (manufactured by Microtrac, Inc.) is set at “particle permeability: permeable, particle refractive index: a refractive index of the hollow glass powder to be measured” and “spherical/nonspherical: spherical”.
[0032] In a more preferable aspect, the precious metal,powder used is a mixed powder, 30 to 70 wt % of which consists of a powder having a mean particle diameter from 2.2 to 3.0 μm, and the reminder of which consists of a powder having a mean particle diameter from 5 to 20 μm.
[0033] The hollow glass powder is a glass powder which consists of particles each having a hollow inside. A bulk density of the hollow glass powder used herein is preferably from 0.075 to 0.38 g/cm 3 . The hollow glass powder has a mean particle diameter (D50) from 15 to 65 μm as described above. It is preferable to use the hollow glass powder in which a particle diameter at 10% value (D10) of cumulative volume counting from a smaller particle size in a particle size distribution is in the range of 5 to 30 μm; and, at 90% value (D90) of cumulative volume, from 20 to 110 μm.
[0034] According to the fourth aspect of the present invention, the composition for precious metal sintering according to the first or second aspect has a maximum measurement value of a pushing load from 0.08 to 1.13 N, if measured by: filling a 2-ml syringe having an inner diameter of 6 mm, an outlet inner diameter of 1.3 mm, and an outlet inner length of 8.3 mm with 1 ml of the composition for precious metal sintering; pushing a plunger of the syringe 10 mm at a speed of 17 mm/minute; and extruding the composition for precious metal sintering from an outlet of the syringe, and the composition for precious metal sintering having the maximum measurement value of a pushing load in the described range above is suitable for manual shaping.
[0035] The maximum measurement value of a syringe pushing load is influenced by a size, a shape, and the like of the precious metal powder and the hollow glass powder. Moreover, it is convenient that the maximum measurement value of a syringe pushing load varies according to a type, a combination, a solvent content, or the like of the organic binder, as well as a combination ratio of the precious metal powder, the hollow glass powder, and the organic binder solution. Therefore, the maximum measurement value of a syringe pushing load has been found as a comprehensive indicator for the composition for precious metal sintering, thus allowing the present invention to be achieved.
[0036] A 2-ml syringe [product name: JMS syringe 2-ml without needle (micro), manufactured by JMS Co., Ltd.] having an inner diameter of 6 mm, an outlet inner diameter of 1.3 mm, an outlet inner length of 8.3 mm is preferably used.
[0037] The composition for precious metal sintering according to the fourth aspect of the present invention is suitable and excellent in shapability if the maximum measurement value of a syringe pushing load of the composition for precious metal sintering is in the range of 0.08 to 1.13 N.
[0038] According to the fifth aspect of the present invention, the composition for precious metal sintering according to the fourth aspect, if having a clay-like plasticity, has the maximum measurement value of the syringe pushing load of from 0.24 to 1.13 N, and is suitable for manual shaping.
[0039] In the fifth aspect of the present invention, the composition for precious metal sintering having the maximum measurement value of the pushing load in the range of 0.24 to 1.13 N has plasticity especially suitable for manual shaping like ordinary clay and has excellent characteristics in shapability.
[0040] According to the sixth aspect of the present invention, the composition for precious metal sintering according to the fourth aspect, if shaped by being extruded from a syringe to make a three dimensional shape, has the maximum measurement value of a syringe pushing load of from 0.08 to 0.23 N when the composition for precious metal sintering within the syringe is extruded, and is suitable for manual shaping.
[0041] In the sixth aspect of the present invention, the composition for precious metal sintering having the maximum measurement value of the pushing load in the range of 0.08 to 0.23 N is suitable for representing a delicate line pattern. This means that the composition for precious metal sintering filled in a syringe, at a tip of which is set a fine nozzle, can be easily extruded in a filament shape or a string shape by manually pressing the plunger (piston) of the syringe.
[0042] According to the seventh aspect of the present invention, a process for producing a precious metal sinter includes the steps of: shaping the composition for precious metal sintering according to the first or second aspect; drying the shaped object; and sintering the dried shaped object to obtain the precious metal sinter.
[0043] In the seventh aspect of the process for producing a precious metal sinter, the composition for precious metal sintering according to the first or second aspect of the present invention can be shaped, dried, and sintered in a similar way to a process of producing a precious metal sinter according to conventional technology, because the composition for precious metal sintering of the present invention does not lose ease of handling such as shapability. The composition for precious metal sintering of the present invention also enables to obtain a precious metal sinter having much less weight while maintaining a visual value.
[0044] According to the eighth aspect of the present invention, a precious metal sinter is produced by the process according to the seventh aspect.
[0045] In the eighth aspect of the present invention, the precious metal sinter including the hollow glass powder therein weighs much less than a precious metal sinter made according to the conventional technology, and maintains a visual value similarly to a precious metal sinter according to conventional technology.
[0046] A composition for precious metal sintering of the present invention: can drastically reduce a precious metal content per unit volume in the composition for precious metal sintering; has easiness of handling such as shapability, similarly to a composition for precious metal sintering according to the conventional technology; and can obtain a precious metal sinter which is reduced by about 60 wt % compared to a precious metal sinter without containing any hollow glass powder according to the conventional technology.
[0047] The obtained precious metal sinter has a visual (aesthetic) value similar to a precious metal sinter made with conventional technology and is suitable for use in a relatively large-sized ornament, which cannot be made using a composition for precious metal sintering without containing a hollow glass powder according to the conventional technology, because the conventional composition for precious metal sintering is too heavy.
[0048] Further, the composition for precious metal sintering of the present invention itself is light, thus improving workability especially in producing a large-sized artistic craft.
[0049] Further, even if an added weight of the hollow glass powder is very small, a used amount of the precious metal powder can be greatly reduced, because a density of the hollow glass powder is remarkably small. This results in a large reduction in cost. For example, a used amount of silver can be reduced by about 60 wt %.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] FIG. 1 is a side elevational view of a syringe pushing load measurement device according to the embodiment of the present invention.
[0051] FIG. 2 is a SEM image (×1000) of a precious metal sinter which has been sintered at 650° C. for 30 minutes according to the embodiment of the present invention.
[0052] FIG. 3 is a SEM image (×5000) of the precious metal sinter which has been sintered at 650° C. for 30 minutes according to the embodiment of the present invention.
[0053] FIG. 4 is a SEM image (×1000) of a precious metal sinter which has been sintered at 800° C. for 30 minutes according to the embodiment of the present invention.
[0054] FIG. 5 is a SEM image (×5000) of the precious metal sinter which has been sintered at 800° C. for 30 minutes according to the embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0055] A composition for precious metal sintering of the present invention includes: a precious metal powder; an organic binder solution, and a hollow glass powder.
[0056] The precious metal powder herein refers to a pure precious metal powder of Au, Ag, Pt, Pd, Rh, Ru, Ir, Os, or the like, or a precious metal alloy powder having one or more those elements as a major component. The particle size of the precious metal powder is not specifically limited. However, it is preferable to use a precious metal powder having a mean particle diameter from 1.0 to 20 μm, a maximum particle size of about 60.0 μm, and a minimum particle size of about 0.3 μm and to control a particle size distribution such that a sintering temperature thereof is from 600 to 900° C. For example, in a more preferable aspect, a mixed powder is used, 30 to 70 wt % of which consists of a powder having a mean particle diameter from 2.2 to 3.0 μm, and the reminder of which consists of a powder having a mean particle diameter from 5 to 20 μm.
[0057] The terms “mean particle diameter” herein are also referred to as an average grain diameter, an average particle diameter, a median diameter, a median size, or a 50% particle size; are typically represented as “D50”; and mean a particle size corresponding to 50% of a cumulative distribution curve. More specifically, the mean particle diameter is a value of D50 of a particle size distribution obtained by using a laser diffraction-type particle size distribution measurement device with tri-laser scattered light detection mechanism (manufactured by Microtrac, Inc.) and setting measurement conditions thereof at “particle permeability: reflection” and “spherical/nonspherical: nonspherical”.
[0058] The method of producing the precious metal powder is not specifically limited. However, it is preferable to produce a precious metal powder whose particles are nearly spherical.
[0059] In the case that particles of the powder included in the composition for precious metal sintering are not spherical but anisotropic, if the composition is extruded from, for example, a syringe or the like to form a bar-shaped object, inner and outer portions of the bar object are extruded at different speeds and consequently the particles tend to be oriented along a flow generated by the different speeds. This means that the inner and the outer portions of the composition for precious metal sintering including the particles behave differently when shrinking upon drying or sintering, which may cause a defect.
[0060] On the other hand, if particles of the powder included in the composition for precious metal sintering are nearly spherical, the powder tends to be densified. This allows the powder to be sintered at a lower temperature or for a shorter period of time. Further, the composition including the powder has a higher fluidity similar to clay, thus facilitating the operation of shaping such as bending and spreading.
[0061] Manufacturing Methods including gas atomization, water atomization, oxidation-reduction method, and gas phase method make it possible to obtain a precious metal powder having substantially spherical particles.
[0062] The hollow glass powder is a glass powder which has a hollow inside. Hollow glass powder having a bulk density from 0.075 to 0.38 g/cm 3 is preferable. The hollow inside is preferable in a reduced atmospheric pressure condition.
[0063] The hollow glass powder has a mean particle diameter (D50) from 15 to 65 μm. It is preferable to use the hollow glass powder in which a particle diameter is at a 10% value (D10) of cumulative volume counting from a smaller particle size, particle size distribution is in the range of 5 to 30 μm; at a 90% value (D90) of, cumulative volume, from 20 to 110 μm; and, at a 95% value (D95) of cumulative volume, from 25 to 120 μm.
[0064] Note that the definition of the above “mean particle diameter” of the hollow glass powder is the same as that of the precious metal powder previously explained. However, the measurement conditions of the laser diffraction-type particle size distribution measurement device with tri-laser scattered light detection mechanism (manufactured by Microtrac, Inc.) are set at “particle permeability: permeable, particle refractive index: a refractive index of the hollow glass powder to be measured” and “spherical/nonspherical: spherical”.
[0065] The hollow glass powder is preferably made of, for example, soda-lime borosilicate glass (major components: SiO 2 , CaO, Na 2 O, and B 2 O 3 ), borosilicate glass, sodium borosilicate glass, aluminosilicate glass, or the like. The hollow glass powder preferably has a softening point of 550° C. or higher. Such a hollow glass powder is commercially available under a product name of, for example, Glass Bubbles (manufactured by Sumitomo 3M Ltd.), CEL-STAR (manufactured by Tokai Kogyo Co., Ltd.), Q-CEL (manufactured by PQ Australia Pty. Ltd.), and Extendospheres (manufactured by Sphere One, Inc.).
[0066] The organic binder solution includes an organic binder, a solvent, and, if necessary to be added, an organic additive mixable with the solvent.
[0067] The organic binder usable in this invention is not to be considered limited to, however, but may include one or more members selected from the following: a cellulose-based binder such as methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose, and carmellose (carboxymethylcellulose); an alginic acid-based binder such as sodium alginate; a polysaccharide-based binder such as starch, wheat flour, British gum, xanthane gum, dextrin, dextran, and pullulan; an animal-derived binder such as gelatin; a vinyl-based binder such as polyvinyl alcohol and polyvinylpyrrolidone; an acryl-based binder such as polyacrylic acid and polyacrylate ester; and other resin-based binder such as polyethylene oxide, polypropylene oxide, and polyethylene glycol, etc.
[0068] One or more of the above organic binders are preferably selected and used herein. If the cellulose-based binder is used, a water-soluble cellulose-based binder is most preferably used.
[0069] Of the organic binders, the water-soluble cellulose-based binder gives plasticity to the composition for precious metal sintering. The polyethylene oxide gives a high viscosity at a low concentration and increases adhesiveness in its liquid form. The sodium alginate gives an appropriate level of water retentivity, similarly to glycerin and also helps increase adhesiveness. The polyacrylate ester and polyacrylic acid further increases adhesiveness.
[0070] Further, one or more organic additives mixable with the solvent as described above may be added to the organic binder solution where necessary.
[0071] The organic additive includes one or more members selected from the following: organic acid (oleic acid, stearic acid, phthalic acid, palmitic acid, sebacic acid, acetylcitric acid, hydroxybenzoic acid, lauric acid, myristic acid, caproic acid, enanthic acid, butyric acid, capric acid); organic acid ester such as n-dioctyl phthalate and n-dibutyl phthalate (organic acid ester having a methyl group, ethyl group, propyl group, butyl group, octyl group, hexyl group, dimethyl group, diethyl group, isopropyl group, and isobutyl group); higher alcohol (octanol, nonanol, decanol); polyol (glycerin, arabite, sorbitan, diglycerin, isoprene glycol, 1,3-butylene glycol); ether (dioctyl ether, didecyl ether); lignin which may be cited as a concrete example of the reticular macromolecular substance that results from the condensation of the component unit having phenylpropane as a backbone; liquid paraffin; and oil, or the mixture thereof (for example, olive oil containing rich oleic acid), etc.
[0072] The organic additive is added so as to improve plasticity or prevent a composition for precious metal sintering from sticking to a hand during shaping. The lignin and glycerin above-cited as the organic additive give an appropriate level of water retentivity.
[0073] The organic additive also includes an anionic, cationic, nonionic, or any other surfactant (surface-active agent). The surfactant improves miscibility between the precious metal powder and the organic binder and improves water retentivity.
[0074] The organic binder and the organic additive which is added if necessary are used by dissolving in a solvent such as water, water/alcohol mixture, alcohol, and ester, etc. The amount of the solvent is determined in accordance with the intended use of the composition for precious metal sintering. If the ratio of the amount of the solvent to the total amount of the composition for precious metal sintering is low, the composition for precious metal sintering behaves like clay. If the ratio of an amount of the solvent to the total amount of the composition for precious metal sintering is high, the composition for precious metal sintering behaves like slurry or paste. Obviously, if the solvent amount is too little, the composition for precious metal sintering becomes hard and is difficult to be handled for shaping. If the solvent amount is too much, the composition for precious metal sintering cannot maintain its shape. In order to finally obtain a prescribed ratio of an amount of the solvent in the composition for precious metal sintering, the solvent may be added portionwisely in two or more installments, or the solvent may be added at one time after a previously-prepared mixture of the organic binder solution in a prescribed concentration is added to the precious metal powder.
[0075] If a paste-like composition for precious metal sintering is desired, oily (meth)acrylate ester copolymer, oily phthalate ester or the like may be used, which serves as both the organic binder and the solvent (that is, as the organic binder solution).
[0076] The organic binder solution containing the organic binder, the solvent, and the organic additive mixable with the solvent to be added where necessary is preferably used in a concentration from 1 to 20 wt % including the organic additive.
[0077] The precious metal powder, the above-mentioned organic binder solution, and an inorganic additive such as a sintering accelerator or an adhesiveness improver to be added where necessary, except for the hollow glass powder, compose a precious metal fundamental composition of the present invention.
[0078] In the precious metal fundamental composition, 0.02 to 3.0 wt %, of starch and 0.02 to 3.0 wt % of a water-soluble cellulose-based binder by the dry solids content excluding the solvent are more preferably used as the above-mentioned organic binder. In this case, the solvent preferably used is water.
[0079] The water-soluble cellulose-based binder gives plasticity as described above. The starch increases dry strength of the composition for precious metal sintering when dried. However, if the starch alone is used as the organic binder, the obtained object tends to crack easily when applied. Thus, the water-soluble cellulose-based binder is also used for solving the problem.
[0080] The starch in a 0.02 to 3.0 wt % by the dry solids content excluding water as the solvent is contained in the precious metal fundamental composition as described above. If an amount of the starch is less than 0.02 wt %, the dry strength tends to be insufficient when dried. If the amount of the starch is more than 3.0 wt %, the obtained object tends to easily crack when applied and its shrinkage ratio is increased. On the other hand, as described above, the water-soluble cellulose-based binder in 0.02 to 3.0 wt % by the dry solids content excluding water as the solvent is also contained in the precious metal fundamental composition, as described above. If an amount of the water-soluble cellulose-based binder is less than 0.02 wt %, its effect of giving plasticity is not sufficiently achieved. If the amount of the water-soluble cellulose-based binder is more than 3.0 wt %, the shrinkage ratio of the obtained object is increased. The water-soluble cellulose-based binder includes methylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, and hydroxypropylmethylcellulose, etc, and is used by being dissolved in water as the solvent.
[0081] If the aforementioned starch and the water-soluble cellulose-based binder are used as the organic binder, the amount of the organic binder in the precious metal fundamental composition is preferably in the range of 0.1 to 4 wt % by the dry solids content excluding water as the solvent. In this case, if the amount of the organic binder is less than 0.1 wt %, it is difficult to obtain a homogeneous precious metal fundamental composition. Further, strength after application or drying becomes disadvantageously lowered. If the amount of the organic binder is more than 4 wt %, the shrinkage ratio of the obtained object is increased and the object tends to easily crack.
[0082] If polyethylene oxide is used, the polyethylene oxide preferably has a molecular weight from a hundred thousand to several millions and is used in an amount in the range of 0.1 to 3 wt %.
[0083] If a surfactant is used, surfactant in the range of 0.03 to 3 wt % is preferably used. If oil is used, oil in the range of 0.1 to 3 wt % is preferably used.
[0084] As a sintering accelerator, a powder of Bi, Se, Sb, In, Sn, and Zn or an alloy powder thereof may be added to the precious metal fundamental composition. Alternatively, at least one compound selected from the group of B 2 O 3 , SiO 2 , and Li 2 O may be added as a sintering accelerator. That is, at least one compound selected from the group of B oxide, Si oxide, and Li oxide may be contained in the precious metal fundamental composition as a sintering accelerator. Note that the hollow glass powder as a commercially-available product contains Si oxide or B oxide as described above, which is expected to effectively work as the sintering accelerator when sintering the precious metal powder.
[0085] Further, as the adhesiveness improver, a glass powder or a metallic compound powder selected from lead carbonate, lithium carbonate, zinc oxide, phosphoric acid, sodium carbonate, vanadium oxide, sodium silicate, phosphate salt, or the like may be added to the precious metal fundamental composition.
[0086] In addition to the above mentioned inorganic additives, a palladium (Pd) powder may be used as another inorganic additive. Herein, if a precious metal used is silver or silver alloy, a film of sulfide such as black-colored silver sulfide (Ag 2 S) is formed by the reaction between a sulfur ion (S 2− ) and the silver at ambient temperature, which drastically decreases a decorative effect of the silver sintered product. Thus, in order to avoid such a drawback, a palladium (Pd) powder in the range of 0.05 to 1 wt % with respect to a pure silver (Ag) powder maybe added so as to provide the silver sintered product with a sulfurization resistant property.
[0087] Additional ratios of the respective components mentioned above in the composition for precious metal sintering are described hereinafter. Preferably, the composition for precious metal sintering comprises the precious metal fundamental composition comprised of 50 to 99 wt % of the precious metal powder, 1 to 50 wt % of the organic binder solution, and the hollow glass powder in the range of the following ratio. That is, a volume ratio of a bulk volume of the hollow glass powder is set in the range of 5 to 160% with respect to a total volume of the composition for precious metal sintering in which the bulk volume of the hollow glass powder being measured in a state where the hollow glass powder exists independently without any other components. In this case, the organic binder solution in the composition for precious metal sintering has a concentration equivalent in the range of 1 to 20 wt % of the composition thereof.
[0088] With the additional ratios of the respective components as described above, the composition for precious metal sintering can be handled similarly to a composition for precious metal sintering according to conventional technology without reducing ease of handling such as shapability, and, while maintaining a visual (aesthetic) value, can obtain a precious metal sinter having much less weight than a precious metal sinter according to the conventional technology.
[0089] “Bulk volume” refers to a volume measured in such a way of, for example, putting a hollow glass powder in a measuring cylinder and measuring its volume with a scale of the measuring cylinder. The bulk volume includes the volume of the powder itself as well as that of interspace between particles of the powder and between the particles and the inside wall surface of the measuring cylinder.
[0090] Therefore, the volume ratio of a bulk volume of the hollow glass powder in the range of 5 to 160% with respect to a total volume of the composition for precious metal sintering in which the bulk volume of the hollow glass powder is measured in a state where the hollow glass powder exists independently without any other components can be expressed by:
[0000] (a bulk volume of a hollow glass powder added/an actual volume of a total composition)×100=5 to 160%. The calculated result may exceed 100% because the “bulk volume” of the hollow glass powder added is used.
[0091] In general, two different powders having different particle sizes from each other (for example, a precious metal powder and a hollow glass powder) are mixed together, the bulk volume of the mixed powder is smaller than a sum of respective bulk volumes of the two different powders. This is because, in the mixed powder, a smaller particle of one powder is crammed between larger particles of the other, which increases the bulk density of the mixed powder. Thus, in the present invention, an actual volume of an entire composition corresponds to an actual volume of the composition for precious metal sintering in which at least the precious metal powder, the hollow glass powder, and the organic binder solution are mixed together. Since the bulk volume of the added hollow glass powder is compared to the above actual volume, the bulk volume may exceed 100%.
[0092] Such a definition on the actual volume as above-mentioned has been made because the bulk density of the precious metal powder or the hollow glass powder varies according to the shape or a state thereof, and even if either one of a wt % or a vol % is used in the explanation, the actual desired conditions of the present invention cannot be clearly shown.
[0093] As described above, the ratios of the respective components in the composition for precious metal sintering are preferable in which: the precious metal fundamental composition is included, comprised of 50 to 99 wt % of the precious metal powder and 1 to 50 wt % of the organic binder solution; and the hollow glass powder is included, set in a volume ratio of a bulk volume of the hollow glass powder in the range of 5 to 160% with respect to a total volume of the composition for precious metal sintering in which the bulk volume of the hollow glass powder is measured in a state where the hollow glass powder exists independently without any other components. In other words, the ratios are expressed as the composition for precious metal sintering having: 40 to 90 vol % of the precious metal fundamental composition with 50 to 99 wt % of the precious metal powder, 0.02 to 10 wt % of the organic binder, and the remainder of the solvent; and 10 to 60 vol % of the hollow glass powder.
[0094] An added amount of the hollow glass powder is preferably 10 vol % or more, especially if an effect obtained by reducing the amount of the precious metal powder with reduction in weight is compared to the cost of preparing a lightweight clay-like composition. On the other hand, if 60 volt or less of the hollow glass powder is included in the composition for precious metal sintering, the obtained object does not fracture or crack after sintering, for example, during polishing.
[0095] The ratios of the respective components in the composition for precious metal sintering greatly vary depending on the size, the shape, or the like of the precious metal powder and the hollow glass powder. Moreover, the ratios are not determined in a uniform way because the different types (in form of clay, slurry, paste, and the like) of a desired composition for precious metal sintering require different types, combinations, solvent quantities, or the like of the organic binder. As a result, the maximum measurement value of a pushing load is used as a comprehensive indicator of the obtained composition for precious metal sintering (for example, as an indicator for determining whether the obtained composition for precious metal sintering obtained as a finished product is good or poor). The maximum measurement value of the pushing load is measured in such a way that a syringe is filled with the composition for precious metal sintering, and a value of the maximum pushing load is measured when the composition for precious metal sintering is extruded from an outlet of the syringe.
[0096] The maximum measurement value of a syringe pushing load is influenced by the size, the shape, and the like of the precious metal powder and the hollow glass powder. Moreover, it is convenient that the maximum measurement value of a syringe pushing load varies according to a type, the combination, the water content, or the like of the organic binder, as well as the combination ratio of the precious metal powder, the hollow glass powder, and the organic binder solution. The maximum measurement value of a syringe pushing load can therefore be a comprehensive indicator of the composition for precious metal sintering.
[0097] Next are described a device for measuring a maximum value of a syringe pushing load and a method of measurement.
(1) Measurement Device
[0098] Herein, description is made taking a case as an example in which a testing device (manufactured by Shimadzu Corporation, a compact desk-sized testing machine EZ Test [EZ-S type]) shown in FIG. 1 is used as the syringe pushing load measurement device. A crosshead 30 is disposed in a vertically movable manner along a support post 20 of a measurement device body 10 at a desired constant speed.
[0099] An upper compression jig 50 is fixed to a lower portion of an end of the crosshead 30 via the lower end of a gauge head of a load cell 40 . A disk-shaped plate 51 is disposed at a tip of the upper compression jig 50 such that the plate 51 can come in contact with and pushes down a plunger (piston) 91 of a syringe 90 .
[0100] A support post base 60 is disposed at a base end lower portion of the support post 20 of the measurement device body 10 . A lower stationary compression stand 70 is fixed on the support post base 60 below the upper compression jig 50 . An H-section steel [H125 (H dimension)×125 (B dimension)] 80 is put on an upper surface of the lower stationary compression stand 70 . A hole 82 is created in an upper flange 81 of the H-section steel 80 . The hole 82 allows a barrel (external cylinder) 92 of the syringe 90 to penetrate but does not allow a flange 93 disposed on the barrel 92 to penetrate.
(2) Method of Measurement
[0101] A 2-ml syringe [product name: JMS syringe 2-ml without needle (micro), manufactured by JMS Co., Ltd.] having an inner diameter of 6 mm, an outlet inner diameter of 1.3 mm, and an outlet inner length of 8.3 mm is filled with 1 ml of the composition for precious metal sintering to be measured. The syringe 90 is inserted from above into the hole 82 of the H-section steel 80 put on the lower stationary compression stand 70 of the measurement device body 10 . The flange 93 of the syringe 90 is brought in contact with the upper flange 81 of the H-section steel 80 , to thereby fix the syringe 90 .
[0102] The crosshead 30 is moved downward along the support post 20 at a constant speed of 17 mm/minute until the plate 51 at a tip of the upper compression jig 50 presses down the plunger 91 of the syringe 90 , to thereby extrude the composition for precious metal sintering from the outlet of the syringe 90 . Values of pushing load during a period in which the plunger 91 of the syringe 90 travels 10 mm are recorded with a recorder (not shown) accompanying the device. The maximum value is extracted from the recorded measurement values.
[0103] If the maximum measurement value of the pushing load measured by the above measurement method is in the range of 0.08 to 1.13 N, the composition for precious metal sintering is good and is excellent in shapability.
[0104] Further, if the maximum measurement value of the pushing load measured by the above measurement method is in the range of 0.24 to 1.13 N, the composition for precious metal sintering has plasticity especially suitable for manual shaping like ordinary clay and is excellent in shapability.
[0105] Even further, if the maximum measurement value of the pushing load measured by the above measurement method is in the range of 0.08 to 0.23 N, the composition for precious metal sintering is suitable for representing a delicate line pattern. This is because the composition for precious metal sintering filled in a syringe, at the tip of which is set a fine nozzle, can be easily extruded in a filament shape or a string shape by manually pressing the plunger (piston) of the syringe.
[0106] Generally, a 10-ml syringe is preferably used in the shaping process. A fine nozzle attached to the syringe preferably has an inner diameter in the range of 0.4 to 1.2 mm.
[0107] When a clay-like composition is extruded from the syringe, it is needed to extrude a necessary amount of the clay-like composition at as constant a speed as possible. If the clay-like composition is extruded at a slow speed or is stopped halfway, the extruded portion thereof in such a state becomes thin and loses its aesthetic value.
[0108] The thinner the nozzle, the larger the resistance of extruding the clay-like composition from the syringe. Accordingly, if the clay-like composition is too hard, it is thus difficult to extrude the clay-like composition at a constant speed. Nonetheless, if a thin nozzle is used, the composition for precious metal sintering quickly gets dry because the surface area thereof is increased. Thus, even if the composition for precious metal sintering is softer than the ordinary one, the composition can maintain its form because the surface thereof becomes hard before the composition drips.
[0109] On the other hand, if the soft clay-like composition is used for drawing a thick line, the composition tends to quickly drip. Accordingly, for drawing a thick line, a hard clay-like composition is conveniently used because the resistance of extruding the clay-like composition from a syringe is reduced in case of the thick line.
[0110] A process for producing a precious metal sinter of the present invention includes the steps of: shaping the composition for precious metal sintering as described above; drying the shaped object; and sintering the dried shaped object to obtain the precious metal sinter.
[0111] The composition for precious metal sintering of the present invention can be shaped, dried, and sintered in a similar way to a process for producing a precious metal sinter according to the conventional technology, because the composition for precious metal sintering of the present invention does not lose ease of handling such as shapability. Accordingly, a precious metal sinter having much less weight can be obtained while maintaining a visual value thereof.
[0112] Thus, in the step of shaping the composition for precious metal sintering, the composition for precious metal sintering may be shaped arbitrarily using a hand or a jig such as a spatula, similar to a conventional composition for precious metal sintering (which does not include the hollow glass powder). Further, the composition for precious metal sintering may be mold-formed using a mold which may be modified from a generally-available mold. Furthermore, the composition for precious metal sintering may be shaped and mold-formed in a combination manner. For example, the composition for precious metal sintering is put in a mold. Then, the molded composition for precious metal sintering is removed from the mold to be further shaped using a hand, a jig, or the like.
[0113] The composition for precious metal sintering of the present invention may be dried and sintered in any suitable combination with a conventional composition for precious metal sintering including no hollow glass powder, a shaped object for precious metal sintering, a precious metal cast object, or the like. Specifically, the composition for precious metal sintering of the present invention may be prepared in combination with, for example, silver and gold, or platinum and gold, and then dried and sintered simultaneously or successively.
[0114] In the step of sintering the dried shaped object, the sintering temperature is adjusted in the range of 600 to 900° C. which is near the softening point of the hollow glass powder. This makes it possible to produce a lightweight precious metal sinter without using a special device or installations, similar to the process according to conventional technology.
[0115] FIG. 2 and FIG. 3 show a SEM (Scanning Electron Microscope) image of a precious metal sinter of the present invention which is produced by sintering the composition for precious metal sintering (a composition for silver sintering) of the present invention having a composition shown in a top row of Table 2. The precious metal sinter is sintered in an electric furnace at 650° C. for 30 minutes.
[0116] In general, a formed object containing powder of a precious metal shrinks more than the bare metal thereof after sintered. The smaller the density of the powder, the larger the shrinkage. This means that a finished sinter may have a shape far from that of its original formed object.
[0117] However, as seen from the SEM image, when the composition for precious metal sintering (containing the hollow glass powder) of the present invention is used, the hollow glass powder maintains shape without melting under sintering conditions of 650° C. for 30 minutes, even though the density of the composition for precious metal sintering is small. Hereby, it can be understood that the hollow glass powder prevents the precious metal powder from shrinking in volume, which allows the precious metal sinter to maintain shape.
[0118] FIG. 4 and FIG. 5 show a SEM image of a precious metal sinter of the present invention which is produced by sintering the composition for precious metal sintering (a composition for silver sintering) of the present invention having the same composition as mentioned above and shown in the top row of Table 2. The sintering was conducted in an electric furnace at 800° C. for 30 minutes.
[0119] The SEM image demonstrates that the hollow glass powder is deformed but does not melt completely to maintain the shape to a certain degree, under the sintering conditions of 800° C. for 30 minutes. Hereby, it can be understood that the hollow glass powder prevents the precious metal powder from shrinking in volume and contributes to maintaining the shape of the sinter, even though the density of the composition for precious metal sintering is small.
[0120] The precious metal sinter of the present invention has a drastically reduced weight by mixing the hollow glass powder therein and maintains a visual value, similarly to a precious metal sinter according to the conventional technology.
[0121] That is, the precious metal sinter of the present invention appears similar to a conventional precious metal sinter including no hollow glass powder and is extremely light, because the precious metal sinter of the present invention has a structure in which the hollow glass powder is dispersed in the precious metal sinter. The precious metal sinter of the present invention is capable of obtaining the precious metallic luster thereof by being polished, similarly to the conventional precious metal sinter. Accordingly, the precious metal sinter of the present invention can be suitably used for accessories to be worn such as a pendant (head) and a brooch as well as glasses, metallic parts of a bag, and lightweight parts of a watch's belt, case, and parts on an hour plate.
[0122] Further, the precious metal sinter of the present invention can provide a more decorative effect by being subjected to surface treatment such as electroplating, electroless plating, a deposition film-formation treatment such as PVD and CVD, or the like. Herein, it is noted that the precious metal sinter of the present invention comprises an electrical insulating material on a portion of the surface thereof. Therefore, particularly if the surface treatment such as electro/electroless plating is performed for the precious metal sinter of the present invention, the plating treatment may be performed after conducting activator or sensitizer treatment (activation) that gives electrical conductivity to the surface of the precious metal sinter. Further, if the PVD/CVD treatment is performed, the precious metal sinter may be provided with an intermediate film so as to improve the adhesiveness thereof.
[0123] Further, it is also possible to enhance the decorative effect of the precious metal sinter by mixing hollow glass powder to which coloring treatment has been conducted, with a clay-like composition for precious metal sintering.
Examples
Example 1
[0124] A silver fundamental composition was prepared by mixing: 8 wt % of an organic binder solution consisting of 8.75 wt % of starch, 10 wt % of cellulose, and the remainder of water; and 92 wt % of a silver mixed powder consisting of 50 wt % of Ag powder having a mean particle diameter of 2.5 μm (46 wt % with respect to a total of the silver fundamental composition) and 50 wt % of Ag powder having a mean particle diameter of 20 μm (46 wt % with respect to the total of the silver fundamental composition).
[0125] With 99.8 g of the silver fundamental composition thus obtained was mixed 0.2 g of a hollow glass powder (equivalent to a bulk volume of 2.67 cm 3 measured in a state where the hollow glass powder exists independently without any other components) (Glass Bubbles, manufactured by Sumitomo 3M Ltd.: a bulk density of 0.075 g/cm 3 , a real density of 0.125 g/cm 3 , and a particle size of 65 μm) to obtain a composition for silver sintering.
[0126] The density of the composition for silver sintering was calculated from the volume and the weight of the composition for silver sintering molded in a cube, to thereby obtain the result of 5.51 g/cm 3 .
[0127] Then, the composition for silver sintering was filled in a 2-ml syringe [product name: JMS syringe 2-ml without needle (micro), manufactured by JMS Co., Ltd.] having an inner diameter of 6 mm, an outlet inner diameter of 1.3 mm, and an outlet inner length of 8.3 mm to measure the value of the above-mentioned pushing load. The measurement value of the pushing load was 0.90 N.
[0128] Next, the composition for silver sintering was molded in a silicon mold having a prescribed volume and was sintered in an electric furnace under conditions shown in Table 1. Subsequently, the obtained sintered sample was barrel-polished and was evaluated as “good” or “poor” by determining whether or not the obtained sintered sample was broken with cracking, fracture, or the like. The evaluation results are also shown in Table 1.
[0129] Further, the weight of each composition for silver sintering filled in the silicon mold and the weight of each sinter obtained by sintering the composition for silver sintering are shown in Table 2. The sintering was conducted under conditions of 600° C. for 30 minutes. The results are shown in Table 3. Herein, each weight reduction rate described in Table 3 was calculated by the following equation:
[0000] Weight reduction rate=(Weight of silver sinter in Comparative Example 6−Weight of silver sinter in each Example)/Weight of silver sinter in Comparative Example 6.
[0000]
TABLE 1
Sintering
Temperature
Time
(° C.)
(min.)
Evaluation
Results
600
30
good
Polishing obtained Metallic
700
15
good
luster. No cracking. 1.9%
800
5
good
weight reduction occurred,
compared to the composition
which added no hollow glass
powder.
Examples 2 to 8
[0130] Examples 2 to 8 were conducted similarly to Example 1 as described above except that an added amount and a size of the hollow glass powder were changed as shown in Table 2, such that a bulk volume of the hollow glass powder was set in the range of 5 to 160% with respect to the entire composition. Sintering was conducted under conditions of 600° C. for 30 minutes. The results are shown in Table 2 and Table 3.
Comparative Example 1
[0131] Comparative Example 1 was conducted similarly to Example 1 as described above except that an added amount and a size of the hollow glass powder were changed as shown in Table 2. Sintering was conducted under conditions of 600° C. for 30 minutes. Compositions of the formula for silver sintering and the results are shown in Table 2 and Table 3, respectively.
Comparative Examples 2 and 3
[0132] Comparative Examples 2 and 3 were conducted similarly to Example 1 as described above except that, in Comparative Example 2, 1.3 g of, and, in Comparative Example 3, 0.1 g of plastic micro objects (product name: EXPANCEL [manufactured by Japan Fillite Co., Ltd.]) having a mean particle diameter of 50 μm and a bulk density of 0.02 g/cm 3 was added respectively, to thereby each prepare 100 g in weight of the compositions for silver sintering. The plastic micro objects were used instead of the hollow glass powder. Sintering was conducted under conditions of 600° C. for 30 minutes. Obtained sinters in both Comparative Example 2 and Comparative Example 3 were deformed during sintering and were not successful. The compositions of the obtained formula for silver sintering and the results are shown in Table 2 and Table 3, respectively.
Comparative Examples 4 and 5
[0133] Comparative Examples 4 and 5 were conducted similarly to Example 1 as described above except that, in Comparative Example 4, 15.8 g of, and, in Comparative Example 5, 1.4 g of, silica-based hollow micro spheres (product name: Fillite [manufactured by Japan Fillite Co., Ltd.]) having a mean particle diameter of 60 μm and a bulk density of 0.4 g/cm 3 was added respectively, to thereby each prepare 100 g in weight of the composition for silver sintering. Here, the silica-based hollow micro spheres were used instead of the hollow glass powder. Sintering was conducted under conditions of 600° C. for 30 minutes. The results show that impurities were observed on the respective surfaces of the sinters in both Comparative Example 4 and Comparative Example 5 even after polishing the sinters, thereby failing to show the sufficient metallic luster. The compositions of the obtained compositions for silver sintering and the results are shown in Table 2 and Table 3, respectively.
Comparative Example 6
[0134] Comparative Example 6 was conducted similarly to Example 1 under the conditions shown in Table 2, except that the hollow glass powder was not used. The sintering was conducted under conditions of 600° C. for 30 minutes. The compositions of the obtained formula for silver sintering and the results are shown in Table 2 and Table 3, respectively.
[0000]
TABLE 2
Hollow Glass Powder
(HGP) or Alternative
(Comparative
Composition for Precious
Examples
Metal Sintering
(Com. Ex.)
(CPMS)
2 to 5)
Bulk
Weight
Weight of
Mean
Weight of
Vol. of
of CPMS
Precious
Particle
Bulk
Added
Bulk
Fundamental
Total
Total
Total
HGP/Total
used in
Metal
Diameter
Density
Amount
Volume
Composition
Weight
Density
Volume
Volume
Mold
Sinter
(μm)
(g/cm 3 )
(g)
(cm 3 )
(g)
(g)
(g/cm 3 )
(cm 3 )
(%)
(g)
(g)
SEM
27
0.378
4.75
12.6
95.25
100
4.02
24.9
50.6
40.0
Image
Example
65
0.075
0.2
2.67
99.8
100
5.51
18.1
14.8
54.9
50.5
(Ex.) 1
Ex. 2
65
0.075
2.8
37.3
97.2
100
4.10
24.4
153
40.8
35.6
Ex. 3
55
0.155
0.5
3.23
99.5
100
5.38
18.6
17.4
53.6
49.3
Ex. 4
55
0.155
6.3
40.6
93.7
100
2.55
39.2
104
25.4
23.5
Ex. 5
40
0.285
0.5
1.75
99.5
100
5.32
18.8
9.3
53.0
48.8
Ex. 6
40
0.285
12.1
42.5
87.9
100
2.39
41.8
102
23.8
22.1
Ex. 7
27
0.378
0.5
1.32
99.5
100
5.39
18.6
7.1
53.7
49.4
Ex. 8
27
0.378
14.9
39.4
85.1
100
2.5
40.0
98.5
24.9
23.2
Ex. 9
27
0.378
5.4
14.3
94.6
100
3.5
28.6
50.0
34.9
31.6
Com.
65
0.075
4.8
64.0
95.2
100
3.05
32.8
195
30.4
Ex. 1
Com.
50
0.02
1.3
65.0
98.7
100
2.3
43.5
149
22.9
Ex. 2
Com.
50
0.02
0.1
5.0
99.9
100
5.06
19.8
25.3
50.4
Ex. 3
Com.
60
0.4
15.8
39.5
84.2
100
2.66
37.6
105
26.5
Ex. 4
Com.
60
0.4
1.4
3.5
98.6
100
5.12
19.5
17.9
51.0
Ex. 5
Com.
0
100
100
5.62
17.8
0
56
51.5
Ex. 6
[0000]
TABLE 3
Evaluation
Results
Ex. 1
good
Polishing obtained metallic luster. No
cracking occurred. 1.9% weight reduction
compared to the composition added no hollow
glass powder (Comparative Example 6).
Ex. 2
good
Polishing obtained metallic luster. No
cracking. 27.0% weight reduction compared to
the composition added no hollow glass powder.
Ex. 3
good
Polishing obtained metallic luster. No
cracking. 4.3% weight reduction compared to the
composition added no hollow glass powder.
Ex. 4
good
Polishing obtained metallic luster. No
cracking. 54.4% weight reduction compared to
the composition added no hollow glass powder.
Ex. 5
good
Polishing obtained metallic luster. No
cracking. 5.2% weight reduction compared to the
composition added no hollow glass powder.
Ex. 6
good
Polishing obtained metallic luster. No
cracking. 57.1% weight reduction compared to
the composition added no hollow glass powder.
Ex. 7
good
Polishing obtained metallic luster. No
cracking. 4.1% weight reduction compared to the
composition added no hollow glass powder.
Ex. 8
good
Polishing obtained metallic luster. No
cracking. 55.0% weight reduction compared to
the composition added no hollow glass powder.
Com.
Poor
Satin finished surface sinter was obtained.
Ex. 1
Fractured during polishing.
Com.
Poor
Deformed during sintering. Failed to obtain
Ex. 2
good sinter.
Com.
Poor
Deformed during sintering. Failed to obtain
Ex. 3
good sinter.
Com.
Poor
Impurities were observed on sinter surface even
Ex. 4
after polishing. Failed to obtain sufficient
metallic luster.
Com.
Poor
Impurities were observed on sinter surface even
Ex. 5
after polishing. Failed to obtain sufficient
metallic luster.
Discussion on Examples 1 to 8 and Comparative Examples 1 to 6
[0135] As seen in Table 2, in Examples 1 to 8 of the present invention, the composition for silver sintering was prepared by using hollow glass powder having the bulk density in the range of 0.075 to 0.378 g/cm 3 (a real density from 0.125 to 0.600 g/cm 3 ) and adding hollow glass powder in an amount equivalent to a bulk volume thereof in the range of 7.1 to 153% with respect to a total volume of the composition for silver sintering including the hollow glass powder (that is, bulk volume of hollow glass powder/total volume of composition for silver sintering=7.1 to 153%) [which is equivalent to an added weight in the range of 0.2 to 14.9 wt %]. The above bulk volume of the hollow glass powder corresponds to a volume percentage thereof in the range of about 10% to about 60% in the composition for silver sintering.
[0136] The compositions for silver sintering of Examples 1 to 8 were each put in a mold of the same type and were sintered to obtain respective silver sinters. The silver sinters demonstrated the weight reduction effect from 1.9 to 57.1% in weight, compared to a silver sinter of Comparative Example 6 without using the hollow glass powder (see Table 3). Little difference was recognized in easiness in handling between the compositions for silver sintering of Examples 1 to 8 and that of Comparative Example 6 containing no hollow glass powder as in conventional technology. In contrast, defects were observed, as shown in Table 3, in the sinter of Comparative Example 1 to which an inappropriate (too much) amount of the hollow glass powder was added, and in the sinters of Comparative Examples 2 to 5 each of which did not use the hollow glass powder. Thus, calculation of weight reduction rates in the Comparative Examples 1 to 5 was decided to be skipped.
Example 9
[0137] A gold fundamental composition was prepared by mixing: 8 wt % of an organic binder solution consisting of 8.75 wt % of starch, 10 wt % of cellulose, and the remainder of water; and 92 wt % of Au powder having a mean particle diameter of 4.5 μm.
[0138] With 94.6 g of the gold fundamental composition thus obtained was mixed 5.4 g of the hollow glass powder (Glass Bubbles, manufactured by Sumitomo 3M Ltd.: a bulk density of 0.378 g/cm 3 , a real density of 0.6 g/cm 3 , and a particle size of 27 μm) to obtain a composition for gold sintering.
[0139] Then, the composition for gold sintering was molded in a silicon mold and was sintered in an electric furnace under conditions of 800° C. for 30 minutes. The weight of the sinter thus obtained after the sintering was 31.6 g, resulting in a 40.0% weight reduction compared to a sinter having the same volume but added no hollow glass powder, which weighed 52.3 g. The results are also shown in Table 2.
[0140] Finally, the obtained sinter was barrel-polished, to thereby obtain a metallic luster thereof without causing cracking, fracture, or the like.
Example 10
[0141] A silver fundamental composition was prepared by mixing: 8 wt % of an organic binder solution consisting of 5.25 wt % of starch, 10 wt % of cellulose, and the remainder of water; and 92 wt % of a silver mixed powder consisting of 50 wt % of Ag powder having a mean particle diameter of 2.5 μm (46 wt % with respect to a total of the silver fundamental composition) and 50 wt % of Ag powder having a mean particle diameter of 20 μm (46 wt % with respect to the total of the silver fundamental composition).
[0142] With 99.8 g of the silver fundamental composition thus obtained was mixed 0.2 g (a bulk volume of 2.67 cm 3 ) of the hollow glass powder (Glass Bubbles, manufactured by Sumitomo 3M Ltd.: a bulk density of 0.075 g/cm 3 , a real density of 0.125 g/cm 3 , and a particle size of 65 μm) to obtain a composition for silver sintering (a total volume of 18.1 cm 3 ). Herein, a ratio of the bulk volume of the added hollow glass powder assuming that the hollow glass powder exists independently was 14.7% with respect to the total volume of the composition for silver sintering.
[0143] Then, the composition for silver sintering was filled in a 2-ml syringe [product name: JMS syringe 2-ml without needle (micro), manufactured by JMS Co., Ltd.] having an inner diameter of 6 mm, an outlet inner diameter of 1.3 mm, and an outlet inner length of 8.3 mm to measure a value of the above-mentioned pushing load. The measurement value was 0.24 N.
[0144] A tip of another unused 2-ml syringe was cut to have indentation. The syringe was filled with the composition for silver sintering and then was pushed to extrude the composition for silver sintering. To make use of lines (or texture) drawn on the extruded bar-shaped composition for silver sintering, both ends of the bar composition were twisted to finally form a ring. The ring was put in a drying oven, and was dried at 80° C. for 20 minutes. Subsequently, the ring was sintered in an electric furnace at 600° C. for 30 minutes, and was finished with a stainless-steel brush and a polishing spatula, to thereby bring about a metallic luster.
[0145] As a result, flowing lines were formed on the surface of the ring, thereby obtaining a ring with excellent decorative performance.
Example 11
[0146] In Example 11, a ring was created similarly to Example 10 but was left in the drying step
[0147] A silver fundamental composition was prepared by mixing: 13.5 wt % of an organic binder solution consisting of 5.25 wt % of starch, 6 wt % of cellulose, and the remainder of water; and 86.5 wt % of a silver mixed powder consisting of 50 wt % of Ag powder having a mean particle diameter of 2.5 μm (43.25 wt % with respect to a total of the silver fundamental composition) and 50 wt % of Ag powder having a mean particle diameter of 20 μm (43.25 wt % with respect to the total of the silver fundamental composition).
[0148] With 99.8 g of the silver fundamental composition thus obtained was mixed 0.2 g (a bulk volume of 2.67 cm 3 ) of the hollow glass powder (Glass Bubbles, manufactured by Sumitomo 3M Ltd.: a bulk density of 0.075 g/cm 3 , a real density of 0.125 g/cm 3 , and a particle size of 65 μm) to obtain a composition for silver sintering (a total volume of 25.3 cm 3 ). Herein, a ratio of the bulk volume of the added hollow glass powder assuming that the hollow glass powder exists independently was 10.5% with respect to the total volume of the composition for silver sintering.
[0149] Then, the composition for silver sintering was filled in a 2-ml syringe [product name: JMS syringe 2-ml without needle (micro), manufactured by JMS Co., Ltd.] having an inner diameter of 6 mm, an outlet inner diameter of 1.3 mm, and an outlet inner length of 8.3 mm to measure a value of the above-mentioned pushing load. The measurement value was 0.08 N.
[0150] Further, the composition for silver sintering was filled in another 10-ml syringe. Then, the syringe was equipped with a resin nozzle (having an inner diameter of 0.84 mm) at the tip thereof. The composition for silver sintering was excluded from the syringe to arrange an initial pattern on a surface of the above-mentioned ring left after the drying step.
[0151] The ring thus obtained was put in a drying oven, dried at 80° C. for 20 minutes, and sintered in an electric furnace at 600° C. for 30 minutes. The ring was then finished with a stainless-steel brush and a polishing palette, to thereby bring about a metallic luster.
[0152] Accordingly, an original three dimensional pattern was added to the surface of the ring, resulting in obtaining a ring with excellent decorative performance.
Comparative Example 7
[0153] In Comparative Example 7, a ring was created similarly to Example 10 but was left in the drying step.
[0154] A silver fundamental composition was prepared by mixing: 20 wt % of an organic binder solution consisting of 3 wt % of starch, 4 wt % of cellulose, and the remainder of water; and a 80 wt % of a silver mixed powder consisting of 50 wt % of Ag powder having a mean particle diameter of 2.5 μm (40 wt % with respect to a total of the silver fundamental composition) and 50 wt % of Ag powder having a mean particle diameter of 20 μm (40 wt % with respect to the total of the silver fundamental composition).
[0155] With 99.8 g of the silver fundamental composition thus obtained was mixed 0.2 g (a bulk volume of 2.67 cm 3 ) of the hollow glass powder (Glass Bubbles, manufactured by Sumitomo 3M Ltd.: a bulk density of 0.075 g/cm 3 , a real density of 0.125 g/cm 3 , and a particle size of 65 μm) to obtain a composition for silver sintering (a total volume of 31.2 cm 3 ). Herein, a ratio of the bulk volume of the added hollow glass powder assuming that the hollow glass powder exists independently was 8.6% with respect to the total volume of the composition for silver sintering.
[0156] Then, the composition for silver sintering was filled in a 2-ml syringe [product name: JMS syringe 2-ml without needle (micro), manufactured by JMS Co., Ltd.] having an inner diameter of 6 mm, an outlet inner diameter of 1.3 mm, and an outlet inner length of 8.3 mm to measure a value of the above-mentioned pushing load. The measurement value was 0.05 N.
[0157] Then, the syringe was equipped with a resin nozzle (having an inner diameter of 0.84 mm) at a tip thereof. The composition for silver sintering was excluded from the syringe to arrange an initial pattern on the surface of the above-mentioned ring left after the drying step.
[0158] The ring thus obtained was put in a drying oven and was dried at 80° C. for 20 minutes. Hereby, a portion of the lines in the initial pattern additionally arranged on the surface of the ring ran off before dried and solidified, making it impossible for the lines to be read as initials.
Comparative Example 8
[0159] A silver fundamental composition was prepared by mixing: 8 wt % of an organic binder solution consisting of 10 wt % of starch, 8.75 wt % of cellulose, and the remainder of water; and 92 wt % of a silver mixed powder consisting of 50 wt % of Ag powder having a mean particle diameter of 2.5 μm (46 wt % with respect to a total of the silver fundamental composition) and 50 wt % of Ag powder having a mean particle diameter of 20 μm (46 wt % with respect to the total of the silver fundamental composition).
[0160] With 99.8 g of the silver fundamental composition thus obtained was mixed 0.2 g (a bulk volume of 2.67 cm 3 ) of the hollow glass powder (Glass Bubbles, manufactured by Sumitomo 3M Ltd.: a bulk density of 0.075 g/cm 3 , a real density of 0.125 g/cm 3 , and a particle size of 65 μm) to obtain a composition for silver sintering (a total volume of 18.1 cm 3 ). Herein, a ratio of the bulk volume of the added hollow glass powder assuming that the hollow glass powder exists independently was 14.7% with respect to the total volume of the composition for silver sintering.
[0161] Then, the composition for silver sintering was filled in a 2-ml syringe [product name: JMS syringe 2-ml without needle (micro), manufactured by JMS Co., Ltd.] having an inner diameter of 6 mm, an outlet inner diameter of 1.3 mm, and an outlet inner length of 8.3 mm to measure a value of the above-mentioned pushing load. The measurement value was 1.5 N.
[0162] Subsequently, the composition for silver sintering was manually shaped in a bar-like form. When both ends of the bar-like composition were pulled to each other so as to form a ring, the bar-like composition was too hard to be bent and was finally broken.
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A composition for precious metal sintering that yields a precious metal sinter for use in jewelry, ornaments, accessories, etc., by sintering, especially that realizes not only production of a precious metal sinter even when the precious metal content per volume of the composition for precious metal sintering is reduced but also in a striking reduction of the weight of the precious metal sinter. Further, there are disclosed a process for producing the precious metal sinter and the precious metal sinter. This composition for precious metal sintering is characterized by comprising a mixture of precious metal powder, hollow glass powder and organic binder solution.
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FIELD OF THE INVENTION
The present invention relates to a system and method for secondary gas introduction, including but not limited to EGR, PCV, EVAP and/or idle air, into the air induction system for a multi-cylinder internal combustion engine, and more particularly to a reservoir for introducing secondary gas into the induction system.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 5,590,488, assigned to the assignee of the prevent invention, which is incorporated herein by reference ('488 patent), describes an intake manifold having an Exhaust Gas Recirculation (EGR) passage formed therein extending generally parallel to a cooling passage formed in the manifold. The EGR flow in the '488 patent is considered ported because EGR flows through secondary EGR passages extending from the EGR supply passage to individual runners in the intake manifold.
In an EGR system according to the '488 patent, the EGR ports are provided in close proximity to the cylinder head. The EGR ports are provided within the individual intake runners, which results in communication between the ports. Such communication short circuits a tuned induction system, resulting in a degradation of engine performance and can provide for unequal distribution of EGR. This unequal distribution can also affect engine performance and emissions because the EGR is not properly controlled between cylinders. This makes it difficult to control the EGR to ensure smooth running of the engine.
U.S. Pat. Nos. 5,535,717 and 5,492,093 provide a system for introducing EGR into the an air induction system. These patents provide introduction of EGR within a balance tube, or into one of the runners, or a primary runner. This system does not promote equal distribution or mixing, as air is typically stagnant in the primary runner unless balance tube valve and the intake valves for the cylinders are open, and therefore distribution of the EGR is uneven between the cylinder banks. As described above, this unequal distribution may produce undesirable operation of the vehicle. A valve for such a balance tube is open normally in mid-range operation, such as between approximately 3000 and 4500 RPM. Thus, outside this range (at low speed or high speed operation), the balance valve is closed and the EGR gas is not properly mixed, and therefore an Inefficient, unequal cylinder bank distribution exists.
It would therefore be desirable to provide an EGR system which is balanced between the cylinders of a multi-cylinder engine and which provides proper mixing of the recirculated exhaust gas with the intake air at separate or coincidental reservoirs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic plan view of an engine including an intake manifold according to the present invention;
FIG. 2 is a partial cross-section through the manifold of FIG. 1;
FIG. 3 is a partial cross-section of the intake manifold of FIG. 1, as indicated in FIG. 2;
FIG. 4 is a partial cross-section through the intake manifold shown in FIG. 1;
FIG. 5 is an isometric frontal view of an engine with a manifold according to the present invention;
FIG. 6 is an isometric rear view of the engine of FIG. 5; and
FIG. 7 is a schematic representation of a partial cross sectional view through a combustion chamber in an internal combustion engine.
SUMMARY OF THE INVENTION
Accordingly, to overcome the EGR and other gas balance and mixing problems of an induction system from the prior art, a novel intake manifold is provided for a multi-cylinder internal combustion engine. The manifold is attached to a pair of cylinder heads. The manifold includes a plurality of intake runners for conducting air and fuel to a plurality of intake ports formed in the cylinder heads. A pair of intake plenums communicate with the plurality of intake runners. Each of the runners supply one of the cylinder heads. A secondary gas supply reservoir is provided in the manifold for introduction of secondary gas to the intake system.
Advantages of the present design include proper distribution and mixing of additional gases introduced into the intake system, including idle air, PCV and EVAP and other fluids at separate or coincidental supply reservoirs.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in the Figures, and particularly FIG. 1, an intake manifold 10 is shown having a provision for mounting a throttle body 12 thereto. The throttle regulates the flow of a primary air flow gas, which is defined as the induction air brought into the manifold through the throttle body from ambient. The Throttle body 12 comprises a valve which is adjusted using a throttle adjustment means 13 as known to one skilled in the art, such as a cable or electronic adjuster.
The manifold includes a plurality of primary runners 60, 61, 62, 63, 64, 65, 66 and 67. In the embodiment shown in FIG. 1, five of eight primary runners 60, 61, 62, 66, 67 are visible for an eight-cylinder engine. The primary runners 60-67 distribute gases, including the primary air flow gas and secondary gases, to the intake ports. A representative intake port is illustrated in FIG. 7 at 23, and is provided in the heads 30, 31 of an internal combustion engine 28 to provide intake air to a combustion chamber 27. The present invention is applicable to a port fuel injection engine as well as a direct injection engine, and therefore the detail of the injector and spark plug positioning are not illustrated in FIG. 7.
The secondary gases include any other gas introduced into the induction system downstream of the throttle body. These gases typically require mixing within the induction system to provide equal cylinder-to-cylinder distribution and thereby promote smooth operation of the engine and to improve the emissions therefrom. The present invention is directed at providing a manifold and a method enabling such mixing and nearly equal distribution. The secondary gases include, but are not limited to, recirculated exhaust gas (EGR), EVAP, idle air and PCV. In a preferred embodiment, EGR is introduced into the manifold 10 through a tube 14. A known valve 15 for EGR regulates the flow of the exhaust gas introduced into the manifold 10. The EGR is fed into a reservoir 16 in the manifold 10 as is shown in FIG. 2.
As intake air is demanded by the engine through the secondary intake runners 18, 19, exhaust gas is drawn from the reservoir 16 through a pair of orifices 20, 22 provided in the manifold 10 leading between the runners 18, 19 and the reservoir 16. In this mariner, the exhaust gas is stored in the reservoir 16 and provided early in the intake system soon after the throttle 12 upon demand. When demand warrants, the EGR is thus drawn from the reservoir 16 and distributed to the secondary intake runners 18, 19 for introduction to the plenums 24, 25, then to primary runners 60-67 and ultimately into the cylinders (not shown) through a plurality of intake ports (not shown). This early introduction into the manifold 10 near the throttle 12 enables mixing within the manifold 10 and nearly equal distribution to all of the cylinders. The throttling of the gas at the throttle causes a venturi effect at the reservoir and sucks the secondary gas from the reservoir for mixing within the intake manifold prior to the air/fuel/secondary gas mixture being pulled into a primary runner. In a similar manner, when the throttle is closed and idle air is introduced into the intake manifold, the idle air draws the secondary gases from the reservoir.
The mixing minimizes any performance degradation due to short circuiting a tuned induction system, whereas introduction elsewhere in the induction system may result in unequal distribution and therefore the combustion in a particular cylinder may not be the same as other cylinders due to varying gas mixtures. This may result in poor performance, a rough feel, or unacceptable emissions. As understood by one skilled in the art and therefore not described in detail here, a tuned induction system is short-circuited using a balance tube 40 and balance tube communication valve 42 to tune the intake system and thereby improve the performance of the induction system and engine performance. The tuning principle and examples thereof are described in U.S pat. Nos. 5,408,962 and 5,638,785, assigned to the assignee of the present invention and which are incorporated herein by reference in their entirety.
Additional gases, such as Positive Crankcase Ventilation (PCV), Evaporative Emissions (EVAP), idle air, alternate fuels such as CNG, LPG, performance enhancing fuels and/or other gases may likewise be introduced into the manifold 10 within the reservoir 16 or a second reservoir 28 for distribution as described above. As illustrated in FIG. 2, PCV is introduced to the reservoir 16 through a second port 26 and thereby equally distribute this supply of PCV to the secondary intake runners 18, 19 in a manner similar to that described above for the EGR.
As shown in FIG. 3, a preferred embodiment includes a second reservoir 28 provided for the idle air and EVAP. As shown in FIG. 1, an idle air valve 32 controls the flow of idle air to the reservoir 28 through a conduit 36. EVAP is introduced to the conduit 36 and to the reservoir 28 at a connection 34 provided therefore. Idle air is introduced through the throttle 12 to a port 38 in the manifold 10. The idle air is then routed to the valve 32 and introduced to the reservoir 28 as described above. In this embodiment, the first reservoir 16 for the PCV and EGR is provided in close proximity to the second reservoir 28 and therefore the distribution of these gases is provided in a manner as described above. Furthermore, although not shown here, one skilled in the art will appreciate that EGR, PCV, EVAP or idle air may also be supplied in either one of the reservoirs 16 and 28 and/or in other separate reservoirs (not shown) for mixing and nearly equal distribution to the secondary intake runners 18, 19, as demanded by the engine.
As shown in the embodiment of FIG. 4, the second reservoir 28 distributes EVAP to the secondary intake runners 18, 19 through orifices 30, 32 in a manner similar to the gas distribution from first reservoir 16, as described above. As is further described above, the reservoirs 16, 28 are positioned adjacent and downstream of the throttle body 12. Thus, the reservoirs 16, 28 store the gases until demand from the engine draws the gases from the reservoirs into the secondary intake runners 18, 19, as demanded by the engine, and is therefore distributed to the cylinders in an equal manner.
While the invention has been shown and described in its preferred embodiments, it will be clear to those skilled in the art to which it pertains that many changes and modifications may be made thereto without departing from the scope of the invention. For example, although the invention has been generally described with respect to an engine having an intake system conveying air and fuel to the intake ports of the cylinder heads, a direct injection engine may similarly utilize the invention. Furthermore, the present invention can likewise be applied to: a single bore throttle body with single plenum, single bore throttle body with multiple plenums, dual bore throttle body with single plenum, dual bore throttle body with multiple plenums (illustrated in the Figures) providing the advantage of minimizing induction tuning loses by introducing the secondary emissions gasses as far away from the cylinder ports as packaging will permit. One skilled in the art appreciates that although a v-type engine is illustrated in the figures, this disclosure is directed at other engine configurations, not described here in specific detail.
While the invention shown herein has discussed the distribution of EGR, EVAP, PCV and idle air, one skilled in the art will further realize that the present invention is directed at the equal distribution and mixing of any secondary gas, including but not limited to alternative fuels (including CNG, LPG, performance enhancing fuels., etc.). One planning to introduce such fuels could also incorporate versions of my reservoir to provide equal cylinder-to-cylinder distribution in multi-cylinder engines. One skilled in the art appreciates that primary air flow gas is typically defined as induction air brought into throttle body from ambient surroundings, and secondary gasses are typically defined as any other gas introduced downstream of the throttle body which requires cylinder-to-cylinder distribution for, but not limited to, engine performance or emission requirements.
While the forms of the invention shown and described herein constitute the preferred embodiments of the invention; they is not intended to illustrate all possible forms thereof. The words used are words of description rather than of limitation, and various changes may be made from that which is described here without departing from the spirit and scope of the invention.
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An intake manifold and method for supplying EGR are provided for a multi-cylinder internal combustion engine. The manifold is attached to a cylinder head. The manifold includes a plurality of intake runners for conducting air to a plurality of intake ports formed in the cylinder head. An intake plenum communicates with the intake runners. A secondary gas reservoir is provided in the manifold for communication of secondary gas to the plenum.
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[0001] This application claims the benefit of U.S. Provisional Application No. 60/236,701, filed on Oct. 2, 2000.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present application relates, generally, to silica glass materials, and, more particularly, to modified rare-earth doped silica glass materials for use in optical fiber amplifiers, ASE sources and lasers.
[0004] 2. Description of the Related Art
[0005] The extraordinary advancement of wide area networking services, e.g., the Internet, over the past several years has been enabled by the confluence of two key technologies, i.e., the erbium doped optical fiber amplifier, EDFA, and wavelength division multiplexing, WDM. Since the discovery by Townsend and Payne in the late 1980's of a method for fabricating high quality rare-earth doped silica fibers, much work has centered on the development of and the exploitation of the EDFA. The typical EDFA consists of Er 3+ doped into an alumino-silicate glass optical fiber. The developments have revolutionized the telecommunications industry as EDFA has replaced electronic repeaters in fiber based networks. The EDFA coupled with the development of WDM technology has allowed for the engineering of high bandwidth optical systems in the region of 1525 to 1570 nm. This is within the “low-loss” or “third” optical fiber telecommunications window. The low-loss window is the range 1420 nm to 1650 nm where the attenuation per unit length for silica optical fiber is near its minimum, e.g., <0.35 dB/km. The C-band 1525 to 1585 nm, and L-band, 1585 to 1650 nm, are each covered by the EDFA, but it is apparent that these two bands represent a portion of the low-loss region for silica but not the total. Due to the fortunate coincidence of the Er 3+ gain transition with the low-loss window, the EDFA has come to be extensively used in optical fiber telecommunications systems. The EDFA has also enabled the transmission of enormous quantities of data via WDM, that is, by providing gain simultaneously for multiple data transmission channels at different wavelengths within the bandwidth of the EDFA. To date no practical amplifier has been demonstrated for wavelengths of <1520 nm, so that fully half of the low-loss window bandwidth is unused.
[0006] There is a desire for the development of the S-band amplifier. This requires that the rare-earth ion with an appropriate transition have fluorescence in the region of approximately 1450 to 1520 nm. Tm 3+ has the necessary fluorescence. The relevant transition is 3 H 4 to 3 F 4 , which fluoresces at 1430-1500 nm. In the absence of nonradiative quenching, the lifetime of the upper level, 3 H 4 , is expected to be approximately, 1.5 ms; this is observed for Tm 3+ in low phonon energy fluorozirconate glasses. However, the energy separation between 3 H 4 level and the next lower level, 3 H 5 , is sufficiently small, 4400 cm −1 , that the upper level is substantially quenched by multiphonon processes in high-phonon energy glasses like the silicates. The lifetime has been measured as <20 μs in a pure silica host. Depletion of the upper state lifetime via nonradiative processes reduces the population available to provide gain on the transition of interest. While fiber amplifiers based on this transition have been demonstrated in fluorozirconate glasses, these have proved impractical due to various problems with the host material.
[0007] Thulium, Tm, has a 3 H 4 to 3 F 4 transition which provided amplification in the S-band wavelength range using a fluorozirconate host. This fluorozirconate material possesses properties that do not lend the material for use in lasers or in optical fibers. These materials are hygroscopic, prone to formation of micro-crystallites over time and have glass transition temperatures at about 400° C. which prevents fusion splicing to standard telecommunications-grade fibers. In the event these glasses are butt spliced they tend to become damaged with heavy pumping.
[0008] Although the fluoride and tellurite hosts doped with thulium offer high quantum efficiencies for the 1.47 μm transition, some of the material's properties are problematic with respect to making a practical device. Fluoride glasses are very difficult to fabricate into low-loss fiber due to a propensity towards crystallization and suffer from poor chemical durability. Tellurite glasses, although stable, have a high index of refraction and high thermal expansion, which complicates splicing into an all-optical system.
[0009] With the advent of new silica fibers with low-loss across the entire region of 1200 to 1600 nm, i.e., <0.35 dB/km, optical amplifiers that can potentially amplify at other wavelengths within this region are increased importance.
[0010] Silica host materials do have both good chemical and mechanical properties, e.g., fusion splicing to the silicates, high mechanical strength, high glass transition temperature, and extremely low thermal expansion. However, doping silica materials with Tm 3+ has low fluorescence and high phonon quenching and therefore not practical for use in optical fiber systems.
SUMMARY OF THE INVENTION
[0011] Accordingly, it is an objection of the present invention provide a silica glass material doped with Tm 3+ , Ho 3+ , and Tm 3+ -sensitized-Ho 3+ in which the material has reduction in the multiphonon quenching compared to the multphonon quenching of pure silicates.
[0012] It is a further object of the present invention is to maximize the lifetime of the radiating ions in the 3 H 4 level for Thulium in silica.
[0013] It is a further object of the present invention is to prepare a glass material that can be fusion spliced directly to conventional silica fibers.
[0014] It is a further object of the present invention is to prepare a doped glass material that can be used as an amplifier.
[0015] It is a further object of the present invention is improve the efficiency of fluorescence for a doped silica glass.
[0016] It is still a further objection of the present invention is to increase the fluorescence quantum efficiencies for the 1.47 μm transition for a Tm 3+ doped silica glass material.
[0017] It is yet a further object of the invention is to provide a silica glass composition that provides fluorescence in the S-band region of approximately 1450 to 1520 nm.
[0018] It is a further object of this invention to provide silica glass dopant with Holmium and Thulium sensitized Holmium that exhibit improved radiative efficiency.
[0019] It is a further object of this invention to use the modified silica glass composition as a laser, an amplifier and ASE source.
[0020] These and additional objects of the invention are accomplished by the structures and processes hereinafter described.
[0021] The present invention relates to a modified silica glass providing a reduction in the multiphonon quenching for a rare-earth dopant that contains: SiO 2 in a host material; a rare-earth oxide dopant selected from the group consisting of Tm 3+ , Ho 3+ and Tm 3+ sensitized—Ho 3+ ; a first SiO 2 modifier; in which the first modifier is a 3+ cation dopant, and the first modifier is selected from the group consisting of Ga, Y and combinations thereof such that the first modifier reduces multiphonon quenching of the rare-earth dopant contained therein.
[0022] The present invention in another aspect of the composition is made by made by combining: between about 70 and about 99 molar percent SiO 2 in a host material; between about 100 and about 100,000 ppm by weight of a rare-earth oxide dopant selected from the group consisting of Thulium, Holmium and Thulium-sensitized-Holmium; between about 0.1 and about 20 molar percent of a first modifier; and between about 0.1 and about 10 molar percent of a second modifier; such that the first and second modifiers reduce multiphonon quenching of the rare-earth contained therein.
[0023] The present invention is another aspect a silica glass composition containing rare-earth dopant and at least one modifier selected from the group consisting of Ga, Y and combinations thereof which is suitable to reduce multiphonon quenching for the rare-earth dopant so that the rare-earth dopant permits significant emission at a wavelength between about 1.4 to about 2.0 μm when pumped.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] A more complete appreciation of the invention will be readily obtained by reference to the following Description of the Preferred Embodiments and accompanying drawings in which like numerals in different figures represent the same structures or elements, wherein:
[0025] [0025]FIG. 1 illustrates the energy level diagram for Tm 3+ ; and
[0026] [0026]FIG. 2 illustrates the fluorescence decay for 3 H 4 for Tm 3+ .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Glass has no long-range order so that is atomic arrangement is characterized by an extended three-dimensional structure which lack symmetry and periodicity, W. H. Zachariasen, J. Am. Chem Soc., 54 (1932), 3841. There is a short range order mainly attributed to local order around structural elements. Most of the elements are covalently bonded with strong directional bonds, i.e., a tetrahedron. Structural modifying elements which adjust the connectivity and the dimensionalily of the structural have weak, ionic and non-directional bonds. Their coordination environments are traditionally considered to be more distorted and variable than in crystals, and their spatial distributions are regarded as random or homogeneous. This view of the structure of glass is known as the “continuous-random-network”, CNR, theory.
[0028] Some have challenged the CNR theory with a new theory, modified-random-network, MRN. The MRN theory states that the immediate environment of the glass-modifying cation is found to be rather more well-defined than would be predicted by the conventional CRN. The glass modifiers are found not to be spread uniformly throughout the glass, but rather to adopt a non-random and inhomogeneous distribution in glass leading to “pools” with modifier-rich regions or separate glass-former-rich regions. See, Wang, J., Journal of Non-Crystalline Solids, 163, pp.26-267, 1993.
[0029] [0029]FIG. 1 illustrates the energy level diagram for thulium with the fluorescence for the 3 H 4 - 3 F 4 transition. The upper 3 H 4 level has a closely lying lower 3 H 5 level that results in significant multiphonon quenching when doped into a host with high phonon energy. The multiphonon relaxation is a process where the excited rare earth ion has a coupling to the phonon, lattice vibrations, of the host material. This process results in a decrease in fluorescence efficiency. In general, a reduction of the highest energy phonon for the glass matrix will result in increased fluorescence efficiencies for rare earth ions.
[0030] Using solution chemistry as a model, the SiO 2 network is poor a solvent for rare earth ions. 3+ cation dopants and/or 5+ cation dopants and/or 4+ cation dopants solublize the rare earth dopant, e.g., Tm 3+ , in the silica. Both the 3+, 4+, and 5+ cations are modifiers in the silica glass and therefore become part of the iso-structure of the network, i.e., they are incorporated into the local bonding configuration of the tetrahedral. When Tm 3+ is added to the structure the 3+ and/or 4+ and/or 5+ cation dopants solublize the Tm 3+ , i.e., a large fraction of the Tm 3+ or other rare-earth dopants are in an environment where dopants are not influenced by the high-energy vibrations of the silica glass. Thus, the vibration energy associated with the modifiers-silica bond is significantly lower than that of the host glass, so that the nonradiative decay from the Tm3+ or other rare-earth ion, i.e., Holmium, and Thulium-sensitized-Holmium, is reduced. This solubilizing lowers the multiphonon quenching of the Tm3+ so that the photons radiate from the 3 H 4 to 3 F 5 without the loss of many phonon relaxing from the 3 H 4 to the 3 H 5 level. The photons for Tm-2 μm, specifically 1.8 to 2.0 μm, radiate from 3 F 4 to 3 H 6 , for Holmium-2 μm energy transfer is from 5 I 7 to 5 I 8 , and for Thulium-sensitized-Holmium-pumped Thulium energy transfer from Tm 3 F 4 level to Ho 5 I 7 , Holmium emission 5 I 7 to 5 I 8 at about 2 μm.
[0031] Tm 2 O 3 is a rare earth element that radiates in the S-band, 1420-1525 nm. A concentration of from about 100 ppm to about 100,000 ppm by weight of the oxide is added to the silica glass. Holmium and Thulium-sensitized-Holmium are also dopants that are possible in the silica glass. A concentration of from about 100 ppm to about 100,00 ppm by weight of the oxide is added to the silica glass.
[0032] There is at least one cation that is desired as modifiers of the silica glass structure. The first modifier is a 3+ cation having a concentration of from about 0.1 to about 20 molar %. Examples of the first modifier are Ga, Y and combinations of the two. A second modifier is a 5+ cation having a concentration of from about 0 to about 10 molar percent and can also be added. Examples of the second modifier are Ta, Bi and combinations thereof. The preferred embodiment will contain a first and a second modifier. When the second modifier is present, the concentration is between about 0.1 to about 10 molar percent.
[0033] It is realized that simple permutations of this patent can take place without substantially changing the core idea. For example, 4+ cations such as Ge and Sn can be substituted into the structure for the Si ion. The motivation for this substitution may be to increase the photosensitivity for the core glass. As these 4+ cations are of heavier mass compared to the Si so that they have the additional beneficial property of further reducing the overall phonon energy for the host material.
[0034] Although, not wanting to be held to a theory, it is thought that the first modifier, e.g., Ga, will solublize the rare-earth resulting in improved radiative efficiency for the rare-earth. The theory of solubilization is similar to the use of a surfactant for solubilizing oil in water. The rare-earth is soluble in the modifier rich regions and the modifiers are soluble in the silica.
[0035] SiO 2 is found in the glass and has a concentration of from about 70 to about 99 molar percent.
[0036] To determine the concentration, one, typically, has to make up a bulk standard of a similar composition to the fiberoptic that is desired. Then, the absorption is measured as a function of the length in this standard with a known concentration of a rare-earth. Then one makes the fiberoptic containing an unknown quantity of the rare-earth. One then measures the absorption of the rare-earth as a function of the length in the fiberoptic and then uses the standard to back-calculate the concentration. For host glass there are an array of characterization techniques to identify the composition. The simplest way to determine the composition of the glass is X-ray analysis. Thus, to determine the concentration of the silica and the first, second and third modifiers is by using X-ray analysis.
[0037] The cross-section of the center of the glass core has a core diameter and the rare-earth ions are substantially contained within a volume of glass core having a cross section whose diameter is equal to or less than that of the core diameter. The optical fiber, laser and ASE source can contain a single mode core composition of the modified rare-earth doped silica glass composition of the present invention. There can also be a multimode core which surrounds the glass core and one or more claddings which surround the multimode core. The multimode core has a non-circular cross-section. The laser, the optical fiber amplifier and the ASE device can have the diode radiation side-pumped into the optical fiber.
[0038] The glasses and fibers of this invention are typically made by a modified CVD (MCVD) technique. This technique is analogous to the organo-metallic CVD technique known in the semiconductor industry, Erbium-Doped Fiber Amplifiers: Fundamentals and Technology, Becker, P. C., et al., 1999, and Rare-Earth-Doped Lasers and Amplifiers, Digonnet, M. J. F. Since this is a non-equilibrium process, glasses made by this technique will not necessarily have the same stoichiometry as the starting components. Typically, compositions are determined spectroscopically or by measuring some property of the glass (e.g., index of refraction) that varies predictably with composition.
[0039] Having described the invention, the following examples are given to illustrate specific applications of the invention, including the best mode now known to perform the invention. The specific examples are not intended to limit the scope of the invention described in this application.
EXAMPLE
[0040] A gallium doped silica preform doped with thulium was fabricated using MCVD. An all vapor process was used where gallium chloride and rare-earth chelate were transported to the MCVD reaction zone via a heated injection assembly. The MCVD/chelate injection tube assembly used is similar to that outlined in the article by Tumminelli, R. P. et al., “Fabrication of high concentration rare-earth doped opticalfibers using chelates”, J. Lightwave Tech., vol 8, no. 11, 1990, p. 1680.
[0041] The following flow conditions were used:
[0042] SiCl 4 : (bubbler T=25° C.) 20 sccm (standard cubic centimeter per minute)
[0043] GaCl 3 (bubbler T=180° C.) 200 sccm
[0044] Tm(TMHD) 3 (bubbler T=170° C.) 30 sccm
[0045] O 2 : 800 sccm
[0046] He: 800 sccm
[0047] 5 grams of GaCl 3 was loaded into a quartz bubbler and heated to 180° C. About 10 g of Tm chelate was dispersed in SiO 2 sand, loaded into a quartz bubbler, and heated to 170° C. These were connected to the heated injection tube assembly. A 16 mm×20 mm substrate tube was used for the MCVD process.
[0048] The gallosilicate core was deposited in the following manner. The 20 sccm of SiCl 4 was sent to the MCVD reaction zone. The GaCl 3 (T=180° C.) was then sent to the reaction zone. When a stable reaction zone was established, the Tm chelate then introduced to the MCVD reaction zone. A relatively small flow rate for the Tm was used to dope a low concentration of rare-earth into the glass. This was to minimize any ion-ion interactions that could complicate subsequent spectroscopy.
[0049] Two passes were deposited under these initial conditions. For the third core deposition pass, the temperature for the GaCl 3 bubbler was increased to 210° C. After three core pass depositions, the tube was collapsed into a preform by standard MCVD techniques.
[0050] The index difference due to gallium was measured to be 0.005 corresponding to an NA˜0.10. The 3 H 4 lifetime for Tm 3+ in this preform measured 32.3 μs. (For comparison purposes, the lifetime for Tm—Al—SiO 2 is 20 μs.) FIG. 2 illustrates the decay for Thulium in the Gallo-silicate host compared to the alumino-silicate host. These samples were excited using a pulsed ti-sapphire laser operating around 770 nm. The fluorescence was passed through a monochromator to separate the pump from the decay. The decay for 3 H 4 was measured around 800 nm. There is a measurable improvement in the lifetime for the Tm:Gallo-silicate host compared to the alumino-silicate. This is evidence of the heavier massed Gallium solubilizing the rare-earth ion resulting in a decrease in the multiphonon relaxation rate.
[0051] Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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A modified silica glass composition for providing a reduction in the multiphonon quenching for a rare-earth dopant comprising:
SiO 2 in a host material;
a rare-earth dopant;
a first SiO 2 modifier; and
a second SiO 2 modifier; such that said first modifier and said second modifier reduce multiphonon quenching of the rare-earth dopant contained therein.
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BACKGROUND OF THE INVENTION
[0001] Fatty Acid Synthase
[0002] Fatty acids have three primary roles in the physiology of cells. First, they are the building bocks of biological membranes. Second, fatty acid derivatives serve as hormones and intracellular messengers. Third, and of particular importance to the present invention, fatty acids are fuel molecules that can be stored in adipose tissue as triacylglycerols, which are also known as neutral fats.
[0003] There are four primary enzymes involved in the fatty acid synthetic pathway, fatty acid synthase (FAS), alkynyl CoA carboxylase (ACC), malic enzyme, and citric lyase. The principal enzyme, FAS, catalyzes the NADPH-dependent condensation of the precursors malonyl-CoA and alkynyl-CoA to produce fatty acids. NADPH is a reducing agent that generally serves as the essential electron donor at two points in the reaction cycle of FAS. The other three enzymes (i.e., ACC, malic enzyme, and citric lyase) produce the necessary precursors. Other enzymes, for example the enzymes that produce NADPH, are also involved in fatty acid synthesis.
[0004] FAS has an Enzyme Commission (E.C.) No. 2.3.1.85 and is also known as fatty acid synthetase, fatty acid ligase, as well as its systematic name acyl-CoA:malonyl-CoA C-acyltransferase (decarboxylating, oxoacyl- and enoyl-reducing and thioester-hydrolysing). There are seven distinct enzymes—or catalytic domains—involved in the FAS catalyzed synthesis of fatty acids: alkynyl transacylase, malonyl transacylase, beta-ketoacyl synthetase (condensing enzyme), beta-ketoacyl reductase, beta-hydroxyacyl dehydrase, enoyl reductase, and thioesterase. (Wakil, S. J., Biochemistry, 28: 4523-4530, 1989). All seven of these enzymes together form FAS.
[0005] Although the FAS catalyzed synthesis of fatty acids is similar in lower organisms, such as, for example, bacteria, and in higher organisms, such as, for example, mycobacteria, yeast and humans, there are some important differences. In bacteria, the seven enzymatic reactions are carried out by seven separate polypeptides that are non-associated. This is classified as Type II FAS. In contrast, the enzymatic reactions in mycobacteria, yeast and humans are carried out by multifunctional polypeptides. For example, yeast have a complex composed of two separate polypeptides whereas in mycobacterium and humans, all seven reactions are carried out by a single polypeptide. These are classified as Type I FAS.
[0006] FAS Inhibitors
[0007] Various compounds have been shown to inhibit fatty acid synthase (FAS). FAS inhibitors can be identified by the ability of a compound to inhibit the enzymatic activity of purified FAS. FAS activity can be assayed by measuring the incorporation of radiolabeled precursor (i.e., alkynyl-CoA or malonyl-CoA) into fatty acids or by spectrophotometrically measuring the oxidation of NADPH. (Dils, et al., Methods Enzymol., 35:74-83).
[0008] Table 1, set forth below, lists several FAS inhibitors.
TABLE 1 Representative Inhibitors Of The Enzymes Of The Fatty Acid Synthesis Pathway Inhibitors of Fatty Acid Synthase 1,3-dibromopropanone cerulenin Ellman's reagent (5,5′-dithiobis(2-nitrobenzoic phenyocerulenin acid), DTNB) melarsoprol 4-(4′-chlorobenzyloxy) benzyl nicotinate (KCD- iodoacetate 232) phenylarsineoxide 4-(4′-chlorobenzyloxy) benzoic acid (MII) pentostam 2(5(4-chlorophenyl)pentyl)oxirane-2-carboxylate melittin (POCA) and its CoA derivative thiolactomycin ethoxyformic anhydride Inhibitors for citrate lyase Inhibitors for malic enzyme (−) hydroxycitrate periodate-oxidized 3-aminopyridine adenine (R,S)-S-(3,4-dicarboxy-3-hydroxy-3-methyl- dinucleotide phosphate butyl)-CoA 5,5′-dithiobis(2-nitrobenzoic acid) S-carboxymethyl-CoA p-hydroxymercuribenzoate N-ethylmaleimide oxalyl thiol esters such as S-oxalylglutathione gossypol phenylglyoxal 2,3-butanedione bromopyruvate pregnenolone Inhibitors for alkynyl CoA carboxylase sethoxydim 9-decenyl-1-pentenedioic acid haloxyfop and its CoA ester decanyl-2-pentenedioic acid diclofop and its CoA ester decanyl-1-pentenedioic acid clethodim (S)-ibuprofenyl-CoA alloxydim (R)-ibuprofenyl-CoA trifop fluazifop and its CoA ester clofibric acid clofop 2,4-D mecoprop 5-(tetradecycloxy)-2-furoic acid dalapon beta, beta′-tetramethylhexadecanedioic acid 2-alkyl glutarate tralkoxydim 2-tetradecanylglutarate (TDG) free or monothioester of beta, beta prime-methyl- 2-octylglutaric acid substituted hexadecanedioic acid (MEDICA N6,02-dibutyryl adenosine cyclic 3′,5′- 16) monophosphate alpha-cyanco-4-hydroxycinnamate N2,02-dibutyryl guanosine cyclic 3′,5′- S-(4-bromo-2,3-dioxobutyl)-CoA monophosphate p-hydroxymercuribenzoate (PHMB) CoA derivative of 5-(tetradecyloxy)-2-furoic N6,02-dibutyryl adenosine cyclic 3′,5′- acid (TOFA) monophosphate 2,3,7,8-tetrachlorodibenzo-p-dioxin
[0009] Of the four enzymes in the fatty acid synthetic pathway, FAS is the preferred target for inhibition because it acts only within the pathway to fatty acids, while the other three enzymes are implicated in other cellular functions. Therefore, inhibition of one of the other three enzymes is more likely to affect normal cells. Of the seven enzymatic steps carried out by FAS, the step catalyzed by the condensing enzyme (i.e., beta-ketoacyl synthetase) and the enoyl reductase have been the most common candidates for inhibitors that reduce or stop fatty acid synthesis. The condensing enzyme of the FAS complex is well characterized in terms of structure and function. The active site of the condensing enzyme contains a critical cysteine thiol, which is the target of antilipidemic reagents, such as, for example, the inhibitor cerulenin.
[0010] Preferred inhibitors of the condensing enzyme include a wide range of chemical compounds, including alkylating agents, oxidants, and reagents capable of undergoing disulphide exchange. The binding pocket of the enzyme prefers long chain, E, E, dienes.
[0011] In principal, a reagent containing the sidechain diene and a group which exhibits reactivity with thiolate anions could be a good inhibitor of the condensing enzyme. Cerulenin [(2S, 3R)-2,3-epoxy-4-oxo-7,10 dodecadienoyl amide] is an example:
Cerulenin covalently binds to the critical cysteine thiol group in the active site of the condensing enzyme of fatty acid synthase, inactivating this key enzymatic step (Funabashi, et al., J. Biochem., 105:751-755, 1989). While cerulenin has been noted to possess other activities, these either occur in microorganisms which may not be relevant models of human cells (e.g., inhibition of cholesterol synthesis in fungi, Omura (1976), Bacteriol. Rev., 40:681-697; or diminished RNA synthesis in viruses, Perez, et al. (1991), FEBS, 280: 129-133), occur at a substantially higher drug concentrations (inhibition of viral HIV protease at 5 mg/ml, Moelling, et al. (1990), FEBS, 261:373-377) or may be the direct result of the inhibition of endogenous fatty acid synthesis (inhibition of antigen processing in B lymphocytes and macrophages, Falo, et al. (1987), J. Immunol., 139:3918-3923). Some data suggest that cerulenin does not specifically inhibit myristoylation of proteins (Simon, et al., J. Biol. Chem., 267:3922-3931, 1992).
[0012] Several more FAS inhibitors are disclosed in U.S. patent application Ser. No. 08/096,908 and its CIP filed Jan. 24, 1994, the disclosures of which are hereby incorporated by reference. Included are inhibitors of fatty acid synthase, citrate lyase, CoA carboxylase, and malic enzyme.
[0013] Tomoda and colleagues (Tomoda et.al., Biochim. Biophys. Act 921:595-598 1987; Omura el. al., J. Antibiotics 39:1211-1218 1986) describe Triacsin C (sometimes termed WS-1228A), a naturally occurring acyl-CoA synthetase inhibitor, which is a product of Streptomyces sp. SK-1894. The chemical structure of Triacsin C is 1-hydroxy-3-(E, E, E-2′,4′,7′-undecatrienylidine) triazene. Triacsin C causes 50% inhibition of rat liver acyl-CoA synthetase at 8.7 μM; a related compound, Triacsin A, inhibits acyl CoA-synthetase by a mechanism which is competitive with long-chain fatty acids. Inhibition of acyl-CoA synthetase is toxic to animal cells. Tomoda et al. (Tomoda el. al., J. Biol. Chem. 266:4214-4219, 1991) teaches that Triacsin C causes growth inhibition in Raji cells at 1.0 μM, and have also been shown to inhibit growth of Vero and Hela cells. Tomoda el. al. further teaches that acyl-CoA synthetase is essential in animal cells and that inhibition of the enzyme has lethal effects.
[0014] A family of compounds (gamma-substituted-alpha-methylene-beta-carboxy-gamma-butyrolactones) has been shown in U.S. Pat. No. 5,981,575 (the disclosure of which is hereby incorporated by reference) to inhibit fatty acid synthesis, inhibit growth of tumor cells, and induce weight loss. The compounds disclosed in the '575 patent have several advantages over the natural product cerulenin for therapeutic applications: [1] they do not contain the highly reactive epoxide group of cerulenin, [2] they are stable and soluble in aqueous solution, [3] they can be produced by a two-step synthetic reaction and thus easily produced in large quantities, and [4] they are easily tritiated to high specific activity for biochemical and pharmacological analyses. The synthesis of this family of compounds, which are fatty acid synthase inhibitors, is described in the '575 patent, as is their use as a means to treat tumor cells expressing FAS, and their use as a means to reduce body weight. The '575 patent also discloses the use of any fatty acid synthase inhibitors to systematically reduce adipocyte mass (adipocyte cell number or size) as a means to reduce body weight.
[0015] The primary sites for fatty acid synthesis in mice and humans are the liver (see Roncari, Can. J. Biochem., 52:221-230, 1974; Triscari et al., 1985, Metabolism, 34:580-7; Barakat et al., 1991, Metabolism, 40:280-5), lactating mammary glands (see Thompson, et al., Pediatr. Res., 19:139-143, 1985) and adipose tissue (Goldrick et al., 1974, Clin. Sci. Mol. Med., 46:469-79).
[0016] Inhibitors of Fatty Acid Synthesis as Antimicrobial Agents Cerulenin was originally isolated as a potential antifungal antibiotic from the culture broth of Cephalosporium caerulens . Structurally cerulenin has been characterized as (2R,3S)-epoxy-4-oxo-7,10-trans,trans-dodecanoic acid amide. Its mechanism of action has been shown to be inhibition, through irreversible binding, of beta-ketoacyl-ACP synthase, the condensing enzyme required for the biosynthesis of fatty acids. Cerulenin has been categorized as an antifungal, primarily against Candida and Saccharomyces sp. In addition, some in vitro activity has been shown against some bacteria, actinomycetes, and mycobacteria, although no activity was found against Mycobacterium tuberculosis . The activity of fatty acid synthesis inhibitors and cerulenin in particular has not been evaluated against protozoa such as Toxoplasma gondii or other infectious eucaryotic pathogens such as Pneumocystis carinii, Giardia lamblia, Plasmodium sp., Trichomonas vaginalis, Cryptosporidium, Trypanosoma, Leishmania , and Schistosoma.
[0017] Infectious diseases which are particularly susceptible to treatment are diseases which cause lesions in externally accessible surfaces of the infected animal. Externally accessible surfaces include all surfaces that may be reached by non-invasive means (without cutting or puncturing the skin), including the skin surface itself, mucus membranes, such as those covering nasal, oral, gastrointestinal, or urogenital surfaces, and pulmonary surfaces, such as the alveolar sacs. Susceptible diseases include: (1) cutaneous mycoses or tineas, especially if caused by Microsporum, Trichophyton, Epidermophyton , or Mucocutaneous candidiasis ; (2) mucotic keratitis, especially if caused by Aspergillus, Fusarium or Candida ; (3) amoebic keratitis, especially if caused by Acanthamoeba ; (4) gastrointestinal disease, especially if caused by Giardia lamblia, Entamoeba, Cryptosporidium, Microsporidium , or Candida (most commonly in immunocompromised animals); (5) urogenital infection, especially if caused by Candida albicans or Trichomonas vaginalis ; and (6) pulmonary disease, especially if caused by Mycobacterium tuberculosis, Aspergillus , or Pneumocystis carinii . Infectious organisms that are susceptible to treatment with fatty acid synthesis inhibitors include Mycobacterium tuberculosis , especially multiply-drug resistant strains, and protozoa such as Toxoplasma.
[0018] Any compound that inhibits fatty acid synthesis may be used to inhibit microbial cell growth. However, compounds administered to a patient must not be equally toxic to both patient and the target microbial cells. Accordingly, it is beneficial to select inhibitors that only, or predominantly, affect target microbial cells.
[0019] Eukaryotic microbial cells which are dependent on their own endogenously synthesized fatty acid will express Type I FAS. This is shown both by the fact that FAS inhibitors are growth inhibitory and by the fact that exogenously added fatty acids can protect normal patient cells but not these microbial cells from FAS inhibitors. Therefore, agents which prevent synthesis of fatty acids by the cell may be used to treat infections. In eukaryotes, fatty acids are synthesized by Type I FAS using the substrates alkynyl CoA, malonyl CoA and NADPH. Thus, other enzymes which can feed substrates into this pathway may also effect the rate of fatty acid synthesis and thus be important in microbes that depend on endogenously synthesized fatty acid. Inhibition of the expression or activity of any of these enzymes will effect growth of the microbial cells that are dependent upon endogenously synthesized fatty acid.
[0020] The product of Type I FAS differs in various organisms. For example, in the fungus S. cerevisiae the products are predominately palmitate and sterate sterified to coenzyme-A. In Mycobacterium smegmatis , the products are saturated fatty acid CoA esters ranging in length from 16 to 24 carbons. These lipids are often further processed to fulfill the cells need for various lipid components.
[0021] Inhibition of key steps in down-stream processing or utilization of fatty acids may be expected to inhibit cell function, whether the cell depends on endogenous fatty acid or utilizes fatty acid supplied from outside the cell, and so inhibitors of these down-stream steps may not be sufficiently selective for microbial cells that depend on endogenous fatty acid. However, it has been discovered that administration of Type I fatty acid synthesis inhibitor to such microbes makes them more sensitive to inhibition by inhibitors of down-stream fatty acid processing and/or utilization. Because of this synergy, administration of a fatty acid synthesis inhibitor in combination with one or more inhibitors of down-stream steps in lipid biosynthesis and/or utilization will selectively affect microbial cells that depend on endogenously synthesized fatty acid. Preferred combinations include an inhibitor of FAS and alkynyl CoA carboxylase, or FAS and an inhibitor of MAS.
[0022] When it has been determined that a mammal is infected with cells of an organism which expresses Type I FAS, or if FAS has been found in a biological fluid from a patient, the mammal or patient may be treated by administering a fatty acid synthesis inhibitor (U.S. Pat. No. 5,614,551).
[0023] The inhibition of neuropeptide-Y to depress appetite and stimulate weight loss is described in International Patent Application No. PCT/US01/05316 the disclosure of which is hereby incorporated by reference. That application, however, does not describe or disclose any of the compounds disclosed in the present application
[0024] The stimulation of carnitine palmitoyl transferase-1 (CPT-1) to stimulate weight loss is described in U.S. Patent Application Ser. No. 60/354,480, the disclosure of which is hereby incorporated by reference. That application does not describe or disclose any of the compounds disclosed herein, either.
[0025] The use of FAS inhibitors to inhibit the growth of cancer cells is described in U.S. Pat. No. 5,759,837, the disclosure of which is hereby incorporated by reference. That application does not describe or disclose any of the compounds disclosed herein.
[0026] The use of FAS inhibitors to inhibit the growth of cancer cells is described in U.S. Pat. No. 5,759,837, the disclosure of which is hereby incorporated by reference. That application does not describe or disclose any of the compounds disclosed herein.
SUMMARY OF THE INVENTION
[0027] New classes of compounds have been discovered which have a variety of therapeutically
valuable properties, eg. FAS-inhibition, NPY-inhibition, CPT-1 stimulation, ability to induce weight loss, and anti-cancer and anti-microbial properties.
[0029] It is a further object of this invention to provide a method of inducing weight loss in animals and humans by administering a pharmaceutical composition comprising a pharmaceutical diluent and a compound of formula I, II, III, or IV.
[0030] It is a further object of the invention to provide a method of stimulating the activity of CPT-1 by administering to humans or animals a pharmaceutical composition comprising a pharmaceutical diluent and a compound of formula I, II, III, or IV.
[0031] It is a further object of the invention to provide a method of inhibiting the synthesis of neuropeptide Y in humans or animals by administering a pharmaceutical composition comprising a pharmaceutical diluent and a compound of formula I, II, III, or IV.
[0032] It is a further object of the invention to provide a method of inhibiting fatty acid synthase activity in humans or animals by administering a pharmaceutical composition comprising a pharmaceutical diluent and a compound of formula I, II, III or IV.
[0033] It is a further object of this invention to provide a method of treating cancer in animals and humans by administering a pharmaceutical composition comprising a pharmaceutical diluent and a compound of formula I, II, III, or IV.
[0034] It is still a further object of this invention to provide a method of preventing the growth of cancer cells in animals and humans by administering a pharmaceutical composition comprising a pharmaceutical diluent and a compound of formula I, II, III, or IV.
[0035] It is a further object of this invention to provide a method of inhibiting growth of invasive microbial cells by administering a pharmaceutical composition comprising a pharmaceutical diluent and a compound of formula I, II, III, or IV.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 shows a synthetic scheme to make thiolactamycin.
[0037] FIG. 2 shows a synthetic scheme to make certain compounds according to the invention.
[0038] FIG. 3 shows a synthetic scheme to make certain compounds according to the invention.
[0039] FIG. 4 shows a synthetic scheme to make certain compounds according to the invention.
[0040] FIG. 5 shows a synthetic schemes to make certain compounds according to the invention.
[0041] FIG. 6 shows a synthetic schemes to make certain compounds according to the invention.
[0042] FIG. 7 shows a synthetic scheme to make a compound according to the invention.
[0043] FIG. 8 shows a synthetic scheme to make certain compounds according to the invention.
[0044] FIG. 9 shows two synthetic schemes to make certain compounds according to the invention.
[0045] FIG. 10 shows a synthetic scheme to make certain compounds according to the invention.
[0046] FIG. 11 shows the results of in vivo testing for weight loss of certain compounds according to the invention.
[0047] FIG. 12 shows the results of in vivo testing for anti-cancer activity of a compound according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0048] The compounds of the invention can be prepared by conventional means. The synthesis of a number of the compounds is described in the examples. The compounds may be useful for the treatment of obesity, cancer, or microbially-based infections.
[0049] One embodiment of the invention is compounds having the following general formula:
wherein:
R 1 ═H R 2 =—OH, —OR 5 , —OCH 2 C(O)R 5 , —OCH 2 C(O)NHR 5 , —OC(O)R 5 , —OC(O)OR 5 , —OC(O)NHNH—R 5 , or —OC(O)NR 5 R 6 , where R 5 is H, C 1 -C 20 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl, and where R 5 can optionally contain halogen atoms; R 3 and R 4 , the same or different from each other, are C 1 -C 20 alkyl cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl; with the proviso that when R 2 is —OH, —OCH 3 , or —OC(O)CF 3 and R 3 is —CH 3 , then R 4 is not —CH 2 CH 2 OH, —CH 2 —(C 6 H 5 ), or —CH═CH—CH 3 , and and the further proviso that when R 3 is —CH 2 —(C 6 H 5 ), then R 4 is not —CH 3 or CH 2 CH 3 .
[0055] (It should be understood that, when applicable, the keto-tautomeric form of the foregoing compounds is also included in formula I.)
[0056] In a preferred embodiment R 5 is C 1 -C 10 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl.
[0057] In another preferred embodiment, R 3 is —H or —CH 3 .
[0058] In another preferred embodiment, R 4 is n-C 6 -C 8 alkyl.
[0059] Another embodiment of the invention is compounds formula II
wherein
R 6 ═C 2 -C 20 alkyl, cycloalkyl, alkenyl, alkynyl, aryl, arylalkyl, or alkylaryl, —CHR 10 OR 11 , —CO(O)R 10 , —C(O)NR 10 R 11 , —CH 2 C(O)R 10 , or —CH 2 C(O)NHR 10 , where R 10 and R 11 are each independently H, C 1 -C 10 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl, but R 6 is not di-, tri-, or tetra-alkyl substituted phenyl, R 7 ═—OH, —OR 12 , —OCH 2 C(O)R 12 , —OCH 2 C(O)NHR 12 , —OC(O)R 12 , —OC(O)OR 12 , —OC(O)NHNH—R 12 , or —OC(O)NR 12 R 13 , where R 12 and R 13 are each independently H, C 1 -C 20 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl, and where R 12 and R 13 can optionally contain halogen atoms; R 8 and R 9 , the same or different from each other, are C 1 -C 20 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl,
with the following provisos:
when R 6 is ethyl, if R 8 and R 9 are not the same, then R 8 or R 9 are not ethyl, —CH 2 COOH, —CH 2 C(O)NH 2 , —CH 2 —(C 6 H 5 ), but R 8 and R 9 can be the same, even if R6 is ethyl, and when R 6 is phenyl, and R 7 is —OH, R 8 and R 9 cannot simultaneously be —CH 3 and -propenyl, and when R 6 is phenyl, R 8 and R 9 cannot simultaneously be —CH 3 or —CH 2 —(C 6 H 5 ).
[0066] In a preferred embodiment R 10 is C 1 -C 10 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl.
[0067] In another preferred embodiment, R 8 is —H or —CH 3 .
[0068] In another preferred embodiment, R 9 is n-C 6 -C 8 alkyl.
[0069] Another embodiment of the invention comprises compounds of formula III:
wherein
R 14 ═—C(O)R 18 , where R 18 is H C 1 -C 10 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl, optionally containing halogen atoms, R 5 ═—OH, —OR 19 , —OCH 2 C(O)R 19 , —OCH 2 C(O)NHR 19 , —OC(O)R 19 , —OC(O)OR 19 , —OC(O)NHNH—R 19 , or —OC(O)NR 19 R 20 , where R 19 and R 20 are each independently H, C 1 -C 20 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl, and where R 19 and R 20 can each optionally contain halogen atoms; R 16 and R 17 , the same or different from each other, are C 1 -C 20 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl,
with the following provisos:
when R 14 is —(O)CH 3 , and R 16 and R 17 are not identical, then either R 16 or R 17 are not are not geranyl, p-fluorobenzyl, cinnamyl, farnesyl, methyl, or —CH 2 -(C 6 H 5 ), and when R 14 is —(O)C 6 H 5 , then either R 16 or R 17 are not are not methyl.
[0075] Another embodiment of this invention is a pharmaceutical composition comprising a pharmaceutical diluent and a compound of formula I, II, III, or IV:
wherein:
R 21 ═H, C 1 -C 20 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl, —CH 2 OR 25 , —C(O)R 25 , —CO(O)R 25 , —C(O)NR 25 R 26 , —CH 2 C(O)R 25 , or —CH 2 C(O)NHR 25 , where R 25 and R 26 are each independently H, C 1 -C 10 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl, R 22 ═—OH, —OR 27 , —OCH 2 C(O)R 27 , —OCH 2 C(O)NHR 27 , —OC(O)R 27 , —OC(O)OR 27 , —OC(O)NHNH—R 27 , or —OC(O)NR 27 R 28 , where R 27 and R 28 are each independently H, C 1 -C 20 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl, and where R 27 and R 28 can each optionally contain halogen atoms;
R 23 and R 24 , the same or different from each other, are C 1 -C 20 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl.
[0078] The compositions of the present invention can be presented for administration to humans and other animals in unit dosage forms, such as tablets, capsules, pills, powders, granules, sterile parenteral solutions or suspensions, oral solutions or suspensions, oil in water and water in oil emulsions containing suitable quantities of the compound, suppositories and in fluid suspensions or solutions. As used in this specification, the terms “pharmaceutical diluent” and “pharmaceutical carrier,” have the same meaning. For oral administration, either solid or fluid unit dosage forms can be prepared. For preparing solid compositions such as tablets, the compound can be mixed with conventional ingredients such as talc, magnesium stearate, dicalcium phosphate, magnesium aluminum silicate, calcium sulfate, starch, lactose, acacia, methylcellulose and functionally similar materials as pharmaceutical diluents or carriers. Capsules are prepared by mixing the compound with an inert pharmaceutical diluent and filling the mixture into a hard gelatin capsule of appropriate size. Soft gelatin capsules are prepared by machine encapsulation of a slurry of the compound with an acceptable vegetable oil, light liquid petrolatum or other inert oil.
[0079] Fluid unit dosage forms or oral administration such as syrups, elixirs, and suspensions can be prepared. The forms can be dissolved in an aqueous vehicle together with sugar, aromatic flavoring agents and preservatives to form a syrup. Suspensions can be prepared with an aqueous vehicle with the aid of a suspending agent such as acacia, tragacanth, methylcellulose and the like.
[0080] For parenteral administration fluid unit dosage forms can be prepared utilizing the compound and a sterile vehicle. In preparing solutions the compound can be dissolved in water for injection and filter sterilized before filling into a suitable vial or ampoule and sealing. Adjuvants such as a local anesthetic, preservative and buffering agents can be dissolved in the vehicle. The composition can be frozen after filling into a vial and the water removed under vacuum. The lyophilized powder can then be scaled in the vial and reconstituted prior to use.
[0081] The clinical therapeutic indications envisioned for the compounds of the invention include: (1) infections due to invasive micro-organisms such as staphylococci and enterococci ; (2) cancers arising in many tissues whose cells over-express fatty acid synthase, and (3) obesity due to the ingestion of excess calories. Dose and duration of therapy will depend on a variety of factors, including (1) the patient's age, body weight, and organ function (eg., liver and kidney function); (2) the nature and extent of the disease process to be treated, as well as any existing significant co-morbidity and concomitant medications being taken, and (3) drug-related parameters such as the route of administration, the frequency and duration of dosing necessary to effect a cure, and the therapeutic index of the drug. In general, does will be chosen to achieve serum levels of 1 ng/ml to 100 ng/ml with the goal of attaining effective concentrations at the target site of approximately 1 μg/ml to 10 μg/ml.
EXAMPLES
[0082] The invention will be illustrated, but not limited, by the following examples:
[0083] A series of compounds according to the invention were synthesized as described below. Biological activity of certain compounds were profiled as follows: Each compound was tested for: [1] inhibition of purified human FAS, [2] inhibition of fatty acid synthesis activity in whole cells and [3] cytotoxicity against cultured MCF-7 human breast cancer cells, known to possess high levels of FAS and fatty acid synthesis activity, using the crystal violet and XTT assays. Select compounds with low levels of cytotoxicity were then tested for weight loss in Balb/C mice. In addition, a representative compound from the group which exhibited significant weight loss and low levels of cytotoxicity was tested for its effect on fatty acid oxidation, and carnitine palmitoyltransferase-1 (CPT-1) activity, as well as hypothalamic NPY expression by Northern analysis in Balb/C mice. Certain compounds were also tested for activity against gram positive and/or negative bacteria.
Chemical Synthesis of Compounds
[0084] (2S,5R)-2-t-Butyl-5-methyl-1,3-oxathiolan-4-one (1). 1 To a solution of (S)-thiolactic acid 1 (4.0 g, 37.7 mmol) in pentane (24 mL) was added trimethylalkynylaldehyde (4.5 mL, 41.5 mmol) and trifluoroacetic acid (TFA) (48 μL). The solution was heated at reflux using a Dean-Stark Trap for 20 hours. After cooling, the solvent was removed to give a cis:trans mixture (2.5:1) of 1 and 2 (6.4 g, 99%). Recrystallization (Pentane/Et 2 O (8:1)-78° C.) provided pure 1 [α] D 24 =−38 (c 0.4, CHCl 3 ). 1 H NMR (300 MHz, CDCl 3 ) Cis Isomer δ 0.99 (s, 9H); 1.53 (d, J=7 Hz, 3H); 3.94 (q, J=7 Hz, 1H); 5.17 (s, 1H). Racemic 1 was also prepared from (i)-thiolactic acid.
[0085] General Procedure A. (2S,5R)-2-(t-Butyl)-5-(1-hydroxy-2-methyl-2 butenyl)-5-methyl-1,3-oxathiolan-4-one (3). To a mixture of diisoproplyamine (0.6 mL, 4.6 mmol) in THF (8.0 mL) at −78° C. was added n-BuLi (3.3 mL, 1.4 M in n-hexane) and the resulting solution was stirred for 30 minutes at °0 C. an then cooled to −78° C. Then 1 (800 mg, 4.6 mmol) in THF at −78° C. was added by cannula dropwise and the resulting solution stirred for 30 minutes at −78° C. Trans 2-methyl-2 butenal (0.4 mL, 4.6 mmol) in THF (1.4 mL), at −78° C. was then added via cannula. After siring at −78° C. for 1.5 hours, 1 N HCl (25 mL) was added and the solution was extracted with Et 2 O (3×30 mL). The combined organics were dried MgSO 4 ), filtered, and evaporated. Flash chromatography (10% EtOAc/Hexanes, rf=0.1) gave 3 (955 mg, 81%) as a 1.6:1 mixture of diastereomers. 1 H NMR (300 MHz, CDCl 3 ) δ (major diastereomer) 0.99 (s, 9H), 1.40 (s, 3H), 1.63 (d, J=6.7 Hz, 3H), 1.69 (m, 3H), 4.36 (s, 1H), 5.25 (s, 1H), 5.60-5.65 (m, 1H); (minor diastereomer) 0.98 (s, 9H), 1.59 (s, 3H), 1.63 (d, J=6.7 Hz, 3H), 1.72 (m, 3H), 4.25 (s, 1H), 5.07 (s, 1H), 5.60-5.64 (m, 1H) 13 C NMR (75 MHz, CDCl 3 ) δ (major diastereomer) 12.5, 13.2, 24.3, 24.8, 60.7, 81.8, 87.9, 126.3, 133.8, 178.3; IR (ATR) 3466, 1743 cm −1 . Analysis Calculated for C 13 H 22 O 3 S: C, 60.4; H, 8.58; Found C, 60.4; H, 8.60.
[0086] (±)-2-(t-Butyl)-5-(1-hydroxy-2-octenyl)-5-methyl-1,3-oxathiolan-4-one (4). From (±) 1 (800 mg, 4.59) and 2-trans octenal (0.58 mL, 5.1 mmol) following general procedure A was obtained 4 (1.1 g, 81%) after flash chromatography (10% EtOAc/Hexanes) as a 1.2:1 mixture of diastereomers. 1 H NMR (300 MHz, CDCl 3 ) major diastereomerδ 0.85 (t, J=7.2 Hz, 3H), 0.97 (bs, 9H), 1.18-1.35 (m, 6H), 1.56 (s, 3H), 2.00-2.08 (m, 2H), 2.38 (d, J=5 Hz, 1H), 4.15-4.19 (m, 1H), 5.13 (s, 1H), 5.45-5.59 (dd, J=7, 14 Hz, 1H), 5.72-5.77 (m, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 13.7, 22.3, 24.7, 28.5, 31.3, 32.1, 35.2, 60.6, 78.8, 87.4, 127.2, 136.5, 175.7. 1 H NMR (300 MHz, CDCl 3 ) minor diastereomer 1 H NMR (300 MHz, CDCl 3 ) δ 0.85 (t, J=7.2 Hz, 3H), 0.97 (s, 9H), 1.18-1.35 (m, 6H), 1.40 (s, 3H), 2.00-2.07 (m, 2H), 2.31 (d, J=5 Hz, 1H), 4.25-4.30 (m, 1H), 5.27 (s, 1H), 5.45-5.59 (dd, J=7, 14 Hz, 1H), 5.79-5.83 (m, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 13.7, 22.3, 23.9, 24.8, 28.5, 31.2, 32.1, 35.3, 61.1, 78.3, 87.8, 127.2, 137.2, 177.0. IR (NaCl) 2959, 1765 cm −1 . Analysis Calculated for C 16 H 28 O 3 S: C, 63.9; H, 9.39; Found: C, 63.9; H, 9.41.
[0087] (±)-2-(t-Butyl)-5-(1-hydroxy-2-hexenyl)-5-methyl-1,3-oxathiolan-4-one. (5). From (±) 1 (800 mg, 4.59) and 2-trans hexenal (0.58 mL, 5.1 mmol) following general procedure A was obtained 5 (813 mg, 65%) after flash chromatography (10% EtOAc/Hexanes) as a 2.4:1 mixture of diastereomers. 1 H NMR (300 MHz, CDCl 3 ) δ 0.87 (t, J=7.3 Hz, 3H), 0.99 (s, 9H), 1.38-1.45 (m, 2H), 1.41 (s, 3H), 2.02 (q, J=7 Hz, 2H), 4.26-4.31 (m, 1H), 5.27 (s, 1H), 5.45-5.63 (m, 1H), 5.74-5.83 (m, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 13.6, 21.6, 24.1, 24.9, 35.2, 37.2, 61.2, 78.5, 87.9, 127.3, 137.3, 179.1. IR (NaCl) 2960 1765 cm −1 . Analysis Calculated for C 14 H 24 O 3 S: C, 61.7; H, 8.88; Found: C, 61.74; H, 8.89.
[0088] (±)-2-(t-Butyl)-5-(1-hydroxy-2-methyl-2-pentenyl)-5-methyl-1,3-oxathiolan-4-one (6). From (±) 1 (800 mg, 4.59 mmol) and 2-methyl-2-pentenal (0.58 mL, 5.0 mmol) following general procedure A was obtained 6 (884 mg, 71%) after flash chromatography (10% EtOAc/Hexanes) as a 1.8:1 mixture of diastereomers. 1 H NMR (300 MHz, CDCl 3 ) δ 0.93-0.99 (m, 12H), 1.40 (s, 3H), 1.68 (s, 3H), 2.01-2.06 (m 2H), 4.33 (d, J=6.9 Hz, 1H), 5.24 (s, 1H), 5.48-5.54 (m, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 12.6, 13.8, 20.9, 21.1, 24.8, 35.4, 60.6, 81.8, 87.9, 132.6, 133.9, 178.3. IR (NaCl) 2961, 1767 cm −1 . Analysis Calculated for C 14 H 24 O 3 S: C, 61.7; H, 8.88; Found: C, 61.6; H, 8.90.
[0089] General Procedure B. (2S,5R)-2-(t-Butyl)-5-(2-methyl-buta-1,3-dienyl)-5-methyl-1,3-oxathiolan-4-one (7). To a solution of 3 (3.23 g, 12.5 mmol) in Cl(CH 2 ) 2 Cl (115 mL) cooled to 0° C. was added NEt 3 (4.2 mL, 30 mmol) and 2,4-dinitrobenzyl sulfenyl chloride (6.6 g, 28.2 mmol). The solution was warmed to room temperature for 30 minutes or until TLC (10%/EtOAc/Hex, rf=0.55 major rf=0.48 minor) indicated complete formation of the diastereomeric sulfenate esters. The mixture was then refluxed 90° C. for 4 hours or until complete conversion of the sulfenate ester was indicated by TLC. After cooling to 0° C., pentane (50 mL) was then added and this mixture was filtered through Celite and evaporated. Flash chromatography (2% EtOAc/Hexanes, rf=0.4) gave pure 7 (2.3 g, 75%). [α] D 24 =+237 (c 1.0, CHCl 3 ). 1 NMR (300 MHz, CDCl 3 ) δ 1.98 (s, 9H), 1.72 (s, 3H), 1.86 (s, 3H), 5.06 (d, J=10.7 Hz, 1H), 5.18 (s, 1H), 5.24 (d, J=17.3 Hz, 1H), 5.70 (s, 1H), 6.24-6.33 (dd, J=10.7, 17.3 Hz, 1H); 13 C NMR (300 MHz, CDCl 3 ) δ 12.5, 25.1, 26.6, 34.9, 53.7, 87.4, 113.7, 132.6, 137.8, 140.9, 176.3; Analysis Calculated. for C 13 H 20 O 2 S: C, 64.9; H, 8.38. Found: C, 63.8; H, 8.28.
[0090] (±)-2-(t-Butyl)-5-(octa-1,3-dienyl)-5-methyl-1,3-oxathiolan-4-one (8). From (±) 4 (306 mg, 1.00 mmol) following general procedure B was obtained 8 (212 mg, 75%, 4:1 trans:cis) after flash chromatography (2% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) trans isomer δ 0.84-0.89 (m, 3H), 1.01 (s, 9H), 1.22-1.38 (m, 4H), 1.61 (s, 3H), 2.04-2.11 (m, 2H), 5.03 (s, 1H), 5.58 (d, J=15 Hz, 1H), 5.64-5.78 (m, 1H), 0.96-6.05 (m, 1H), 6.19 (dd, J=10.1, 15.1 Hz, 1H). 13 C NMR (75 MHz, CDCl 3 ) trans isomer δ 13.6, 22.0, 22.5, 25.2, 31.2, 32.1, 34.6, 55.9, 87.0, 128.5, 129.6, 130.2, 137.2, 174.7. IR (NaCl) 2959, 1772 cm −1 ; HRMS (E) m/z calculated for C 16 H 26 O 2 S (M + ) 282.1653, obsd 282.1681.
[0091] (±)-2-(t-Butyl)-5-(hexa-1,3-dienyl)-5-methyl-1,3-oxathiolan-4-one (9). From (i) 5 (690 mg, 2.53 mmol) following general procedure B was obtained 9 (461 mg, 72%, 4:1 trans:cis) after flash chromatography (2% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 0.95-1.01 (m, 12H), 1.61 (s, 3H), 2.07-2.12 (m, 2H), 5.05 (s, 1H), 5.58 (d, J=15 Hz, 1H), 5.81 (dt, J=6, 15 Hz, 1H), 6.00-6.05 (m, 1H), 6.15-6.24 (dd, J=10, 15.2 Hz, 1H); 13 C (75 MHz, CDCl 3 ) δ 13.3, 24.8, 25.3, 25.7, 34.5, 56.1, 87.2, 127.4, 129.4, 130.0, 138.9, 175.1. IR (NaCl) 2966, 1771 cm −1 . HRMS (ES) m/z calculated for C 14 H 22 O 2 SNa + (M + Na + ) 277.1232, obsd 277.1237.
[0092] (±)-2-(t-Butyl)-5-(2-methyl-penta-1,3-dienyl)-5-methyl-1,3-oxathiolan-4-one (10). From (±) 6 (500 mg, 2.51 mmol) following general procedure B was obtained 10 (342 mg, 73% 14:1 trans:cis) after flash chromatography (2% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 1.00 (s, 9H), 1.70 (s, 3H), 1.75 (d, J=6.6 Hz, 3H), 1.85 (s, 3H), 5.18 (s, 1H), 5.57 (s, 1H), 5.75 (dq, J=6.6, 16 Hz, 1H), 5.97 (d, J=16 Hz, 1H); 13 C NMR (75 MHz, CDCl 3 ) d 13.0, 18.0, 25.2, 27.4, 34.8, 53.8, 87.4, 125.4, 129.3, 135.5, 137.8, 176.3. IR (NaCl) 2961, 1770 cm −1 . HRMS (EI) m/z calculated for C 14 H 22 O 2 S (M + ) 254.1341, obsd 254.1309.
[0093] General Procedure C. 2-(R)-2,4-Dimethyl-2-thiopropionyl-hexa-3,5-dienoic acid ethyl ester (12). Cesium carbonate (332 mg, 1.0 mmol) was added directly to a solution of 7 (250 mg, 1.0 mmol) in EtOH (3.9 mL). After 20 minutes this mixture was poured into a mixture of NH 4 Cl(sat)/1 N HCl (15 mL, 3:1) and extracted with Et 2 O (3×20 mL). The combined organics were dried (MgSO 4 ), filtered and evaporated to give crude 11. To 11 was added CH 2 Cl 2 (7.5 mL) and the solution was cooled to 0° C. NEt 3 (0.14 mL, 1.0 mmol) and propionyl chloride (0.09 mL, 1.0 mmol) were added and the solution stirred at 0° C. After 40 minutes. NH 4 Cl (sat) (20 mL) was added and this mixture was extracted with CH 2 Cl 2 (3×15 mL). The combined organics were dried (MgSO4), filtered and evaporated. Flash chromatograpy (5% EtOAc/Hex, rf=0.4) gave pure 12 (261 mg, 72%). [α] D 23 =+4.2 (c 0.9, CHCl 3 ) 1 H NMR (300 MHz, CDCl 3 ) δ 1.11 (t, J=7.4 Hz, 3H), 1.23 (t, J=7.0 Hz, 3H, 1.83 (s, 3H), 1.85 (s, 3H), 2.48 (q, J=7.5 Hz, 2H), 4.18 (q, J=6.9 Hz, 2H), 5.02 (d, J=10.7 Hz, 1H), 5.18 (d, J=17.3 Hz, 1H), 5.73 (s, 1H), 6.24-6.34 (dd, J=10.7, 17.3 Hz, 1H); 13 C NMR (300 MHz, CDCl 3 ) δ 9.43, 12.9, 13.9, 26.1, 36.5, 55.2, 61.9, 113.1, 131.4, 138.2, 141.4, 172.1, 198.9. IR (NaCl) 2981, 1735, 1694 cm −1 . HRMS (EI) m/z calculated for C 13 H 20 O 3 S (M + ) 256.1133 obsd 256.1127.
[0094] (±)-2-Thioalkynyl-2-methyl-deca-3,5-dienoic acid ethyl ester (13). From 8 (200 mg, 0.71 mmol) and alkynyl chloride (55 μL, 0.78 mmol) following general procedure C gave 13 (119 g 59%) after flash chromatography (5% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 0.84-0.89 (m, 3H), 1.23 (t, J=7.1 Hz, 3H), 1.28-1.38 (m, 4H), 1.71 (s, 3H), 2.01-2.08 (m, 2H), 2.23 (s, 3H), 4.18 (q, J=7.1 Hz, 2H), 5.66-5.76 (m, 2H), 5.89-6.03 (m, 1H), 6.20 (dd, J=10.3, 15.3 Hz, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 13.8, 13.9, 22.2, 22.8, 29.9, 31.2, 32.3, 56.1, 61.9, 128.4, 129.2, 132.2, 137.1, 171.6, 194.6. IR (NaCl) 2930, 1737, 1694 cm 41 . HRMS (ES) m/z calculated for C 15 H 24 O 3 SNa + (M+Na + ) 307.1338 obsd. 307.1339.
[0095] (±)-2-Thioalkynyl-2-methyl-octa-3,5-dienoic acid ethyl ester (14). From 9 (353 mg, 1.39 mmol) and alkynyl chloride (98 mL, 1.39 mmol) following general procedure C gave 14 (142 g. 40%) after flash chromatography (5% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 0.83 (t, J=7.3 Hz, 3H), 1.24 (t, J=7.1 Hz, 3H), 1.72 (s, 3H), 2.03-2.17 (m, 2H), 2.25 (s, 3H), 4.17 (q, J=7.1 Hz, 2H), 5.72-5.81 (m, 2H), 5.95-6.04 (dd, J=10, 15 Hz, 1H), 6.18-6.27 (dd, J=10, 15 Hz, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 13.2, 13.9, 22.8, 25.6, 30.2, 56.1, 61.9, 128.2, 128.4, 132.1, 138.5, 171.6, 194.8. IR (NaCl) 2929, 1736, 1693 cm −1 ; HRMS (ES) m/z calculated for C 13 H 20 O 3 SNa + (M+Na + ) 279.1025 obsd 279.1032.
[0096] (±)-2-Thioalkynyl-2,4-dimethyl-hepta-3,5-dienoic acid ethyl ester (15). From 10 (369 mg, 1.46 mmol) and alkynyl chloride (103 μL, 1.46 mmol) following general procedure C gave 15 (271 mg, 77%) after flash chromatography (5% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 1.26 (t, J=7.1 Hz, 3H), 1.74 (d, J=6.6 Hz, 3H), 1.81 (s, 3H), 1.85 (s, 3H), 2.25 (s, 3H), 4.17 (q, J=7.1 Hz, 2H), 5.56 (s, 1H), 5.65-5.73 (dq, J=6.6, 16 Hz, 1H), 5.99 (d, J=16 Hz, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 13.8, 14.1, 18.2, 26.2, 30.5, 55.6, 62.0, 125.2, 128.3, 135.7, 138.5, 172.2, 194.8. IR (NaCl) 2926, 1737, 1694 cm −1 ; HRMS (EI) m/z calculated for C 13 H 20 O 3 S (M + ) 256.1133 obsd 256.1118.
[0097] (±)-2-Thioalkynyl-2,4-dimethyl-hexa-3,5-dienoic acid ethyl ester (16). From (±) 7 (380 mg, 1.56 mmol) and alkynyl chloride (110 μL, 1.56 mmol) following general procedure C gave 16 (230 mg, 61%) after flash chromatography (5% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 1.25 (t, J=7.1 Hz, 3H), 1.84 (s, 3H), 1.87 (s, 3H), 2.24 (s, 3H), 4.21 (q, J=7.1 Hz, 2H), 5.03 (d, J=10.6 Hz, 1H), 5.21 (d, J=17.3 Hz, 1H), 5.74 (s, 1H), 6.26-6.35 (dd, J=10.6, 17.3 Hz, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 12.9, 13.9, 25.9, 30.1, 55.8, 62.0, 113.3, 131.3, 138.3, 141.3, 182.3, 194.6. IR (NaCl) 2982, 1735, 1692 cm −1 .
[0098] General Procedure D. 5-(R)4-Hydroxy-3,5-dimethyl-5-(2-methyl-buta-1,3-dienyl)-5-H-thiophen-2-one (17) Thiolactamycin). To 12 (315 mg, 1.23 mmol) in THF (18.5 mL) at −78° C. was added LiHMDS (3.1 mL, 3.1 mmol, 1.0 M in THF) and the solution was allowed to slowly warm to −5° C. The solution was then poured into 1 N HCl (25 mL) and extracted with EtOAc (3×15 mL). The combined organics were dried MgSO 4 ), filtered and evaporated. This crude mixture was taken up in NaHCO 3 (sat, 15 mL) and extracted with Et 2 O (3×10 mL). The aqueous layer was then acidified to pH 3 (pH paper) with 1 N HCl and extracted with Et 2 O (3×10 mL) and EtOAc (2×10 mL). The combined organics were dried (MgSO 4 ), filtered and evaporated to provide pure 17. (182 mg, 70%, 96% ee). Recrystallization from Hexanes/Acetone (3:1) gave optically enriched 17. [α] D 24=+174 (c 0.6, MeOH), mp 119.5-121° C. (lit [α] D 20 +176 (c 1.0, MeOH), mp 120° C.) 2 . 1 H NMR (300 MHz, CDCl 3 ) δ 1.72 (s, 3H), 1.76 (s, 3H), 1.91 (s, 3H), 5.05 (d, J=10.7 Hz, 1H), 5.23 (d, J=17.3 Hz, 1H), 5.58 (s, 1H), 6.23-6.33 (dd, J=10.7, 17.3 Hz, 1H); 13 C NMR (300 MHz, CDCl 3 ) δ 7.60, 12.0, 29.8, 55.3, 110.6, 113.9, 129.1, 140.3, 140.7, 179.2, 196.7. IR (NaCl) 3422, 1607 cm −1 . Analysis Calculated for C 11 H 14 O 2 S: C, 62.8; H, 6.71; Found: C, 62.1, 6.71.
[0099] (±)-4-Hydroxy-5-methyl-5-octa-1,3-dienyl-5-H-thiophen-2-one (18). From 13 (62 mg, 0.22 mmol following general procedure D was obtained 18 (21 mg, 41%). 1 H NMR (300 MHz, CDCl 3 ) keto tautomer) δ 0.88 (t, J=6.9 Hz, 3H), 1.19-1.41 (m, 4H), 1.75 (s, 3H), 2.03-2.19 (m, 2H), 3.22 (d, J=21 Hz, 1H), 3.51 (d, J=21 Hz, 1H), 5.67 (d, J=15 Hz, 1H), 5.80 (dt, J=7, 17 Hz, 1H), 6.02 (dd, J=10, 15 Hz, 1H), 6.37 (dd, J=10, 15 Hz, 1H). 1 H NMR (300 MHz, MeOD) enol tautomer δ 0.97-1.03 (m, 3H), 1.36-1.53 (m, 4H), 1.87 (s, 3H), 2.15-2.22 (m, 2H), 5.78 (d, J=15 Hz, 1H), 5.82-5.90 (m, 1H), 6.10-6.19 (m, 1H), 6.38 (dd, J=10.3, 15.4 Hz, 1H); 13 C (75 MHz, MeOD) enol tautomer δ 14.4, 23.3, 25.2, 32.6, 33.4, 60.9, 102.1 (m), 130.7, 131.7, 132.7, 137.5, 188.9, 196.9. IR (NaCl) 2927, 1588 cm −1 ; HRMS (ES) calculated for C 13 H 18 O 2 SNa + (M+Na + ) 261.0911; obsd 261.0912.
[0100] (±)-4-Hydroxy-5-methyl-5-hexa-1,3-dienyl-5-H-thiophen-2-one (19). From 14 (364 mg, 0.46 mmol) following general procedure D was obtained 19 (180 mg, 60%). 1 H (300 MHz, CDCl 3 , exists as a mixture 2.3:1 of the keto:enol tautomer) keto tautomer: δ 1.00 (t, J=7.4 Hz, 3H); 1.76 (s, 3H); 2.09-2.16 (m, 2H); 3.21 (d, J=21 Hz, 1H); 3.52 (d, J=21 Hz, 1H); 5.70 (d, J=15 Hz, 1H); 5.86 (dt, J=15 Hz, 6 Hz, 1H), 6.02 (dd, J=10, 15 Hz, 1H), 6.38 (dd, J=15, 10 Hz, 1H); 1 H NMR (300 MHz, MeOD) enol tautomer δ 1.09 (t, J=7.4 Hz, 3H), 1.87 (s, 3H), 2.14-2.29 (m, 2H), 5.78 (d, J=15 Hz, 1H), 5.87 (dt, J=15, 6.57 Hz, 1H), 6.09-6.18 (m, 1H), 6.38 (dd, J=10.2, 15 Hz, 1H); 13 C NMR (75 MHz, MeOD) enol tautomer δ 14.1, 25.2, 26.9, 61.0, 101 (m), 129.7, 131.7, 132.7, 138.9, 188.9, 197.1. IR (NaCl) 2965, 1592 cm −1 ; HRMS (ES) m/z calculated for C 11 H 14 O 2 SNa + (M+Na + ) 233.0607, obsd 233.0626.
[0101] (±)-4-Hydroxy-5-methyl-5 (2-methyl-penta-1,3-dienyl)-5-H-thiophen-2-one (20). From 15 (226 mg, 0.9 mmol) following general procedure D was obtained 20 (95 mg, 49%). 1 H NMR (300 MHz, CDCl 3 ) keto-tautomer) δ 1.75 (s, 3H), 1.77 (d, J=3.2 Hz, 3H), 1.84 (s, 3H), 3.42 (d, J=1.5 Hz, 2), 5.43 (d, J=21 Hz, 1), 5.66 (bs, 1H), 5.78 (dd, J=6, 22 Hz, 1H), 6.04 (d, J=15 Hz, 1H); 1 H NMR (300 MHz, MeOD) (enol tautomer) δ 1.80-1.85 (m, 6H), 1.90 (s, 3H), 5.59 (s, 1H), 5.80-5.95 (m, 1H), 6.17 (d, J=15 Hz, 1H); 13 C NMR (75 MD, MeOD) (enol tautomer) δ 13.4, 18.4, 30.7, 59.2, 101.2 (m) 126.2, 128.4, 136.9, 140.6, 190.2, 197.6. IR (NaCl) 2929, 1593 cm −1 ; HRMS (ES) m/z calculated for C 11 H 14 O 2 SNa + (M+Na + ) 233.0607 obsd. 233.0597.
[0102] (±)-4-Hydroxy-5-methyl-5 (2-methyl-buta-1,3-dienyl)-5-H-thiophen-2-one (21). From 16 (181 mg, 0.75 mmol) following general procedure D was obtained 21 (66 mg, 45%). 1 H NMR (300 MHz, CDCl 3 ) keto tautomer) δ 1.78 (s, 3H), 1.86 (s, 3H), 3.43 (d, J=5.6 Hz, 2H), 5.12 (d, J=10.6 Hz, 1H), 5.27 (d, J=17.3 Hz, 1H), 5.83 (s, 1H), 6.27-6.37 (dd, J=10.6, 17.3 Hz, 1H). 1 H NMR (300 MHz, MeOD) (enol tautomer) δ 1.79 (s, 3H), 1.84 (s, 3H), 5.04 (d, J=10.7 Hz, 1H), 5.25 (d, J=17.3 Hz, 1H), 5.66 (s, 1H), 6.36 (dd, J=10.7, 17.3 Hz, 1H); 13 C NMR (75 MHz, MeOD) δ 12.6, 30.4, 59.0, 102 (m), 116.9, 131.4, 140.6, 142.3, 189.9, 197.3. HRMS (EI) m/z calculated for C 10 H 12 O 2 S + (M + ) 196.0552 obsd. 196.0552.
[0103] (±t)-5-Benzyl-4-hydroxy-5-methyl-5-H-thiophen-2-one (22). From 31 (1.4 mg, 5.0 mmol) following general procedure D was obtained 22 (500 mg, 45%). 1 H NMR (300 MHz, CDCl 3 ) δ 1.71 (s, 3H), 2.89 (ab q, J=22 Hz, 2H), 3.17 (ab q, J=14 Hz, 2H), 7.26 (m, 5H); 13 C NMR (75 MHz, CDCl 3 ) d 26.2, 46.6, 48.5, 67.9, 127.7, 128.6, 130.6, 134.9, 195.3, 207.3.
[0104] General Procedure E. (±)-2-tert-butyl-5-methyl-5-octyl-[1,3]-oxathiolan-4-one (23). To a mixture of LiHMDS (6.2 mL, 6.20 mmol, 1 M in THF) in THF (9.7 mL) at −78° C. was added (±)-1 (1.00 g, 5.75 mmol) in THF (9.60 mL) by cannula dropwise, and the resulting solution stirred for 30 minutes. at −78° C. Then, octyl triflate (1.63 g, 6.20 mmol) in TH (4 mL) at −78° C. was added via cannula. After stirring at −78° C. for 2 hours, 1 N HCl (10 mL) was added and the solution was extracted with Et 2 O (3×15 mL). The combined organics were dried (MgSO 4 ), filtered and evaporated. Flash chromatography (2% EtOAc/Hexanes) gave pure 23 as a 2:1-6:1 mixture of separable diastereomers (1.33 g, 81%). 1 H NMR (300 MHz, CDCl 3 ) δ 0.86 (t, J=6.5 Hz, 3H), 0.99 (s, 9H), 1.24-1.26 (m, 12H), 1.54 (s, 3H), 1.72-1.84 (m, 2H), 5.13 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 13.9, 22.6, 24.9, 25.1, 25.9, 29.2, 29.3, 29.5, 31.8, 35.2, 41.2, 55.3, 86.5, 177.7. IR (NaCl) 3443, 2929, 1829, 1769 cm −1 ; Analysis Calculated. for C 16 H 30 O 2 S: C, 67.0; H, 10.6; Found: C, 66.3; H, 10.5. HRMS (ED m/z calculated for C 16 H 30 O 2 S + (M + ) 286.1967 obsd. 286.1969.
[0105] (±)-2-tert-butyl-5-methyl-5-hexyl-[1,3]-oxathiolan-4-one (24). From (±)-1 (500 mg, 2.87 mL) and hexyl triflate (738 mg, 2.87 mmol) following general procedure E was obtained 24 (557 mg, 75%) as a 2:1-6:1 mixture of separable diastereomers. 1 H NMR (300 MHz, CDCl 3 ) δ 0.87 (t, J=6.5 Hz, 3H), 0.99 (s, 9H), 1.24-1.29 (m, 8H), 1.54 (s, 3H), 1.72-1.80 (m, 2H), 5.13 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 13.9, 22.5, 24.9, 24.9, 25.1, 25.9, 29.1, 31.6, 41.2, 55.3, 86.7, 177.8. IR (NaCl) Analysis Calculated. for C 14 H 26 O 2 S: C, 65.1; H, 10.1; Found: C, 64.5; H, 10.1. HRMS (EI) m/z calculated for C 14 H 26 O 2 S + (M + ) 258.1654 obsd. 286.1653.
[0106] General Procedure F. (±)-2-Alkylsulfanyl-2-methyl-decanoic acid ethyl ester (26). To 23 (650 mg, 2.27 mmol) in EtOH (14.1 mL) was added NaOEt (2.1 M) (2.16 mL, 4.54 mmol) (freshly prepared from Na metal (200 mg, 8.3 mmol) in EtOH (4.0 mL)) and the solution was allowed to stir at room temperature. After 2 hours, the solution was poured into NH 4 Cl (sat) /1 N HCl (25 mL, 3:1) and this mixture was extracted with Et 2 O (3×20 mL). The combined organics were then washed with H 2 O (3×25 mL), dried (MgSO 4 ), filtered and evaporated to give crude 25. To 25 dissolved in CH 2 Cl 2 (26 mL) at 0° C. was added NEt 3 (0.5 mL, 3.49 mmol) and alkynyl chloride (0.3 mL, 3.49 mmol). After 40 minutes at 0° C., NH 4 Cl (sat) (30 mL) was added and the solution was extracted with CH 2 Cl 2 . The combined organics were dried (MgSO 4 ), filtered and evaporated. Flash chromatography (5% EtOAc/Hexanes) gave pure 26 (542 mg, 79%). 1 H NMR (300 MHz, CDCl 3 ) δ 0.87 (t, J=6.9 Hz, 3H); 1.22-1.27 (m, 15H), 1.61 (s, 3H), 1.75-1.84 (m, 2H), 2.26 (s, 3H), 4.18 (q, J=7.1 Hz, 2H); 13 C NMR (75 MHz, CDCl 3 ) δ 13.9, 14.1, 22.6, 23.4, 24.4, 29.1, 29.2, 29.6, 30.3, 31.8, 38.3, 55.8, 61.5, 173.1, 195.8. IR (NaCl) 3430, 1868, 1693, 1644 cm −1 ; Analysis Calculated. for C 15 H 28 O 3 S: C, 62.5; H, 9.78; Found: C, 62.6; H, 9.83.
[0107] (±)-2-Alkynylsufanyl-2-methyl-octanoic acid ethyl ester (28) From 24 (940 mg, 3.63 mmol) and alkynyl chloride (0.3 mL, 3.63 mmol) following general procedure F was obtained 28 (727 mg, 77%) after flash chromatography (5% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) d 0.86 (t, J=6.9 Hz, 3H), 1.22-1.27 (m, 11H), 1.61 (s, 3H), 1.75-1.79 (m, 2H), 2.25 (s, 3H), 4.17 (q, J=7 Hz, 2H); 13 C NMR (75 MHz, CDCl 3 ) δ 13.9, 14.1, 22.4, 23.4, 24.4, 29.3, 30.3, 31.5, 38.4, 55.7, 61.5 173.0, 194.7. IR (NaCl) 3449, 1736, 1694 cm −1 ; Analysis Calculated. for C 13 H 24 O 3 S: C, 59.9; H, 9.29; Found: C, 60.6; H, 9.44.
[0108] (±)-2-Methyl 2-propionylsulfanyl-decanoic acid ethyl ester (30). From 23 (613 mg, 2.14 mmol) and propionyl chloride (0.19 mL, 2.14 mmol) following general procedure F was obtained 30 (484 mg, 75%) after flash chromatography (5% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 0.84 (t, J=6.9 Hz, 3H), 1.10 (t, J=7.5 Hz, 3H), 1.19-1.24 (m, 15H), 1.58 (s, 3H), 1.72-1.77 (m, 2H), 2.48 (q, J=7.5 Hz, 2H), 4.17 (q, J=7 Hz, 2H); 13 C NMR (75 MHz, CDCl 3 ) δ 9.45, 14.1, 14.1, 22.6, 23.5, 24.5, 29.1, 29.3, 29.7, 31.8, 36.9, 38.5, 55.5, 61.4, 173.2, 199.2. Analysis Calculated for C 16 H 30 O 3 S: C, 63.5; H, 10.0; Found: C, 63.7; H, 10.0.
[0109] (±)-2-Alkynylsulfanyl-2-methyl-3-phenyl-decanoic acid ethyl ester (31). From 5-Benzyl-2-tert-butyl-5-methyl-[1,3]oxathiolan-4-one 1 . (1.2 g, 4.7 mmol) following general procedure F was obtained 31 (954 mg, 76%) after flash chromatography (5% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 1.19 (t, J=7 Hz, 3H), 1.55 (s, 3H), 2.26 (s, 3H), 3.13 (q, J=13 Hz, 2H), 4.13 (q, J=7 Hz, 2H), 7.1 (m, 2H), 7.2 (m, 3H); 13 C NMR (75 MHz, CDCl 3 ) δ 14.0, 23.1, 30.3, 43.6, 56.3, 61.7, 127.2, 128.1, 130.7, 135.4, 172.8, 194.8.
[0110] General Procedure G. (±)-4-Hydroxy-5-methyl-5-octyl-5-H-thiophen-2-one (32). To 26 (500 mg, 1.7 mmol) in toluene (27 mL) at −78° C. was added LiHMDS (4.3 mL, 4.3 mmol, 1.0 M in THF) and the solution was allowed to slowly warm to −5° C. The solution was then poured into 1 N HCl (40 mL) and extracted with EtOAc (3×25 mL). The combined organics were dried (MgSO 4 ), filtered and evaporated. Flash chromatography (20% EtOAc/2% CH 3 CO 2 H/Hexanes) gave 32 (308 mg, 73%). 1 H NMR (300 MHz, CDCl 3 ) (keto-tautomer) δ 0.86 (t, J=6 Hz, 3H), 1.19-1.24 (m, 10H), 1.48-1.53 (m, 2H), 1.65 (s, 3H), 1.77-1.85 (m, 1H), 1.94-2.01 (m, 1H), 3.36 (s, 2H); 1 H NMR (300 MHz, MeOD) (enol tautomer) 0.87-0.89 (m, 3H), 1.29 (m, 10H), 3.29 (s, 3H), 1.81-1.87 (m, 2H); 13 C NMR (75 MHz, MeOD) (enol tautomer) δ 14.7, 23.8, 26.4, 27.1, 30.5, 30.6, 30.8, 33.2, 39.8, 61.3, 103.1 (m), 189.8, 197.8. IR (NaCl) 3422, 1593 cm −1 ; Analysis Calculated for C 13 H 22 O 2 S: C, 64.4; H, 9.15; Found: C, 64.3; H, 9.10.
[0111] (±)-4-Hydroxy-5-methyl-5-hexyl-5-H-thiophen-2-one (33). From 28 (715 mg, 2.75 mmol) following general procedure G was obtained 33 (402 mg, 69%) after flash chromatography (20% EtOAc/2% CH 3 CO 2 H/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) 3 keto tautomer) 0.86 (t, J=7 Hz, 3H), 1.27 (bs, 8H), 1.68 (s, 3H), 1.94-2.26 (m, 2H), 3.35 (s, 2H). 1 H NMR (300 MHz, MeOD) (enol tautomer) δ 0.89 (t, J=6.5 Hz, 3H), 1.21-1.36 (m, 7H), 1.46-1.54 (m, 1H), 1.64 (s, 3H), 1.80-1.90 (m, 2H); 13 C NMR (75 MHz, MeOD) δ 14.6, 23.8, 26.3, 27.1, 30.5, 32.9, 39.8, 61.3, 103.5 (m), 189.8, 197.8. Analysis Calculated for C 11 H 18 O 2 S: C, 61.6; H, 8.47; Found: C, 61.7; H, 8.67.
[0112] (±)-4-Hydroxy-3,5-dimethyl-5-octyl-5-H-thiophen-2-one (34). From 30 (469 mg, 1.55 mmol) and NaHMDS (3.87 mL, 3.87 mmol, 1.0 M in TH) following general procedure G was obtained 34 (397 mg, 70%). 1 H NMR (300 MHz, CDCl 3 ) (enol tautomer) δ 0.86 (t, J=6.8 Hz, 3H), 1.23 (s, 11H), 1.30-1.45 (m, 1H), 1.59 (s, 3H), 1.74 (s, 3H), 1.84-1.88 (m, 2H); 13 C NMR (75 MHz, CDCl 3 ) δ 7.48, 14.0, 22.6, 25.2, 25.9, 29.2, 29.4, 29.6, 31.8, 38.5, 58.2, 110.5, 180.9, 198.0. IR (NaCl) 2927, 1601 cm −1
[0113] General Procedure H. (±)-4-Methoxy-5-methyl-5-octyl-5-H-thiophen-2-one (35). To 32 (70 mg, 0.27 mmol) in DMF (1.1 mL) cooled to −40° C. was added NaH (14 mg, 0.35 mmol, 60% in mineral oil) and the solution was allowed to warm and stir at 0° C. for 30 minutes. Dimethyl sulfate (50 μl, 0.55 mmol) was then added directly and the mixture was allowed to warm and stir for 2.5 hours at room temperature. NH 4 Cl (sat) /1 N HCl (3:1, 10 mL) was added and the solution was extracted with Et 2 O (3×10 mL). The combined organics were washed with H 2 O (3×15 mL), dried (MgSO 4 ), filtered and evaporated. Flash chromatography (15% EtOAc/Hexanes) gave pure 35 (59 mg, 80%). 1 H NMR (300 MHz, CDCl 3 ) δ 0.85 (t, J=7 Hz, 3H); 1.07-1.18 (m, 1H), 1.23 (s, 10H), 1.43-1.49 (m, 1H), 1.61 (s, 3H), 1.74-1.81 (m, 2H), 3.81 (s, 3H), 5.29 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 14.0, 22.6, 25.1, 26.4, 29.1, 29.3, 29.5, 31.8.38.8, 59.3, 59.4, 101.3, 187.3, 193.8. Analysis. Calculated for C 14 H 24 O 2 S: C, 65.6; H, 9.50; Found: C, 65.8; H, 9.50.
[0114] (±)-4-Methoxy-5-methyl-5-hexyl-5-H-thiophen-2-one (36). From 33 (40.3 mg, 0.19 mmol) and dimethyl sulfate (35 μL, 0.37 mmol) following general procedure H was obtained 36 (25 mg, 58%) after flash chromatography (15% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 0.86 (t, J=6.7 Hz, 3H), 1.08-1.13 (m, 1H), 1.24 (s, 6H), 1.35-1.39 (m, 1H), 1.61 (s, 3H), 1.75-1.82 (m, 2H), 3.81 (s, 3H), 5.30 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 14.0, 22.5, 25.1, 26.4, 29.2, 31.5, 38.9, 59.4, 59.4, 101.3, 187.3, 193.8.
[0115] (±)-4-Methoxy-3,5-dimethyl-5-octyl-5-H-thiophen-2-one (37). From 34 (40 mg, 0.16 mmol), KH (27 mg, 0.20 mmol, 30% in mineral oil) and dimethyl sulfate (30 μL, 0.31 mmol) following general procedure H was obtained 37 (30 mg, 71%). 1 H NMR (300 MHz, CDCl 3 ) δ 0.86 (t, J=7 Hz, 3H), 1.06-1.09 (m, 1H), 1.24 (s, 10H), 1.41-1.48 (m, 1H), 1.55 (s, 3H), 1.71-1.79 (m, 2H), 1.98 (s, 3H), 4.09 (s, 3H); 13 C NMR (75 MHz, CDCl 3 ) δ 9.59, 14.1, 22.6, 25.2, 26.5, 29.2, 29.4, 29.6, 31.8, 38.9, 58.7, 59.8, 111.3, 180.2, 195.7. IR (NaCl) 2927, 1676, 1631, 1582 cm −1 . Analysis Calculated for C 15 H 26 O 2 S: C, 66.6; H, 9.69; Found: C, 66.5; H, 9.67.
[0116] (±)-5-Benzyl-4-methoxy-5-methyl-5-H-thiophen-2-one (38). From 22 (50 mg, 0.23 mmol), and dimethyl sulfate (44 μL, 0.45 mmol) following general procedure H was obtained 38 (38 mg, 74%). 1 H NMR (300 MHz, CDCl 3 ) δ 1.65 (s, 3H), 3.1 (q, J=7 Hz, 2H), 3.84 (s, 3H), 5.19 (s, 1H), 7.21 (m, 5H); 13 C NMR (75 MHz, CDCl 3 ) δ 26.0, 45.0, 59.3, 59.9, 101.9, 127.2, 128.0, 130.4, 135.9, 186.5, 192.9.
[0117] (±)-5-Methyl-5-octyl-2-oxo-thiophen-4-yloxy)-acetic acid ethyl ester (39). From 32 (39 mg, 0.16 mmol) and ethyl bromoacetate (36 μL, 0.32 mmol) following general procedure H was obtained 39 (39 mg, 73%) after flash chromatography (15% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 0.86 (t, J=6 Hz, 3H), 1.24 (s, 11H), 1.29 (t, J=7 Hz, 3H), 1.47-1.48 (m, 1H), 1.68 (s, 3H), 1.85-1.88 (m, 2H), 4.25 (q, J=7 Hz, 2H), 4.54 (s, 2H), 5.20 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 14.1, 14.1, 22.6, 25.1, 26.4, 29.2, 29.3, 29.5, 31.8, 38.8, 59.7, 61.9, 67.9, 102.3 166.2, 185.3, 193.4. IR (NaCl) 2928, 1762, 1682, 1612 cm −1 . Analysis Calculated for C 17 H 28 O 4 S: C, 62.2; H, 8.59: Found: C, 62.2; H, 8.67.
[0118] (±)-5-Methyl-5-hexyl-2-oxo-thiophen-4-yloxy)-acetic acid ethyl ester (40). From 33 (20 mg, 0.09 mmol) and ethyl bromoacetate (20 μL, 0.2 mmol) following general procedure H was obtained 40 (18 mg, 67%) after flash chromatography (15% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) d 0.86 (t, J=6.8 Hz, 3H), 1.24-1.27 (m, 7H), 1.32 (t, J=7 Hz, 3H), 1.47-1.48 (m, 1H), 1.68 (s, 3H), 1.84-1.88 (m, 2H); 4.25 (q, J=7 Hz, 2H), 4.54 (s, 2H), 5.21 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 14.1, 14.1, 22.5, 25.1, 26.4, 29.2, 31.6, 38.9, 59.7, 61.9, 68.0, 102.3, 166.2, 185.3, 193.3. IR (NaCl) 2932, 1762, 1682, 1612 cm −1 . Analysis Calculated for C 15 H 24 O 4 S: C, 59.9; H, 8.05: Found: C, 59.9; H, 8.08.
[0119] (±)-4-(4-Chloro-butoxy)-5-methyl-5-octyl-5H-thiophen-2-one (41). From 32 (47 mg, 0.18 mmol) and 3-iodo-1-chlorobutane (40 μL, 0.36 mmol) following general procedure H was obtained 41 (46 mg, 85%) after flash chromatography (20% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 0.86 (t, J=7 Hz, 3H), 1.07-1.27 (m, 1H), 1.24 (s, 10H) 1.48-1.51 (m, 1H), 1.62 (s, 3H), 1.75-1.82 (m, 2H), 1.89-1.98 (m, 4H), 3.59 (t, J=5.9 Hz, 2H), 3.95-3.98 (m, 2H), 5.28 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 14.1, 22.6, 25.1, 26.0, 26.5, 29.0, 29.2, 29.3, 29.5, 29.7, 31.8, 44.1, 59.6, 71.7, 101.6, 186.1, 193.8. Analysis Calculated for C 17 H 29 C 2 S: C, 61.3, H, 8.78, Found: C, 61.9; H, 9.01.
[0120] (±)-4-(4-Chloro-butoxy)-5-methyl-5-hexyl-5H-thiophen-2-one (42). From 33 (36 mg, 0.17 mmol) and 3-iodo-1-chlorobutane (40 μL, 0.34 mmol) following general procedure H was obtained 42 (32 mg, 75%) after flash chromatography (20% EtOAc/Hexanes). 1 H NMR (400 MHz, CDCl 3 ) δ 0.86 (t, J=5.1 Hz, 3H), 1.09-1.14 (m, 1H), 1.25 (s, 6H), 1.44-1.53 (m, 1H), 1.63 (s, 3H), 1.77-1.85 (m, 2H), 1.90-2.00 (m, 4H), 3.59 (t, J=4.5 Hz, 2H), 3.95-3.99 (m, 2H), 5.28 (s, 1H). 13 C NMR (75 MHz, CDCl 3 ) δ 13.7, 22.3, 25.1, 26.1, 26.4, 29.1, 29.1, 31.5, 39.0, 43.9, 59.5, 71.6, 101.5, 185.9, 192.9. IR(NaCl) 2927, 1683, 1607 cm −1 . Analysis Calculated for C 15 H 25 C 2 S: C, 59.1; H, 8.27; Found: C, 59.3; H, 8.39.
[0121] (±)-4-allyloxy-5-methyl-5-octyl-5H-thiophen-2-one (43). From 32 (31 mg, 0.12 mmol) and allyl bromide (21 μL, 0.25 mmol) following general procedure H was obtained a 3:1 mixture of 43 and 44 (26 mg, 74%) which could be separated and purified using flash chromatography (15% EtOAc/Hexanes). O-alkylated product 43. 1 H NMR (300 MHz, CDCl 3 ) δ 0.86 (t, J=6.3 Hz, 3H), 1.12-1.17 (m, 1H), 1.24 (s, 10H), 1.45-1.49 (m, 1H), 1.64 (s, 3H), 1.77-1.84 (m, 2H), 4.47 (d, J=5.6 Hz, 2H), 5.29 (s, 1H), 5.31 (d, J=11 Hz, 1H), 5.39 (d, J=17 Hz, 1H), 5.90-5.99 (ddd, J=5.6, 11, 17 Hz, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 14.1, 22.6, 25.1, 26.5, 29.2, 29.3, 29.5, 31.8, 38.9, 59.7, 72.8, 102.0, 119.5, 130.8, 185.8, 193.8. IR (NaCl) 3441, 1681, 1609 cm −1 . Analysis Calculated for C 16 H 26 O 2 S: C, 68.0, H, 9.20, Found: C, 68.1; H, 9.34.
[0122] (44) C-alkylated product 1 H NMR (300 MHz CDCl 3 ) δ 0.86 (t, J=6.5 Hz, 3H), 1.25 (m, 12H), 1.54 (s, 3H), 1.79-1.84 (m, 2H), 2.43-2.47 (m, 2H), 5.05-5.11 (m, 2H), 5.57-5.69 (1H).
[0123] (±)-4-allyloxy-5-methyl-5-hexyl-5H-thiophen-2-one (45). From 33 (270 mg, 1.3 mmol) and allyl bromide (0.2 mL, 2.52 mmol) following general procedure H, was obtained a 2.3:1 mixture of 45 and 46 (205 mg, 58%) which could be separated and purified using flash chromatography (15% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) (45) (O-alkylation) δ 0.84 (t, J=7 Hz, 3H), 1.09-1.17 (m, 1H), 1.23 (s, 6H), 1.40-1.51 (m, 1H), 1.62 (s, 3H), 1.73-1.83 (m, 2H), 4.46 (d, J=5.6 Hz, 2H), 5.33 (d, J=10 Hz, 1H), 5.38 (d, J=17 Hz, 1H), 5.28 (s, 1H), 5.87-5.98 (ddd, J=5.6, 10, 17 Hz, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 14.0, 22.5, 25.1, 26.5, 29.2, 31.6, 38.9, 59.7, 72.8, 101.9, 119.6, 130.7, 185.8, 193.9. Analysis Calculated for C 14 H 22 O 2 S: C, 66.10; H, 8.72; Found: C, 66.04; H, 8.72.
[0124] (46) (C-alkylation) 1 H NMR (300 MHz, CDCl 3 ) δ0.86 (t, J=7 Hz, 3H), 1.24 (bs, 8H), 1.54 (s, 3H), 1.81-1.84 (m, 2H), 2.42-2.48 (m, 2H), 5.05-5.10 (m, 2H), 5.56-5.67 (m, 1H).
[0125] (±)-4-alkyloxy-3,5-dimethyl-5-octyl-5H-thiophen-2-one (47). (±)-Allyl-3,5-Dimethyl-5-octyl-thiophene-2,4-dione (48). From 34 (70 mg, 0.27 mmol) and allyl bromide (47 μL, 0.55 mmol) following general procedure H, was obtained a 2.3:1 mixture of 47 and 48 (C-alkylation data not shown) (67 mg, 82%) which could be separated and purified using flash chromatography (20% EtOAc/Hexanes).
[0126] (47). 1 H NMR (300 MHz, CDCl 3 ) δ 0.86 (t, J=7 Hz, 3H), 1.06-1.48 (m, 12H), 1.58 (s, 3H), 1.71-1.82 (, 2H), 1.94 (s, 3H), 4.80-4.82 (m, 2H), 5.28-5.46 (m, 2H), 5.89-5.03 (m, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 9.65, 14.0, 22.6, 25.2, 26.6, 29.2, 29.3, 29.6, 31.8, 39.2, 57.5, 72.5, 118.2. 119.5, 132.6, 179.4, 193.8. IR (NaCl) 2855, 1676, 1628, 1580 cm −1 .
[0127] (48). 1 H NMR (300 MHz, CDCl 3 ) δ 0.86 (t, J=7 Hz, 3H), 1.16-1.47 (m, 15H), 1.57 (s, 3H), 1.74-1.96 (m, 2H), 2.42-2.46 (m, 2H), 5.04-5.10 (m, 2H), 5.53-5.67 (m, 1H).
[0128] (±)-5-methyl-5-4-prop-2-ynyloxy-5H-thiophen-2-one (49). From 33 (45 mg, 0.21 mmol) and propargyl bromide (37 μL, 0.21 mmol) following general procedure H was obtained 49 (21 mg, 40%). 1 H NMR (300 MHz, CDCl 3 ) d 0.86 (t, J=7 Hz, 3H), 1.11-1.20 (m, 1H), 1.24 (s, 6H), 1.41-1.49 (m, 1H), 1.63 (s, 3H), 1.76-1.86 (m, 2H), 2.59 (t, J=2.5 Hz, 1H), 4.62 (d, J=3.7 Hz, 1H), 4.63 (d, J=3.7 Hz, 1H), 5.43 (s, 1H).
[0129] (±)-5-Methyl-5-octyl-2-oxo-thiophen-4-yloxy)-acetic acid tert-butyl ester (50). From 32 (60 mg, 0.25 mmol) and tert-butyl bromoacetate (73 μL, 0.49 mmol) following general procedure H, was obtained 50 (62 mg, 70%) after flash chromatography (15% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 0.86 (t, J=7 Hz, 3H), 1.24 (s, 12H), 1.49 (s, 9H), 1.68 (s, 3H), 1.83-1.86 (m, 2H), 4.43 (s, 2H), 5.19 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) 8314.0, 22.6, 25.2, 26.3, 28.1, 29.2, 29.3, 29.5, 31.8, 38.9, 59.7, 68.5, 83.4, 102.1, 165.2, 185.5, 193.4. Analysis Calculated for C 19 H 32 O 4 S: C, 64.0; H, 9.05; Found: C, 64.1; H, 9.08.
[0130] (±)-5-Methyl-5-hexyl-2-oxo-thiophen-4-yloxy)-acetic acid tert-butyl ester (51). From 33 (169 mg, 0.79 mmol) and tert-butyl bromoacetate (0.23 mL, 1.58 mmol) following general procedure H, was obtained 51 (206 mg, 80%) after flash chromatography (15% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 0.82 (t, J=6.8 Hz, 3H), 1.21 (s, 8H), 1.47 (s, 9H), 1.64 (s, 3H), 1.78-1.83 (m, 2H), 4.41 (s, 2H), 5.15 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 14.0, 22.5, 25.1, 26.3, 28.0, 29.1, 31.5, 38.9, 59.6, 68.4, 83.4, 102.1, 165.2, 185.5, 193.4.
[0131] (±)-5-Phenyl-5-methyl-2-oxo-thiophen-4-yloxy)-acetic acid tert-butyl ester (52). From 22 (150 mg, 0.68 mmol) and tert-butyl bromoacetate (0.20 mL, 1.36 mmol) following general procedure H, was obtained 52 (159 mg, 74%) after flash chromatography (20% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 1.49 (s, 9H), 1.69 (s, 3H), 3.17 (s, 2H), 4.44 (q, J=8 Hz, 2H), 5.13 (s, 1H), 7.24 (m, 5H); 13 C NMR (75 MHz, CDCl 3 ) δ 25.8, 28.1, 45.0, 60.1, 68.4, 83.6, 102.6, 127.2, 128.1, 130.5, 135.9, 165.3, 184.9, 192.8.
[0132] General Procedure I. (±)-5-Methyl-octyl-2-oxo-thiophen-4-yloxy)-acetic acid (53). To 50 (65 mg, 0.18 mmol) dissolved in CH 2 Cl 2 (1.4 mL) was added trifluoroacetic acid (TFA) (0.7 mL) and the solution was stirred at room temperature for 4 hours. The solvents were evaporated and the crude material was chromatographed (20% EtOAc/2% CH 3 CO 2 H/Hexanes) to give pure 53 (48 mg, 89%). 1 H NMR (300 MHz, CDCl 3 ) δ 0.86 (t, J=6.9 Hz, 3H), 1.24 (s, 11H), 1.47-1.48 (m, 1H), 1.68 (s, 3H), 1.84-1.88 (m, 2H), 4.62 (s, 2H), 5.31 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 14.1, 22.6, 25.1, 26.1, 29.2, 29.3, 29.5, 31.8, 38.9, 60.1, 67.7, 102.4, 169.8, 185.8, 195.4. IR (NaCl) 3442, 1645 cm −1 ; Analysis Calculated for C 15 H 24 O 4 S: C, 59.9; H, 8.05; Found: C, 60.0; H, 8.09.
[0133] (+5-Methyl-5-hexyl-2-oxo-thiophen-4-yloxy)-acetic acid (54). To 51 (177 mg, 0.54 mmol) and trifluoroacetic acid (TFA) (2.61 mL) following general procedure I was obtained 54 (144 mg, 98%) after flash chromatography (20% EtOAc/2% CH 3 CO 2 H/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 0.85 (t, J=6.8 Hz, 3H), 1.24 (s, 7H), 1.44-1.47 (m, 1H), 1.68 (s, 3H), 1.84-1.91 (m, 2H), 4.62 (s, 2H), 5.33 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 14.1, 22.6, 25.1, 26.1, 29.2, 31.6, 38.9, 60.3, 67.7, 102.4, 169.8, 185.9, 196.1.
[0134] (±)-5-Phenyl-5-methyl-2-oxo-thiophen-4-yloxy)-acetic acid (55). To 52 (117 mg, 0.35 mmol) and trifluoroacetic acid (TFA) (1.4 mL) following general procedure I was obtained 55 (68 mg, 70%) after flash chromatography (30% EtOAc/2% CH 3 CO 2 H/(Hexanes). 1 H NMR (300 MHz, MeOD) δ 1.63 (s, 3H), 3.11 (dd, J=6.8 Hz, 13.6 Hz, 2H), 4.59 (s, 2H), 5.21 (s, 1H), 7.1 (m, 5H); 13 C NMR (75 MHz, MeOD) δ 26.7, 45.7, 61.9, 67.1, 103.9, 128.3, 129.1, 131.8, 137.5, 169.3, 187.3, 195.8.
[0135] (±)—N-Allyl-(5-methyl-5-octyl-2-oxo-thiophen-4-yloxy)-acetamide (41). To a cooled solution (0° C.) of 53 (64 mg, 0.21 mmol) in CH 2 Cl 2 (1.1 mL) was added 1-[3-(Dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride (EDC) (49 mg, 0.25 mmol), DMAP (3 mg, 0.02 mmol), and allyl amine (18 μL, 0.25 mmol) and the mixture was allowed to warm to room temperature and stir for 12 hours. The solution was poured into a solution of 1 N HCl/ (sat) (1:3) and extracted with Et 2 O (3×10 mL). The combined organics were dried (MgSO 4 ), filtered and evaporated to give crude 56. Flash chromatography (50% EtOAc/Hexanes) gave pure 56 (50 mg, 66%). 1 H NMR (300 MHz, CDCl 3 ) δ 0.86 (t, J=7 Hz, 3H), 1.12-1.22 (m, 1H), 1.24 (s, 10H), 1.41-1.51 (m, 1H), 1.68 (s, 3H), 1.82-1.87 (m, 2H), 3.98 (app t, J=6 Hz, 2H), 4.50 (s, 2H), 5.20 (d, J=10 Hz, 1H), 5.22 (d, J=17.3 Hz, 1H), 5.35 (s, 1H), 5.80-5.90 (ddd, J=6, 10, 17 Hz, 1H), 6.19 (bs, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 14.0, 22.6, 25.3, 26.5, 29.2, 29.4, 29.5, 31.8, 39.1, 41.6, 59.3, 70.3, 103.4, 117.2, 133.2, 165.3, 183.9, 192.8. Analysis. Calculated. for C 18 H 29 NO 3 S: C, 63.7; H, 8.61; Found: C, 63.4; I-8.67.
[0136] General Procedure J. (±)-(5-methyl-5-hexyl-2-oxo-thiophen-4-yloxy)-alkynyl-methyl glycinate (57). To a solution of 54 (42.4 mg, 0.15 mmol) in CH 3 CN (0.86 mL) was added tris(2-oxo-3-oxazolinyl)phosphine oxide 3 (91 mg, 0.20 mmol), methylglycinate hydrochloride (19.7 mg, 0.16 mmol) and NEt 3 (43 μL, 0.31 mmol) and the solution was allowed to stir at room temperature for 20 minutes. The mixture was poured into a solution of NH 4 Cl (sat) /1 N HCl (10 mL) and extracted with Et 2 O (3×10 mL). The combined organics were dried MgSO 4 ), filtered, evaporated and chromatographed (40-50% EtOAc/Hexanes) to give pure 57 (43 mg, 80%). 1 H NMR (300 MHz, CDCl 3 ) δ 0.85 (t, J=6.8 Hz, 3H), 1.23-1.26 (m, 7H), 1.49-1.55 (m, 1H), 1.65 (s, 3H), 1.84-1.90 (m, 2H), 3.79 (s, 3H), 4.11 (d, J=5 Hz, 1H), 4.12 (d, J=5 Hz, 1H), 4.47 (s, 2H), 5.36 (s, 1H), 6.76 (bs, 1H).
[0137] (±)-(5-methyl-5-hexyl-2-oxo-thiophen-4-yloxy)-alkynyl glycinate (58). To 57 (22 mg, 0.06 mmol) dissolved in THF/H 2 O (0.5 mL, 3:1), cooled to 0° C. was added LiOH (3 mg, 0.07 mmol) and this solution was allowed to stir for 45 minutes. Then the mixture was poured into a solution of HCl (10 mL, 1 N) and extracted with Et 2 O (3×10 mL). The combined organics were dried (MgSO 4 ), filtered and evaporated to give crude 58. Flash chromatography (50% EtOAc/2% CH 3 CO 2 H/Hexanes) gave pure 58 (19 mg, 86%). 1 H NMR (300 MHz, CDCl 3 ) δ 0.85 (t, J=6.7 Hz, 3H), 1.25 (s, 7H), 1.48-1.52 (m, 2H), 1.68 (s, 3H), 2.08-2.10 (m, 2H), 4.05 (s, 2H), 4.56 (s, 2H), 5.41 (s, 1H).
[0138] (±) N-(4-Bromobutyl)-(5methyl-5-hexyl-2-oxo-thiophen-4-yloxy)-acetamide (59). To 54 (61 mg, 0.22 mmol) and l-aminopropanol hydrobromide (50 mg, 0.23 mmol) following general procedure J gave 59 (65 mg, 74%) after flash chromatography (50% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 0.86 (t, J=6.9 Hz, 3H), 1.12-1.15 (m, 1H), 1.23-1.28 (s, 6H), 1.46-1.53 (m, 1H), 1.69 (s, 3H), 1.82-1.88 (m, 2H), 2.14 (quint. J=6 Hz, 2H), 3.42 (m, 2H), 3.54 (q, J=6.3 Hz, 2H), 4.43 (s, 2H), 5.35 (s, 1H) 6.45 (bs, 1H).
[0139] (±) N-allyl-(5-phenyl-5-methyl-2-oxo-thiophen-4-yloxy)-acetamide (60). To 55 (72 mg, 0.26 mmol) and allyl amine (21 μL, 0.28 mmol) following general procedure J gave 60 (39 mg, 47%) after flash chromatography (gradient 10-50% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 1.73 (s, 3H), 3.17 (s, 2H), 3.93 (m, 2H), 4.41 (s, 2 E), 5.22 (m, 2H), 5.24 (s, 1H), 5.80 (m, 1H), 5.83 (s, 1H), 7.24 (m, 5H) 13 C NMR (75 MHz, CDCl 3 ) δ 26.0, 41.6, 45.4, 59.7, 70.3, 103.9, 117.1, 127.5, 128.3, 130.2, 133.3, 135.6, 165.3, 183.4, 192.0.
[0140] General Procedure K. (±)-4-Carbonic acid ethyl ester-5-methyl-5-octyl-5H-thiophen-2-one (61). To a solution of 32 (95 mg, 0.39 mmol) in THF (1.8 mL) cooled to −78° C. was added LiHMDS (0.58 mL, 0.58 mmol, 1 M in THF) and the solution was allowed to stir for 30 minutes at −78° C. Ethyl chloroformate (60 μL, 0.62 mmol) was then added and the mixture was transferred to an ice bath and then allowed to slowly warn to room temperature. After 1 hour at room temperature the mixture was poured into a solution of HCl (1 N)/NH 4 Cl (sat) (10 mL) and extracted with Et 2 O (3×10 mL). The combined organics were dried (MgSO 4 ), filtered, evaporated and chromatographed (20% EtOAc/Hexanes) to give pure 61 (111 mg, 91%). 1 H NMR (300 MHz, CDCl 3 ) δ 0.85 (t, J=6.9 Hz, 3H), 1.12-1.17 (m, 11H), 1.38 (t, J=7 Hz, 3H), 1.42-1.50 (m, 1H), 1.67 (s, 3H), 1.82 (d, J=9 Hz, 1H), 1.85 (d, J=9 Hz, 1H), 4.33 (q, J=7 Hz, 2H), 6.38 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 14.0, 14.0, 22.6, 25.2, 25.8, 29.1, 29.2, 20.4, 31.8, 38.4, 60.1, 66.0, 112.8, 150.2, 175.6, 193.9. IR (NaCl) 2928, 1782, 1690, 1625 cm −1 . Analysis Calculated for C 16 H 26 O 4 S: C, 61.1; H, 8.33; Found: C, 61.5; H, 8.32.
[0141] (±)-4-Carbonic acid methyl ester-5-methyl-5-octyl-5H-thiophen-2-one (62). From 32 (73 mg, 0.30 mmol) and methyl chloroformate (37 μL, 0.48 mmol) following general procedure K was obtained 62 (63 mg, 70%) after flash chromatography (20% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 0.85 (t, J=7 Hz, 3H), 1.15-1.21 (m, 1H), 1.22 (s, 10H), 1.41-1.51 (m, 1H), 1.66 (s, 3H), 1.81 (d, J=9 Hz, 1H), 1.83 (d, J=9 Hz, 1H), 3.92 (s, 3H), 6.39 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 14.1, 22.6, 25.2, 25.9, 29.2, 29.3, 29.4, 31.8, 38.4, 56.2, 60.2, 112.9, 150.9, 175.5, 194.1. IR (NaCl) 3382, 1626, 1560, 1542 cm −1 . Analysis Calculated for C 15 H 24 O 4 S: C, 59.9; H, 8.05; Found: C, 60.3; H, 8.10.
[0142] (±)-4-Carbonic acid allyl ester-5-methyl-5-octyl-5H-thiophen-2-one (63). From 32 (51.5 mg, 0.21 mmol) and allyl chloroformate (33 μL, 0.32 mmol) following general procedure K was obtained 63 (46.3 mg, 67%) after flash chromatography (15% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ 0.85 (t, J=7, 3H), 1.16-1.23 (bs, 10H), 1.41-1.51 (m, 2H), 1.67 (s, 3H), 1.81-1.87 (m, 2H), 4.74 (app dt, J=6, 1.3 Hz, 2H), 5.37 (app dq, J=10.3, 1.02 Hz, 1H), 5.44 (app dq, J=15.9, 1.02 Hz, 1H), 5.90-6.0 (m, 1H), 6.39 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) 14.0, 22.6, 25.2, 25.8, 29.1, 29.2, 29.4, 31.8, 38.4, 60.1, 70.2, 112.9, 120.6, 130.23, 150.0, 175.5, 193.7. IR (NaCl) 2927, 1782, 1691, 1606 cm −1 . Analysis Calculated for C 17 H 26 O 4 S: C, 62.5; H, 8.03; Found: C, 62.6; H, 8.07.
[0143] (±)-4-Propionyl-5-methyl-5-octyl-5H-thiophen-2-one (64). From 32 (40 mg, 0.17 mmol) and propionyl chloride (20 μL, 0.22 mmol) following general procedure K was obtained 64 (23.1 mg, 47%) after flash chromatography (15% EtOAc/Hexanes). 1 H NMR (300 MHz, CDCl 3 ) δ0.85 (t, J=7 Hz, 3H), 1.12-1.25 (m, 13H), 1.42-1.49 (m, 2H), 1.64 (s, 3H), 1.78-1.84 (m, 2H), 2.57 (q, J=7.5 Hz, 2H), 6.39 (s, 1H); 13 C NMR (75 MHz, CDCl 3 ) δ 8.71, 14.0, 22.6, 25.1, 25.9, 27.9, 29.1, 29.3, 29.5, 31.8, 38.6, 60.4, 113.8, 169.1, 177.0, 179.9. IR (NaCl) 2928, 1787, 1688 cm −1 ; Analysis Calculated for C 16 H 26 O 3 S: C, 64.4; H, 8.78; Found: C, 64.3; H, 8.89.
[0144] (4)-4-carbonic acid ethyl-ester-5-phenyl-5-methyl-5H-thiophen-2-one (65). From 22 (50 mg, 0.23 mmol) and ethyl chloroformate (35 μL, 0.36 mmol) following general procedure K was obtained 65 (67 mg, 88%). 1 H NMR (300 MHz, CDCl 3 ) δ 1.31 (t, J=7 Hz, 3H), 1.69 (s, 3H), 3.15 (s, 2H), 4.36 (q, J=7 Hz, 2H), 6.33 (s, 1H), 7.18-7.27 (m, 5H); 13 C NMR (75 MHz, CDCl 3 ) δ 14.1, 25.3, 44.6, 60.6, 66.2, 113.2, 127.4, 128.2, 130.3, 135.4, 150.1, 175.1, 193.3.
[0145] (±)-4-Hydroxy-3-(1-hydroxyethyl)-5-methyl-5-octyl-5H-thiophen-2-one. (66, 67). To 32 (247 mg, 1.02 mmol) dissolved in hexanes was added triethylamine (0.23 mL, 1.68 mmol) and trimethylsilylchloride (0.21 mL, 1.64 mmol) and the solution was allowed to stir at room temperature for 4 h. The mixture was filtered over celite and evaporated to provide 5-methyl-5-octyl-4-trimethylsilanyloxy-5-H-thiopen-2-one. To a solution of TiCl 4 (0.7 mL, 0.7 mmol) in CH 2 Cl 2 (1.95 mL) at −78° C. was added acetaldehyde (54 μL, 0.97 mmol) and this solution was allowed to stir for 5 min at −78° C. Then, 5-methyl-5-octyl-4-trimethylsilanyloxy-5-H-thiopen-2-one dissolved in CH 2 Cl 2 (0.4 mL) was cannulated into TiCl 4 /acetaldehyde solution giving a bright orange color. This mixture was allowed to warm and stir for 20 min at 0° C. The mixture was poured into NH 4 Cl (sat) (15 mL) and extracted with CH 2 Cl 2 (3×15 mL). The organics were combined, dried (MgSO 4 ), filtered and evaporated. Flash chromatography (10% EtOAc/Hexanes) provided pure 66 (34 mg) and 67 (24 mg) (50%). (66) 1 H NMR (300 MHz, CDCl 3 ) δ 0.86 (t, J=6.9 Hz, 3H), 1.05-1.08 (m, 1H), 1.24 (bs, 11H), 1.49 (d, J 6.5 Hz, 3H, rotamer) 1.55 (d, J=5.2 Hz, 3H, rotamer), 1.62 (s, 3H), 1.78-1.82 (m, 2H), 4.68 (q, J=6.5 Hz, 1H, rotamer), 5.04 (q, J=5.2 Hz, 1H, rotamer). HRMS (ES) m/z calculated for C 16 H 28 O 3 SNa + (M+CH 2 +Na + ) 323.1660 obsd. 323.1660.
[0146] (67) 1 H NMR (300 MHz, CDCl 3 ) δ 0.85 (t, J=6.9 Hz, 3H), 1.24 (bs, 12H), 1.47 (d, J=6.6 Hz, 3H, rotamer), 1.54 (d, J=5.4 Hz, 3H, rotamer), 1.59 (s, 3. H), 1.76-1.82 (m, 2H), 4.65 (q, J=6.3 Hz, 1H), 5.06 (q, J=5.4 Hz, 1H). HRMS (ES) m/z calculated for C 16 H 28 O 3 SNa+M+CH 2 +Na + ) 323.1660 obsd. 323.1660.
[0147] General Procedure L. 3-Alkynyl-4-hydroxy-5-methyl-5-octyl-5H-thiophen-2-one. (68). To 32 (94 mg, 0.38 mmol) in CH 2 Cl 2 (1.9 mL) at 0° C. was added NEt 3 (58 μL, 0.42 mmol), dimethylaminopyridine (DMAP) (19 mg, 0.15 mmol) and acetic anhydride (43 μL, 0.47 mmol). The solution stirred at 0° C. for 15 min then was allowed to warm and stir at room temperature for 2-14 h or until TLC indicated completion of the reaction. The mixture was poured into NH 4 Cl(sat)/HCl (1 N) (3:1, 8 mL) and extracted with CH 2 Cl 2 (3×10 mL). The organics were combined, dried (MgSO 4 ), filtered and evaporated to giver crude 68. Flash chromatography 30% EtOAc/2°% AcOH/Hex (rf=0.44) gave pure 68 (83 mg, 78%). 1 H NMR (300 MHz, CDCl 3 ) δ 0.84 (m, 3H), 1.22 (bs, 10H), 1.48 (m, 2H), 1.65 (s, 3H), 1.77-1.92 (m, 2H), 2.55 (s, 3H). 13 C NMR (75 MHz, CDCl 3 ) δ 13.9, 22.6, 23.8, 25.1, 26.3, 29.1, 29.2, 29.5, 31.7, 39.4, 59.7, 109.7, 190.5, 195.5, 204.9. HRMS (EI) m/z calculated for C 15 H 24 O 3 S + (M + ) 284.1441 obsd. 284.1414.
[0148] 4-Hydroxy-5-methyl-5-octyl-3-(2,2,2-trifluoro-alkynyl)-5H-thiophen-2-one. (69). To 32 (90 mg, 0.37 mmol), trifluoroacetic anhydride (114 μL, 0.81 mmol), dimethylaminopyridine (DMAP) (18 mg, 0.15 mmol) and NEt 3 (108 μL, 0.77 mmol) following General Procedure L was obtained 69 (107 mg, 86%) after flash chromatography (40% Hex/10% THF/2% AcOH/EtOAc). 1H NMR (300 MHz, MeOD) d 0.85 (t, J=6.9 Hz, 3H), 1.09 (m, 1H), 1.21 (bs, 1H), 1.38 (s, 3H), 1.51-1.60 (m, 1H), 1.65-1.71 (m, 1H). HRMS (EI) m/z calculated for C 15 H 21 F 3 O 3 S + (M + ) 338.1158 obsd. 338.1171.
[0149] 4-Hydroxy-5-methyl-5-octyl-2-oxo-2,5-dihydro-thiophene-3-carboxylic acid methyl ester (70). To 32 (91 mg, 0.37 mmol), methyl chloroformate (63 μL, 0.81 mmol), dimethylaminopyridine (DMAP) (23 mg, 0.18 mmol) and NEt 3 (108 μL, 0.77 mmol) following General Procedure L was obtained 70 (66 mg, 59%, 79% based on recovered starting material) after flash chromatography (30% EtOAc/2% AcOH/Hexanes-10% THF/2% AcOH/EtOAc). 1 H NMR (300 MHz, MeOD) δ 0.86 (t, J=6.9 Hz, 3H), 1.20 (bs, 12H), 1.35 (s, 3H), 1.55 (m, 1H), 1.71-1.75 (m, 1H), 3.59 (s, 3H); 13 C NMR (75 MHz, MeOD) δ 13.3, 21.8, 24.4, 27.0, 28.5, 28.6, 29.0, 30.2, 31.0, 50.4, 58.3, 124.6, 168.1, 187.7, 196.7. HRMS (EI) m/z calculated for C 15 H 24 O 4 S+) 300.1389 obsd. 300.1375.
[0150] Isopropyl-carbamic acid 2-methyl-2-octyl-5-oxo-2,5-dihydro-thiophen-3-yl ester (71). To 32 (46 mg, 0.19 mmol) dissolved in hexanes was added triethylamine (43 μL, 0.31 mmol) and trimethylsilylchloride (36 μL, 0.29 mmol) and the solution was allowed to stir at room temperature for 4 h. The mixture was filtered over celite and evaporated to provide 5-methyl-5-octyl-4-trimethylsilanyloxy-5-H-thiopen-2-one which was redissolved in CH 2 Cl 2 (0.4 mL). To this mixture was added isopropyl isocyanate (19.2 mL, 0.19 mmol) and the solution was allowed to stir at room temperature for 2 hours. NH4Cl(sat) (5 mL) was added and the mixture was extracted with CH 2 Cl 2 (3×10 mL). The organics were combined, dried (MgSO 4 ), filtered and evaporated to give crude 71. Flash chromatography (20% EtOAc/2% AcOH/Hexanes) gave pure 71 (35 mg, 60%). 1 H NMR (300 MHz, CDCl 3 ) δ 0.85 (t, J=7.0 Hz, 3H), 1.14-1.24 (m, 17H), 1.45 (m, 1H), 1.63 (s, 3H), 1.76-1.79 (m, 2H), 3.81-3.88 (m, 1H), 5.16 (d, J=7 Hz, 1H), 6.33 (s, 1H). 13 C NMR (75 MHz, CDCl 3 ) δ 13.9, 20.4, 22.5, 22.8, 25.1, 25.9, 29.1, 29.3, 29.5, 31.8, 38.7, 44.0, 60.2, 111.6, 149.7, 176.2, 194.5.
[0151] General Procedure M. (±)-(5-Methyl-5-octyl-2-oxo-thiophen-4-yloxy)-acetic-acid-N′-(2-furoic)-hydrazide (72). To a cooled solution (0° C.) of 53 (100 mg, 0.33 mmol) in CH 2 Cl 2 (1.61 mL) was added 1-[3-(dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride EDC) (128 mg, 0.43 mmol), DMAP (6.0 mg, 0.05 mmol), and 2-furoic hydrazide (54 mg, 0.43 mmol). This mixture stirred at 0° C. for 30 minutes, then was allowed to warm to room temperature and stir for 12 h. The solution was poured into NH 4 Cl (10 ml, sat) and extracted with CH 2 Cl 2 (3×10 ml). The combined organics were dried (Na 2 SO 4 ), filtered and evaporated to give crude 72. Flash chromatography (10% EtOAc/Hex) gave pure 72 (91 mg, 68%). 1 H NMR (400 MHz, CDCl 3 ) δ 0.84 (t, J=6.6 Hz, 3H), 1.21 (m, 11H), 1.43-1.47 (m, 1H), 1.66 (s, 3H), 1.81-1.86 (m, 2H), 4.64 (s, 2H), 5.42 (s, 1H), 6.47 (dd, J=1.6, 3.6 Hz, 1H), 7.16 (d, J=4 Hz, 1H), 7.45 (m, 1H), 9.32 (d, J=4 Hz, 1H), 9.44 (d, J=4 Hz, 1H); 13 C NMR (100 MHz, CDCl 3 )δ 14.0, 22.6, 25.3, 26.0, 29.2, 29.3, 29.5, 31.7, 38.8, 59.7, 69.1, 103.0, 112.3, 116.5, 145.1, 145.4, 156.4, 164.2, 184.8, 193.9.
[0152] (±)-(5-Methyl-5-octyl-2 oxo-thiophen-4-yloxy)-acetic-acid-N′-acetylhydrazide (73). To 53 (100 mg, 0.33 mmol) and acetic hydrazide (26.8 mg, 0.36 mmol) following General Procedure M was obtained 73 (70.4 mg, 60%) after flash chromatography (2% AcOH/EtOAc). 1 H NMR (400 MHz, CDCl 3 ) δ 0.85 (t, J=7.2 Hz, 3H), 1.23 (m, 11H), 1.48-1.52 (m, 1H), 1.67 (s, 3H), 1.84-1.86 (m, 2H), 2.07 (s, 3H), 4.64 (s, 2H), 5.42 (s, 1H). 13 C NMR (100 MHz, CDCl 3 ) δ 14.1, 20.6, 22.6, 25.2, 26.0, 29.2, 29.3, 29.5, 31.8, 38.8, 59.8, 68.9, 102.9, 163.1, 168.1, 184.9, 194.2.
[0153] (±)-(5-Methyl-5-octyl-2-oxo-thiophen-4-yloxy)-acetic-acid-N′-(4-chloro-phenyl)-hydrazide (74) To 53 (100 mg, 0.33 mmol) and 4-chlorophenylhydrazine hydrochloride (76.8 mg, 0.43 mmol) following General Procedure M was obtained 74 (74 mg, 53%) after flash chromatography (50% EtOAc/Hex). 1 H NMR (300 MHz, CDCl 3 ) δ 0.86 (t, J=6 Hz, 3H), 1.24 (m, 11H), 1.46-1.54 (m, 1H), 1.71 (s, 3H), 1.82-1.90 (m, 2H), 4.57 (s, 2H), 5.39 (s, 1H), 6.75 (d, J=8.8 Hz, 2H), 7.18 (d, J=8.8 Hz, 2H), 7.38 (s, 1H), 8.09 (s, 1H); 13 C NMR (100 MHz, CDCl 3 ) δ 14.1, 22.6, 25.3, 26.1, 29.2, 29.3, 29.5, 31.8, 38.8, 59.7, 69.7, 103.2, 114.7, 126.4, 145.8, 129.2, 165.9, 184.3, 193.5. IR (NaCl) 2957, 1695, 1658, 1609 cm −1 .
[0154] (±)—N-Allyl-N-methyl-(5-Methyl-5-octyl-2-oxo-thiophen-4-yloxy)-acetamide (75). To 53 (83 mg, 0.28 mmol) and N-methyl,N-allyalmine (29 μL, 0.30 mmol) following General Procedure M was obtained 75 (51 mg, 52%) after flash chromatography (40% EtOAc/Hex). 1 H NMR (300 MHz, CDCl 3 ) δ 0.83 (t, J=6.9 Hz, 3H), 1.22 (m, 11H), 1.43-1.47 (m, 1H), 1.67 (s, 3H), 1.82-1.86 (m, 2H), rotamer 1: 2.91 (s, 3H), rotamer 2: 2.95 (s, 3H), rotamer 1: 3.84 (d, J=4.8 Hz, 2H), rotamer 2: 3.98 (d, J=6 Hz, 2H), rotamer 1: 4.62 (s, 2H), rotamer 2: 4.65 (s, 2H), 5.12-5.28 (m, 2H), rotamer 1: 5.18 (s, 1H), rotamer 2: 5.25 (s, 1H), 5.65-5.81 (m, 1H); 13 C NMR (100 MHz, CDCl 3 ) δ 14.0, 22.5, 25.1, 26.2, 29.1, 29.3, 29.4, 31.7, 33.4 (rotamer 2: 33.9), 38.8, 50.2 (rotamer 2: 51.0), 59.7, 69.0 (rotamer 2: 69.3), 102.3, 117.4 (rotamer 2: 118.2), 131.6 (rotamer 2: 131.8), 164.5 (rotamer 2: 164.9), 185.5 (rotamer 2: 185.6), 193.4.
[0155] (±)-4-Benzyloxy-3,5-dimethyl-5-octyl-5-H-thiophen-2-one (76). To 32 (50 mg, 0.21 mmol) and benzyl bromide (37 mL, 0.31 mmol) following General Procedure H, was obtained 76 (49 mg, 75%) after flash chromatography (15% EtOAc/Hex). 1 H NMR (300 MHz, CDCl 3 ) δ0.86 (t, J=6.9 Hz, 3H), 1.24 (m, 11H), 1.41-1.48 (m, 1H), 1.66 (s, 3H), 1.79-1.86 (m, 2H), 4.98 (s, 2 H), 5.39 (s, 1H), 7.31-7.42 (m, 5H); 13 C NMR (100 MHz, CDCl 3 ) δ 14.1, 22.6, 25.0, 26.4, 29.1, 29.3, 29.4, 31.8, 38.8, 59.7, 74.0, 102.2, 127.6, 128.8, 128.8, 134.3, 185.8, 194.1. IR (NaCl) 2928, 1681, 1610 cm -1 .
REFERENCES
[0000]
1. Strijtveen, B.; Kellogg, R. M. Tetrahedron. 1987, 43, 5039-5054.
2. Sasaki, H.; Oishi, H.; Hayashi, T.; Matsuura, I.; Ando K.; Sawada, M. J. Antibiotics 1982,
3. Kunieda, T.; Nagamatsu, T.; Higuchi, T.; Hirobe, M. Tetrahedron Lett. 1988, 29, 2203-2206.
Biological and Biochemical Methods
Purification of FAS from ZR-75-1 Human Breast Cancer Cells.
[0159] Human FAS was purified from cultured ZR-75-1 human breast cancer cells obtained from the American Type Culture Collection. The procedure, adapted from Linn et al., 1981, and Kuhajda et al., 1994, utilizes hypotonic lysis, successive polyethyleneglycol (PEG) precipitations, and anion exchange chromatography. ZR-75-1 cells are cultured at 37° C. with 5% CO 2 in RPMI culture medium with 10% fetal bovine serum, penicillin and streptomycin.
[0160] Ten T150 flasks of confluent cells are lysed with 1.5 ml lysis buffer (20 mM Tris-HCl, pH 7.5, 1 mM EDTA, 0.1 mM phenylmethanesulfonyl fluoride (PMSF), 0.1% Igepal CA-630) and dounce homogenized on ice for 20 strokes. The lysate is centrifuged in JA-20 rotor (Beckman) at 20,000 rpm for 30 minutes at 4° C. and the supernatant is brought to 42 ml with lysis buffer. A solution of 50% PEG 8000 in lysis buffer is added slowly to the supernatant to a final concentration of 7.5%. After rocking for 60 minutes at 4° C., the solution is centrifiged in JA-20 rotor (Beckman) at 15,000 rpm for 30 minutes at 4° C. Solid PEG 8000 is then added to the supernatant to a final concentration of 15%. After the rocking and centrifugation is repeated as above, the pellet is resuspended overnight at 4° C. in 10 ml of Buffer A (20 mM K 2 HPO 4 , pH 7.4). After 0.45 μM filtration, the protein solution is applied to a Mono Q 5/5 anion exchange column (Pharmacia). The column is washed for 15 minutes with buffer A at 1 ml/minute, and bound material is eluted with a linear 60-ml gradient over 60 minutes to 1 M KCl. FAS (MW˜270 kD) typically elutes at 0.25 M KCl in three 0.5 ml fractions identified using 4-15% SDS-PAGE with Coomassie G250 stain (Bio-Rad). FAS protein concentration is determined using the Coomassie Plus Protein Assay Reagent (Pierce) according to manufacturer's specifications using BSA as a standard. This procedure results in substantially pure preparations of FAS (>95%) as judged by Coomassie-stained gels.
[0000] Measurement of FAS Enzymatic Activity and Determination of the IC 50 of the Compounds
[0161] FAS activity is measured by monitoring the malonyl-CoA dependent oxidation of NADPH spectrophotometrically at OD 340 in 96-well plates (Dils et al and Arslanian et al, 1975). Each well contains 2 μg purified FAS, 100 mM K 2 HPO 4 , pH 6.5, 1 mM dithiothreitol (Sigma), and 187.5 μM β-NADPH (Sigma). Stock solutions of inhibitors are prepared in DMSO at 2, 1, and 0.5 mg/ml resulting in final concentrations of 20, 10, and 5 μg/ml when 1 μl of stock is added per well. For each experiment, cerulenin (Sigma) is run as a positive control along with DMSO controls, inhibitors, and blanks (no FAS enzyme) all in duplicate.
[0162] The assay is performed on a Molecular Devices SpectraMax Plus Spectrophotometer. The plate containing FAS, buffers, inhibitors, and controls are placed in the spectrophotometer heated to 37° C. Using the kinetic protocol, the wells are blanked on duplicate wells containing 100 μl of 100 mM K 2 HPO 4 , pH 6.5 and the plate is read at OD 340 at 10 sec intervals for 5 minutes to measure any malonyl-CoA independent oxidation of NADPH. The plate is removed from the spectrophotometer and malonyl-CoA (67.4 μM, final concentration per well) and alkynyl-CoA (61.8 μM, final concentration per well) are added to each well except to the blanks. The plate is read again as above with the kinetic protocol to measure the malonyl-CoA dependent NADPH oxidation. The difference between the A OD 340 for the malonyl-CoA dependent and non-malonyl-CoA dependent NADPH oxidation is the specific FAS activity. Because of the purity of the FAS preparation, non-malonyl-CoA dependent NADPH oxidation is negligible.
[0163] The IC 50 for the compounds against FAS is determined by plotting the A OD 340 for each inhibitor concentration tested, performing linear regression and computing the best-fit line, r 2 values, and 95% confidence intervals. The concentration of compound yielding 50% inhibition of FAS is the IC 50 . Graphs of A OD 340 versus time are plotted by the SOFTmax PRO software (Molecular Devices) for each compound concentration. Computation of linear regression, best-fit line, r 2 , and 95% confidence intervals are calculated using Prism Version 3.0 (Graph Pad Software).
[0000] Crystal Violet Cell Growth Assay
[0164] The crystal violet assay measure cell growth but not cytotoxicity. This assay employs crystal violet staining of fixed cells in 96-well plates with subsequent solubilization and measurement of OD 490 on a spectrophotometer. The OD 490 corresponds to cell growth per unit time measured. Cells are treated with the compounds of interest or vehicle controls and IC 50 for each compound is computed.
[0165] To measure the cytotoxicity of specific compounds against cancer cells, 5×10 4 MCF-7 human breast cancer cells, obtained from the American Type Culture Collection are plated per well in 24 well plates in DMEM medium with 10% fetal bovine serum, penicillin, and streptomycin. Following overnight culture at 37° C. and 5% CO 2 , the compounds to be tested, dissolved in DMSO, are added to the wells in 1 μl volume at the following concentrations: 50, 40, 30, 20, and 10 μg/ml in triplicate. Additional concentrations are tested if required. 1 μl of DMSO is added to triplicate wells are the vehicle control. C75 is run at 10, and 5 μg/ml in triplicate as positive controls.
[0166] After 72 hours of incubation, cells are stained with 0.5 ml of Crystal Violet stain (0.5% in 25% methanol) in each well. After 10 minutes, wells are rinsed, air dried, and then solubilized with 0.5 ml 10% sodium dodecylsulfate with shaking for 2 hours. Following transfer of 100 μL from each well to a 96-well plate, plates are read at OD 490 on a Molecular Devices SpectraMax Plus Spectrophotometer Average OD 490 values are computed using SOFTmax Pro Software (Molecular Devices) and IC 50 values are determined by linear regression analysis using Prism version 3.02 (Graph Pad Software, San Diego).
[0000] XTT Cytotoxicity Assay
[0167] The XTT assay is a non-radioactive alternative for the [ 51 Cr] release cytotoxicity assay. XTT is a tetrazolium salt that is reduced to a formazan dye only by metabolically active, viable cells. The reduction of XTT is measured spectrophotometrically as OD 490 -OD 650 .
[0168] To measure the cytotoxicity of specific compounds against cancer cells, 9×10 3 MCF-7 human breast cancer cells, obtained from the American Type Culture Collection are plated per well in 96 well plates in DMEM medium with 10% fetal bovine serum, insulin, penicillin, and streptomycin. Following overnight culture at 37° C. and 5% CO 2 , the compounds to be tested, dissolved in DMSO, are added to the wells in 1 μl volume at the following concentrations: 80, 40, 20, 10, 5, 2.5, 1.25, and 0.625 μg/ml in triplicate. Additional concentrations are tested if required. 1 μl of DMSO is added to triplicate wells are the vehicle control. C75 is run at 40, 20, 10, 15, 12.5, 10, and 5 μg/ml in triplicate as positive controls. After 72 hours of incubation, cells are incubated for 4 hours with the XTT reagent as per manufacturer's instructions (Cell Proliferation Kit II (XTT) Roche). Plates are read at OD 490 and OD 650 on a Molecular Devices SpectraMax Plus Spectrophotometer. Three wells containing the XTT reagent without cells serve as the plate blank. XTT data are reported as OD 490 -OD 650 -Averages and standard error of the mean are computed using SOFTmax Pro software (Molecular Dynamics).
[0169] The IC 50 for the compounds is defined as the concentration of drug leading to a 50% reduction in OD 490 -OD 650 compared to controls. The OD 490 -OD 650 are computed by the SOFTmax PRO software (Molecular Devices) for each compound concentration. IC 50 is calculated by linear regression, plotting the FAS activity as percent of control versus drug concentrations. Linear regression, best-fit line, r 2 , and 95% confidence intervals are determined using Prism Version 3.0 (Graph Pad Software).
[0000] Measurement of [ 14 C]Acetate Incorporation into Total
[0000] Lipids and Determination of IC 50 of Compounds
[0170] This assay measures the incorporation of [ 14 C]acetate into total lipids and is a measure of fatty acid synthesis pathway activity in vitro. It is utilized to measure inhibition of fatty acid synthesis in vitro.
[0171] MCF-7 human breast cancer cells cultured as above, are plated at 5×10 4 cells per well in 24-well plates. Following overnight incubation, the compounds to be tested, solubilized in DMSO, are added at 5, 10, and 20 μg/ml in triplicate, with lower concentrations tested if necessary. DMSO is added to triplicate wells for a vehicle control. C75 is run at 5 and 10 μg/ml in triplicate as positive controls. After 4 hours of incubation, 0.25 μCi of [ 14 C]acetate (10 μl volume) is added to each well.
[0172] After 2 hours of additional incubation, medium is aspirated from the wells and 800 μl of chloroform:methanol (2:1) and 700 μl of 4 mM MgCl 2 is added to each well. Contents of each well are transferred to 1.5 Eppendorf tubes, and spun at full-speed for 2 minutes in a high-speed Eppendorf Microcentrifuge 5415D. After removal of the aqueous (upper) layer, an additional 700 μl of chloroform:methanol (2:1) and 500 μl of 4 mM MgCl 2 are added to each tube and then centrifuged for 1 minutes as above. The aqueous layer is removed with a Pasteur pipette and discarded. An additional 400 μl of chloroform:methanol (2:1) and 200 μl of 4 mM MgCl 2 are added to each tube, then centrifiged and aqueous layer is discarded. The lower (organic) phase is transferred into a scintillation vial and dried at 40° C. under N 2 gas. Once dried, 3 ml of scintillant (APB #NBC5104) is added and vials are counted for 14 C. The Beckman Scintillation counter calculates the average cpm values for triplicates.
[0173] The IC 50 for the compounds is defined as the concentration of drug leading to a 50% reduction in [ 14 C]acetate incorporation into lipids compared to controls. This is determined by plotting the average cpm for each inhibitor concentration tested, performing linear regression and computing the best-fit line, r 2 values, and 95% confidence intervals. The average cpm values are computed by the Beckman scintillation counter (Model LS6500) for each compound concentration. Computation of linear regression, best-fit line, r 2 , and 95% confidence intervals are calculated using Prism Version 3.0 (Graph Pad Software).
[0000] Carnitine Palmitoyltransferase-1 (CPT-1) Assay
[0174] CPT-1 catalyzes the ATP dependent transfer of long-chain fatty acids from acyl-CoA to acyl-carnitine that is inhibited by malonyl-CoA. As CPT-1 requires the mitochondrial membrane for activity, enzyme activity is measured in permeabilized cells or mitochondria. This assay uses permeabilized cells to measure the transfer of [methyl- 14 C]L_carnitine to the organically soluble acyl-carnitine deriviative.
[0175] MCF-7 cells are plated in DMEM with 10% fetal bovine serum at 10 6 cells in 24-well plates in triplicate for controls, drugs, and malonyl-CoA. Two hours before commencing the assay, drugs are added at the indicated concentrations made from stock solutions at 10 mg/ml in DMSO, vehicle controls consist of DMSO without drug. Since malonyl-CoA cannot enter intact cells, it is only added in the assay buffer to cells that have not been preincubated with drugs. Following overnight incubation at 370° C., the medium is removed and replaced with 700 μl of assay buffer consisting of: 50 mM imidazole, 70 mM KCl, 80 mM sucrose, 1 mM EGTA, 2 mM MgCl 2 , 1 mM DTT, 1 mM KCN, 1 mM ATP, 0.1% fatty acid free bovine serum albumin, 70 μM palmitoyl-CoA, 0.25 μCi [methyl- 14 C]L-carnitine, 40 μg digitonin with drug, DMSO vehicle control, or 20 μM malonyl-CoA. The concentrations of drugs and DMSO in the assay buffer is the same as used in the 2 hr preincubation. After incubation for 6 minutes at 37° C., the reaction is stopped by the addition of 500 μl of ice-cold 4 M perchloric acid. Cells are then harvested and centrifuged at 13,000×g for 5 minutes. The pellet is washed with 500 μl ice cold 2 mM perchloric acid and centrifuged again. The resulting pellet is resuspended in 800 μl dH 2 ° and extracted with 150 μl of butanol. The butanol phase is counted by liquid scintillation and represents the acylcarnitine derivative.
[0000] Weight Loss Screen for Novel FAS Inhibitors
[0176] Balb/C mice (Jackson Labs) are utilized for the initial weight loss screening. Animals are housed in temperature and 12 hour day/night cycle rooms and fed mouse chow and water ad lib. Three mice are utilized for each compound tested with vehicle controls in triplicate per experiment. For the experiments, mice are housed separately for each compound tested three mice to a cage. Compounds are diluted in DMSO at 10 mg/ml and mice are injected intraperitoneally with 60 mg/kg in approximately 100 μl of DMSO or with vehicle alone. Mice are observed and weighed daily; average weights and standard errors are computed with Excel (Microsoft). The experiment continues until treated animals reach their pretreatment weights.
[0177] Select compounds are tested in animals housed in metabolic cages. Dosing of animals are identical to the screening experiments with three animals to a single metabolic cage. Animal weights, water and food consumption, and urine and feces production are measured daily. The results for the testing of Compounds 21 and 44 are shown in FIG. 10 .
[0000] Antimicrobial Properties
[0178] A broth microdilution assay is used to assess the antimicrobial activity of the compounds. Compounds are tested at twofold serial dilutions, and the concentration that inhibits visible growth (OD 600 at 10% of control) is defined as the MIC. Microorganisms tested include Staphylococcus aureus (ATCC # 29213), Enterococcus faecalis (ATCC # 29212), Pseudomonas aeruginosa (ATCC # 27853), and Escherichia coli (ATCC # 25922). The assay is performed in two growth media, Mueller Hinton Broth and Trypticase Soy Broth.
[0179] A blood (Tsoy/5% sheep blood) agar plate is inoculated from frozen stocks maintained in T soy broth containing 10% glycerol and incubated overnight at 370° C. Colonies are suspended in sterile broth so that the turbidity matches the turbidity of a 0.5 McFarland standard. The inoculum is diluted 1:10 in sterile broth (Mueller Hinton or Trypticase soy) and 195 μl is dispensed per well of a 96-well plate. The compounds to be tested, dissolved in DMSO, are added to the wells in 5 μl volume at the following concentrations: 25, 12.5, 6.25, 3.125, 1.56 and 0.78 μg/ml in duplicate. Additional concentrations are tested if required. 5 ul of DMSO added to duplicate wells are the vehicle control. Serial dilutions of positive control compounds, vancomycin ( E. faecalis and S. aureus ) and tobramycin ( E. coli and P. aeruginosa ), are included in each run.
[0180] After 24 hours of incubation at 37° C., plates are read at OD 600 on a Molecular Devices SpectraMax Plus Spectrophotometer. Average OD 600 values are computed using SOFTmax Pro Software (Molecular Devices) and MIC values are determined by linear regression analysis using Prism version 3.02 (Graph Pad Software, San Diego). The MIC is defined as the concentration of compound required to produce an OD 600 reading equivalent to 10% of the vehicle control reading.
[0000] In Vivo Testing for Anti-Tumor Activity
[0181] The results of this experiment are shown in FIG. 11 . Subcutaneous flank xenografts of the human colon cancer cell line, HCT-116 in nu/nu female mice (Harlan) were used to study the anti-tumor effects of Compound 36 in vivo. All animal experiments complied with institutional animal care guidelines. 10 7 HCT-116 cells (˜0.1 ml packed cells) were xenografted from culture in DMEM supplemented with 10% FBS into 10 athymic mice. Treatment began when measurable tumors developed about 4 days after inoculation. Compound 36 (10 mg/kg) was diluted into 20 μl DMSO and treated intraperitoneally, i.p. Five animals received JMM-II-265 i.p. at days indicated by arrows in FIG. 11 , and 5 received DMSO control. Tumors were measured on days indicated. Error bars represent standard error of the mean.
[0182] Results of the Biological Testing
FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) 71.2 ug/ml 17.3 ug/ml >80 ug/ml >50 ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 4.1%(day1) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 52 ug/ml 87 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) Neg Neg Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) 50.0 ug/ml 16.9 ug/ml >80 ug/ml >50 ug/ml FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) 50.0 ug/ml 16.9 ug/ml >80 ug/ml >50 ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 3.2%(day5) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 202 ug/ml 85 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 186 ug/ml Neg 225 ug/ml Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) 8.8 ± 0.02 ug/ml 40.3 ± 11.5 ug/ml >80 ug/ml >50 ug/ml CPT I Stim Weight Loss 95% of control 60 mg/kg: 7.8%(day3) at 20 ug/ml(MCF7) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 235 ug/ml 102 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 220 ug/ml Neg 290 ug/ml Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) 8.6 ± 1.7 ug/ml 25.7 ug/ml 59.4 ± 6.4 ug/ml 43.9 ± 4.8 ug/ml CPT I Stim Weight Loss 115% of control 60 mg/kg: 11%(day6) at 20 ug/ml(MCF7) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) Neg 55 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 78 ug/ml 42 ug/ml Neg 263 ug/ml FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 16.5 ± 3.8 ug/ml >80 ug/ml >50 ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 3 of 3 dead(day4) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 48 ug/ml 31 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 98 ug/ml 43 ug/ml Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) 4.5 ug/ml 12.6 ± 4.4 ug/ml 17.6 ± 0.1 ug/ml 28.7 ug/ml CPT I Stim Weight Loss 115% of control 60 mg/kg: 2% and 0.3%(day1), 30 mg/kg: 4.8%(day3) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) Neg 47 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 16.9 ug/ml 3.3 ug/ml Neg 278 ug/ml FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) 49.2 ± 1.9 ug/ml 16.5 ± 5.7 ug/ml 48.0 ± 1.4 ug/ml 29.4 ± 4.3ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 0%(day1), 30 mg/kg: +1%(day1) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 45 ± 2 ug/ml 23.5 ± 0.4 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 44 ug/ml 105 ug/ml Neg 290 ug/ml FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 14.0 ± 2.8 ug/ml 9.4 ± 1.5 ug/ml 26.3 ± 4.3ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 3 of 3 dead(day1); 30mg/kg: 8.7%(day1) 10 mg/kg(multiple doses): 1% (day3) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 45 ug/ml 48 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 43 ug/ml 126 ug/ml Neg 264 ug/ml FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 11.0 ug/ml 16.4 ± 2.3 ug/ml 21.4 ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 6.1%(day1), didn'tregain; 30 mg/kg: 0 and 5.7%(day4) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 252 ug/ml 67 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 72 ug/ml Neg Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 63.8 ug/ml 17.3 ± 5.9 ug/ml 15.9 ± 1.9ug/ml CPT I Stim Weight Loss Not Tested Not Tested SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 132 ug/ml 108 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 208 ug/ml 94 ug/ml Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg Neg 9.0 ± 1.1 ug/ml 8.1 ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 2 of 3 dead(day2); 30 mg/kg: 8.8%(day2) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 73 ug/ml 54 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) Neg 158 ug/ml Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg Neg 14.5 ± 1.5 ug/ml 11.0 ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 3 of 3 dead(day3); 30 mg/kg: 4.7% and 3%(day2) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 127 ug/ml 85 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 238 ug/ml 238 ug/ml Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Not Tested Neg Not Tested 15.1 ug/ml CPT I Stim Weight Loss Not Tested Not Tested SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) Not Tested Not Tested Not Tested Not Tested EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) Not Tested Not Tested Not Tested Not Tested FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 23.1 ± 17.4 ug/ml 55.0 ± 2.0 ug/ml 22.3 ug/ml CPT I Stim Weight Loss 125% of control 60 mg/kg: 7.9% and 8.0%(day1) at 20 ug/ml(MCF7) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) Neg 98 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) Neg 169 ug/ml Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 14.9 ug/ml 50.4 ± 4.7 ug/ml >50 ug/ml CPT I Stim Weight Loss Not Tested Not Tested SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) Neg 97 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 133 ug/ml 91 ug/ml Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 21.9 ± 1.5 ug/ml 8.9 ± 2.3 ug/ml 12.1 ± 1.5 ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 3 of 3 dead(day2); 30 mg/kg: 5.9% and 3%(day3) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 53 ug/ml 80 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) Neg 83 ug/ml 203 ug/ml Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 8.6 ug/ml 20.8 ± 0.9 ug/ml 16.3 ug/ml CPT I Stim Weight Loss Not Tested Not Tested SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 164 ug/ml 50 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 117 ug/ml 165 ug/ml Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 6.8 ug/ml 35.3 ± 2.2 ug/ml 10.3 ± 0.3ug/ml CPT I Stim Weight Loss Not Tested Not Tested SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 115 ug/ml 134 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 64 ug/ml Neg Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 14.2 ± 0.2 ug/ml 39.6 ± 2.2 ug/ml 17.0 ug/ml CPT I Stim Weight Loss Not Tested Not Tested SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) Neg 129 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 21.3 ug/ml Neg Neg 281 ug/ml FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 10.8 ± 5.8 ug/ml 35.3 ± 10.4 ug/ml 17.9 ± 5.1 ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 1.8% and 3.6%(day 1); 30 mg/kg: 4.5%(day1) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) Neg 83 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 86 ug/ml Neg Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 13.8 ± 1.1 ug/ml 50.3 ± 2.8 ug/ml 33.7 ug/ml CPT I Stim Weight Loss Not Tested Not Tested SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 98 ug/ml 60 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 77 ug/ml 164 ug/ml Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg Neg 12.1 ± 0.6 ug/ml 10.4 ug/ml CPT I Stim Weight Loss Not Tested 30 mg/kg: 1.8%(day2), 15 mg/kg: 0%(day1) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 28 ug/ml 31 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) Not Tested Not Tested Not Tested Not Tested FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 9.8 ug/ml 40.5 ± 5.1 ug/ml 32.5 ± 11.7 ug/ml CPT I Stim Weight Loss Not Tested Not Tested SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 69 ug/ml 111 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) Neg Neg 156 ug/ml Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 6.6 ug/ml >80 ug/ml >50 ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 3.5%(day2), SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 78 ug/ml 225 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 121 ug/ml 173 ug/ml Neg 235 ug/ml FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 6.7 ug/ml 21.2 ± 1.1 ug/ml 12.6 ± 3.7 ug/ml CPT I Stim Weight Loss Not Tested Not Tested SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 147 ug/ml 237 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 99 ug/ml 121 ug/ml Neg 293 ug/ml FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) 3.0 ± 0.8 14.5 ± 6.9 ug/ml 15.1 ± 2.6 ug/ml 31.4 ± 5.7 ug/ml CPT I Stim Weight Loss 150% of control 60 mg/kg: 6.9% and 5.7%(day 2); 30 mg/kg: 1.3%(day4) at 20 ug/ml(MCF7) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 45 ug/ml 83 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 86 ug/ml 62 ug/ml Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) 1.8 ug/ml 10.7 ug/ml 21.6 ± 0.2 ug/ml 41.4 ± 14.1 ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 7.65%(day 1); SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 64 ug/ml 41 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 73 ug/ml 65 ug/ml 296 ug/ml Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) 5.5 ug/ml 14.2 ug/ml 34.9 ± 10.0 ug/ml 35.8 ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 6.2%(day2); 30 mg/kg: 1%(day2) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 57 ug/ml 28 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 79 ug/ml 75 ug/ml 82 ug/ml 87 ug/ml FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 22.6 ug/ml 26.8 ± 0.6 ug/ml 38.6 ug/ml CPT I Stim Weight Loss Not Tested Not Tested SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 88 ug/ml 62 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 102 ug/ml 147 ug/ml Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg Neg >80 ug/ml >50 ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 1.6%(day2); SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 57 ug/ml 67 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 128 ug/ml Neg Neg 299 ug/ml FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg Not Tested 61.3 ± 3.9 ug/ml 20.9 ug/ml CPT I Stim Weight Loss Not Tested Not Tested SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 83 ug/ml 129 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 170 ug/ml 189 ug/ml Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) 2.8 ug/ml 21.7 ug/ml 21.0 ± 2.9 ug/ml 23.2 ug/ml CPT I Stim Weight Loss Not Tested 30 mg/kg: 0.2%(day2); SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 53.3 ± 2.1 ug/ml 16.2 ± 3.8 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 77 ug/ml 25 ug/ml Neg 249 ug/ml FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) 3.3 ug/ml 17.6 ug/ml 23.9 ± 2.9 ug/ml 19.5 ug/ml CPT I Stim Weight Loss Not Tested Not Tested SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 53.1 ± 0.5 ug/ml 12.0 ± 0.5 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 66 ug/ml 21 ug/ml Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 12.1 ± 0.1 ug/ml 125 ± 0.7 ug/ml 8.4 ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 8.2%(day2); SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 3.4 ug/ml 1.4 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 2.5 ug/ml 2.0 ug/ml Neg 177 ug/ml FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) 41.0 14.7 ug/ml 18.4 ± 2.7 ug/ml 45.3 ug/ml CPT I Stim Weight Loss Not Tested Not Tested SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 54 ug/ml 65 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) Not Tested Not Tested Not Tested Not Tested FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Not Tested Not Tested Not Tested Not Tested CPT I Stim Weight Loss Not Tested Not Tested SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) Not Tested 23 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) Not Tested Not Tested Not Tested Not Tested FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) 80.6 ug/ml 23.1 ± 13.2 ug/ml 45.7 ± 25.9 ug/ml 22.5 ug/ml CPT I Stim Weight Loss Not Tested Not Tested SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) 32 ug/ml 39 ug/ml Neg Neg EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) 60 ug/ml 64 ug/ml Neg Neg FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 16.4 ug/ml 26.4 ±ug/ml(M) 26.3 ug/ml 21.3 ug/ml(OV) CPT I Stim Weight Loss Not Tested 60 mg/kg: 6.3%(day4); SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) Not Tested Not Tested Not Tested Not Tested EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) Not Tested Not Tested Not Tested Not Tested FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 11.5 ug/ml 25.3 ±ug/ml(M) 28.7 ug/ml 16.0 ug/ml(OV) CPT I Stim Weight Loss Not Tested 60 mg/kg: 5.9%(day4) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) Not Tested Not Tested Not Tested Not Tested EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) Not Tested Not Tested Not Tested Not Tested FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 10.5 ± 2.6 ug/ml 6.7 ±ug/ml(M) <5 ug/ml 16.0 ug/ml(OV) CPT I Stim Weight Loss Not Tested 60 mg/kg: 1.4%(day2) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) Not Tested Not Tested Not Tested Not Tested EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) Not Tested Not Tested Not Tested Not Tested FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg 25.7 ug/ml 9.2 ± 2.2 ug/ml(M) 9.0 ug/ml CPT I Stim Weight Loss Not Tested 60 mg/kg: 1.5%(day3) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) Not Tested Not Tested Not Tested Not Tested EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) Not Tested Not Tested Not Tested Not Tested FAS(IC 50 ) 14 C(IC 50 ) XTT(IC 50 ) Cr. Violet(IC 50 ) Neg Neg(stim) 29.2 ±ug/ml(M) 9.5 ug/ml 27.8 ug/ml(OV) CPT I Stim Weight Loss Not Tested 60 mg/kg: 5.2%(day3) SA/MH(MIC) SA/Tsoy(MIC) PSAE/MH(MIC) PSAE/Tsoy(MIC) Not Tested Not Tested Not Tested Not Tested EF/MH(MIC) EF/Tsoy(MIC) Ecoli/MH(MIC) Ecoli/Tsoy(MIC) Not Tested Not Tested Not Tested Not Tested
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A pharmaceutical composition comprising a phamaceurtical diluent and a compound of formula IV wherein R 21 ═H, C 1 -C 20 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl, —CH 2 OR 25 , —C(O)R 25 , —CO(O)R 25 , —C(O)NR 25 R 26 , —CH 2 C(O)R 25 , or —CH 2 C(O)NHR 25 , where R 25 and R 26 are each independently H, C 1 -C 10 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl, optionally containing one or more halogen atoms. R 22 ═—OH, —OR 27 , —OCH 2 C(O)R 27 , —OCH 2 C(O)NHR 27 , —OC(O)R 27 , —OC(O)OR 27 , —OC(O)NHNH—R 5 , or —OC(O)NR 27 R 28 , where R 27 and R 28 are each independently H, C 1 -C 20 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl, and where R 27 and R 28 can each optionally contain halogen atoms; R 23 and R 24 , the same or different from each other, are C 1 -C 20 alkyl, cycloalkyl, alkenyl, aryl, arylalkyl, or alkylaryl. Methods of using such formulations for the treatment of cancer, to effect weight loss, to treat microbially-based infections, to inhibit neuropeptide-Y and/or fatty acid synthase, and to stimulate CPT-1.
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FIELD OF THE INVENTION
[0001] The present invention relates to window blind. More particularly, the present invention relates to a safety device for window blinds which are operated by cords.
BACKGROUND OF THE INVENTION
[0002] Blinds are commonly used in windows and other apertures so that privacy may be maintained and light transfer between the internal and external surroundings can be controlled. The ability to reduce amount of sun light entering a room also helps in reducing heat load. Blinds are also used for separating spaces since they are easily maneuverable and aesthetically appealing. A window blind usually includes a plurality of slats, vanes or fabric pleats hung from a head rail. Blinds can be typically closed and opened by using cords.
[0003] There are different types of conventional window blinds, including the roman blind and the venetian blinds. The roman blind has a curtain cloth mounted to an inner side of a window, and one side of the curtain cloth is provided with some guide rings. Some cords extend through the guide rings, and are then connected to a bottom portion of the curtain cloth. Manipulation of the cords results in folding and unfolding of the curtain cloth.
[0004] Venetian blinds have a headrail, a bottom rail and a set of slats carried on ladders that extend from the headrail to the bottom rail. Lift cords extend from the bottom rail through or adjacent the slats and into the headrail. The lift cords may be wound and unwound on an axle within the headrail, but more commonly pass through a cord lock in the headrail and exit the headrail at one end. Conventional cord locks will restrain the lift cords when the blind is in a fully raised, or partially lowered, position. But, typically those cord locks do not lock the cords in place when the blind is fully lowered. Consequently, anyone can grasp a lift cord of a fully lowered blind and pull the lift cord away from the blind. Children sometimes wrap the hanging cord around themselves while playing which creates a potential threat of strangulation. Indeed, some children have become entangled in a cord loop created in this way and have been strangled. Consequently, the industry has been encouraged to provide safety devices on blinds to prevent cords from being pulled away from the slats.
[0005] There is a need for a mechanism that can be used in blinds that will prevent loose cords from being pulled away from a fully lowered blind. That mechanism should not detract from either the operation or appearance of the blind.
OBJECTS OF THE INVENTION
[0006] An object of the invention is to provide a safety device for a window blind.
[0007] Another object of the invention is to provide a safety device which provides protection to children from getting strangled in a chord of the window blind.
[0008] Yet another object of the invention is to provide a safety device that is easy to use.
BRIEF SUMMARY OF THE INVENTION
[0009] The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed invention. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.
[0010] The present invention is applicable to both window blinds and shades. For convenience, blinds and shades will simply be referred to herein as blinds, it being understood that both blinds and shades are intended unless otherwise stated.
[0011] The present invention cooperates with the existing window blind systems to provide a safe window blind system. Accordingly, a safety device for a window blind system is provided which consists of a telescoping pole which includes a predetermined number of tubular sections of similar lengths and a handle at one extremity. The tubular sections are slidingly engaged with each other which provide a variable length for the telescoping pole. The handle is hollow inside. In an embodiment of the present invention, handle is secured to tubular section by means of press fitting. At one end of the tubular section there provided a hole which facilitates installation of the telescoping pole to a window blind.
[0012] The particular length, size and the total quantity of each tubular section comprising each telescoping pole can vary depending upon the overall requirement for the telescoping pole. Limiters, which are annular rings, are press fitted at the extremities of the tubular sections of the telescoping pole which prevents the tubular sections from totally coming out from engagement with each other.
[0013] In an embodiment of the present invention, the safety device is attached to the head rail by means of a simple clip and wire mechanism which is passed through hole provided at the upper tubular section of the telescoping pole. The cord is passed through the passage provided inside the safety device from upper end of the first tubular section all the way to the handle. The end of the cord, after taking it out from the bottom of the handle, is tied into a knot so that the cord does not go back.
[0014] By pulling down or extending the telescoping pole, the blind can be lifted and, by pushing up or retracting the telescoping pole, the blind can be lowered. The cord remains inside the telescoping pole irrespective of the position of the blind without any loose hanging portion. Thus, the telescoping pole of the present invention, when installed to a conventional blind, does not leave any portion of the blind cord loose and, hence, completely eliminates risk of a child playing with a loose hanging blind cord and getting strangulated.
[0015] To the accomplishment of the foregoing and related ends, certain illustrative aspects of the disclosed invention are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles disclosed herein can be employed and is intended to include all such aspects and their equivalents. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1A is a broken front elevational view of the safety device of the present invention illustrated in the fully extended position;
[0017] FIG. 1B is a broken front elevational sectional view of the safety device of the present invention illustrated in the fully extended position;
[0018] FIG. 2 is a partial perspective sectional view of the ends of adjacent sections of the telescoping pole of the present invention with limiters positioned there between;
[0019] FIG. 3 is a perspective view of the safety device of the present invention illustrated in the fully extended position;
[0020] FIG. 4 shows a conventional horizontal blind in partially lifted condition;
[0021] FIG. 5 is a conventional horizontal blind in partially lifted condition with safety device of the present invention installed;
[0022] FIG. 6 is a conventional horizontal blind in lowered condition with safety device of the present invention installed;
DETAILED DESCRIPTION OF THE INVENTION
[0023] In the following detailed description, a reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that the logical, mechanical and other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense.
[0024] The invention is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known components, systems, materials or methods have not been described in detail in order to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. In the following description, for purpose of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the invention can be practiced without these specific details.
[0025] The safety device of the present invention has a mechanism that can be used in window blinds that will prevent cords from being pulled away from a fully lowered blind. This mechanism does not detract from either the operation or appearance of the blind. The mechanism of the present invention prevents anyone from grasping a cord of a fully lowered blind and from forming of a loop. Thus, children are protected from getting entangled in a cord loop created from a cord and are thus saved from getting strangled.
[0026] FIG. 1A illustrates a safety device 100 of the present invention which comprises a telescoping pole and a handle. The telescoping pole is attached to a handle 140 at one extremity. The telescoping pole includes a predetermined number of tubular sections such as first tubular section 110 , second tubular section 120 and a third tubular section 130 of similar lengths and a handle 140 at one extremity. The tubular sections 110 , 120 and 130 are slidingly engaged with each other which provide a variable length for the telescoping pole. The handle 140 is hollow inside. In an embodiment of the present invention, as can be seen in FIG. 1B , handle 140 is secured to tubular section 130 by means of press fitting. At one end of the first tubular section 110 there provided a hole 150 which facilitates installation of the safety device 100 to a window blind.
[0027] To facilitate telescoping engagement of the sections 110 to 130 , the tubular sections 110 to 130 are provided with progressively decreasing cross-sectional dimensions as illustrated in FIG. 1A and FIG. 1B wherein the first tubular section 110 has the largest cross-sectional dimension and third tubular section 130 has the smallest cross-sectional dimension. The sections 110 to 130 are tubular and have a close-fit slidingly engaged relation one with the other. This close fit engagement ensures that, when extended, the telescoping pole would have little or no transverse movement and would remain co-axial.
[0028] FIG. 1B illustrates a sectional view of the safety device 100 of the present invention which reveals that the tubular sections 110 to 130 along with the hollow handle 140 provides a thorough passage from one extremity to the other in extended condition. This thorough passage would remain same even when the telescoping pole is in retracted condition.
[0029] The particular length, size and the total quantity of each tubular section 110 to 130 comprising the telescoping pole can vary depending upon the overall requirement for the safety device 100 . It would be obvious to any person skilled in the art that any combination of lengths, sizes and quantity of tubular sections may be used to provide the desired length, size and satisfy the intended uses of the safety device 100 .
[0030] FIG. 2 illustrates an exemplary embodiment of the present invention wherein, at one extremity, at the inner periphery of the first tubular section 110 , a limiter 220 is press fitted. Similarly, a limiter 210 is press fitted at the outer periphery of the second tubular section 120 at one end after inserting the second tubular section 120 through the first tubular section 110 . The limiters 210 and 220 ensures that the first tubular section 110 and the second tubular section 120 do not come out of engagement completely while being extended. The limiters 210 and 220 also guide axial movement of the tubular sections 110 and 120 . The same kind of limiter arrangement is also made between tubular sections 120 and 130 .
[0031] The particular length, size, total quantity and means of fitting the limiters can vary depending upon the overall requirement for the safety device 100 . It would be obvious to any person skilled in the art that any combination of lengths, sizes and quantity of limiters may be used to provide the desired length, size and satisfy the intended uses of the safety device 100 .
[0032] FIG. 3 illustrates a perspective view of the safety device 100 in extended condition.
[0033] FIG. 4 illustrates a conventional blind in partially lifted condition which comprises of a head rail 410 , a bottom rail 430 and a plurality of slates 420 horizontally arranged between the head rail 410 and bottom rail 430 . A cord 440 is also shown in FIG. 4 by means of which the blind can be operated. As can be seen in FIG. 4 , when the blind is in lifted condition, be it partially or fully, the cord 440 hangs loosely from head rail 410 . If a child play with this cord and wraps it around him, it may lead to strangulation of the child.
[0034] Referring to FIG. 5 , in an embodiment of the present invention, the same conventional blind of FIG. 4 in partially lifted condition is shown with the safety device 100 extended and attached to the head rail 410 . The safety device 100 is attached to the head rail 410 by means of a simple clip and wire mechanism (not shown in figures) which is passed through hole 150 shown in FIG. 1A , FIG. 1B and in FIG. 3 . The cord 440 is passed through the passage provided inside the safety device 100 from upper end of the first tubular section 110 all the way to the handle 140 . The end of the cord 440 , after taking it out from the bottom of the handle 140 , is tied into a knot so that the cord 440 does not go back.
[0035] FIG. 6 illustrates a conventional blind in fully lowered condition with the safety device 100 of the present invention installed to head rail 410 . As can be seen in FIG. 6 , to lower the blind, a person can push the safety device 100 upward and, as the tubular sections of the telescoping pole retract, the cord 440 goes up and the blind gets lowered.
[0036] Referring to FIG. 4 , FIG. 5 and FIG. 6 together, it can be seen that, by pulling down or extending the telescoping pole of the safety device 100 , the blind can be lifted and, by pushing up or retracting the telescoping pole of the safety device 100 , the blind can be lowered. The cord 440 remains inside the safety device 100 irrespective of the position of the blind without any loose hanging portion. Thus, the safety device 100 of the present invention, when installed to a conventional blind, does not leave any portion of the blind cord loose and, hence, completely eliminates risk of a child playing with a loose hanging blind cord and getting strangulated.
[0037] Telescoping pole of the safety device 100 can be manufactured from any suitable material known in the art such as polyetheretherketone (PEEK) etc. Telescoping pole of the safety device 100 can also be manufactured in a variety of sizes and colors to accommodate user preference.
[0038] Handle 140 can be manufactured from any suitable material known in the art such as PE High Density Film etc. Handle 140 can also be manufactured in a variety of sizes, designs and colors to accommodate user preference.
[0039] Additionally, other variations are within the spirit of the present invention. Thus, while the invention is susceptible to various modifications and alternative constructions, a certain illustrated embodiment thereof is shown in the drawings and has been described above in detail. It should be understood, however, that there is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention, as defined in the appended claims.
[0040] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The term “connected” is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[0041] Preferred embodiments of this invention are described herein. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor expects skilled artisans to employ such variations as appropriate, and the inventor intends for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
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A safety device for a window blind, comprising of: a telescoping pole having plurality of tubular sections and a handle; wherein a first tubular section of the telescoping pole is attached to a window blind and a third tubular section of the telescoping pole is attached to the handle and at least one cord from the window blind is fed through the plurality of tubular sections all the way to said handle wherein the cord is tied into a knot so that the cord doesn't go back through the handle whereby the safety device protects kids from wrapping themselves up in the cord.
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CROSS-REFERENCE TO A RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 08/127,394, filed on Sep. 27, 1993; which is a continuation-in-part of application Ser. No. 08/023,990, filed Feb. 26, 1993, now U.S. Pat. No. 5,248,329; which a continuation-in-part of application Serial No. 07/828,056, filed January 30, 1992, now U.S. Pat. No. 5,221,327; which is a continuation-in-part of application Ser. No. 07/682,491, filed on Apr. 9, 1991, now abandoned, which was a continuation-in-part of application Ser. No. 07/660,312, filed Feb. 22, 1991, now abandoned.
BACKGROUND OF THE INVENTION
The ancient Romans are thought to have been the first to recover metal using a biological process. It is believed that they took advantage of natural sites to recover copper sulfate resulting from the microbial biooxidative acid leaching of sulfide ore. Details of the copper recovery process were not documented until 1670 at Rio Tinto in Spain. The methods documented in 1670 are still used today. One organism instrumental in the modern use of this biological recovery process is Thiobacillus ferrooxidans, which was isolated in 1947 from an abandoned coal mine in West Virginia (Colmer [1947]). This organism's activity is normally limited by the amount of substrate exposed to the atmosphere where the necessary oxygen is present to carry out the oxidation of the metal sulfide.
Although deposits of high grade ore are frequently most efficiently extracted by smelting, it has been found that low grade inherent deposits of sulfide ore can be extracted by heap leaching which utilizes the biooxidation processes (Manchee [1979]). In this process, roughly fist-sized lumps of ore are piled upon a surface that is impervious to liquids. Water is applied to the top of the heap by a sprinkler system to provide moisture for the natural flora and to create a constant flow of fluid throughout the pile. Within the heap, two methods of leaching occur. The first occurs at the surface of the pile where the natural flora, in the presence of oxygen, attack iron pyrites producing ferric sulfate and sulfuric acid. The bacteria likewise act upon other mineral sulfides to dissolve other metallic minerals as well. In the center of the heap, out of the presence of oxygen, a second leaching process occurs. This indirect leaching is a purely chemical process by which the highly oxidizing acidic ferric sulfate produced by the bacterial leaching process at the surface of the pile reacts with mineral sulfides and oxides. Effluent running from the heap containing the products of these two leaching processes can be collected and treated to recover purified metal ore.
Normally the heap need not be inoculated with extraneous bacteria but rather the heap's natural flora is relied upon for the leaching process. Similar biooxidative processes are exploited for in situ leaching situations. Enargrite, Cu 3 (As,Sb)S 4 ; Chalcopyrite, CuFeS 2 ; Bornite, Cu 5 FeS 4 ; Covellite, CuS; Chalcocite, Cu 2 S; Tetrahedrite, Cu 8 Sb 2 S 7 ; and Chalcomenite, CuSeO 3 .2H 2 O are examples of the copper ores which are amenable to this biooxidative process. Other metals that can be recovered by the process of sulfide biooxidation include iron, molybdenum, nickel, lead, arsenic, antimony, tin, uranium, vanadium, gold, and zinc.
In the case of copper recovery, copper sulfide breaks down more slowly than copper oxide because sulfide minerals are composed of reduced sulfur and iron that must be oxidized in order for dissolution to occur. Bacterial oxidation is important to the dissolution of copper sulfide minerals, particularly chalcopyrite, and to a lesser extent, chalcocite.
Several kinds of bacteria have been described that oxidize reduced forms of iron and/or sulfur including Thiobacillus ferrooxidans, T. thiooxidans, Leptospirillum ferrooxidans, Sulfolobus, Acidianus, Sulfobacillus, Strain ALV, Strain LM2, and others. New strains of mineral-oxidizing bacteria have more recently been described by Huber and Stetter (1989, 1990) called T. cuprinus and T. prosperus.
While T. ferrooxidans has received the most attention, as mentioned above, many other microbes are present in heaps and dumps that can contribute to the extraction of copper. Most of these sulfide/iron-oxidizing bacteria are capable of using carbon dioxide to satisfy their carbon needs. Many organic compounds inhibit T. ferrooxidans (Torma et al. [1976]; Tuttle and Dugan [1976]; and Puhakka and Tuovinan [1987]). T. cuprinus, however can use certain forms of organic carbon. The limiting nutrients for most bacteria found in the ore containing environment are nitrogen and phosphorus. The most preferred form of nitrogen for these organisms is ammonium; phosphate serves as a source of phosphorus. These nutrients must be solubilized before the bacteria can use them. Phosphate requirements may also be satisfied if minerals such as apatite are present and solubilized. Some strains of T. ferrooxidans are able to use atmospheric nitrogen if ammonium nitrogen is not available (Stevens et al. [1986]).
BRIEF SUMMARY OF THE INVENTION
The subject invention relates generally to a microbial bioremediation method for recovering heavy metals from ore. In a preferred embodiment, the subject invention relates to an improved method for the microbial biooxidative acid leaching of heavy metals from sulfide ore. The method comprises contacting said ore with novel nutrient supplements. The supplements enhance the growth of the natural flora on the ore. The bacteria of the natural flora solubilize the ore into a form that is more amenable to refinement.
In a specific embodiment exemplified herein, a nutrient medium is sprayed onto a mineral ore leach pile to recover copper from the ore. In preferred embodiments the nutrient medium can comprise extracts prepared from corn or potatoes as described herein.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1. Rates of copper extraction from sulfide ore using unmodified On solution and On solution supplemented with nutrients designated TFN and TCN, respectively.
FIG. 2. Rates of copper extraction from sulfide ore by unmodified On solution and On solution amended with PEGM.
FIG. 3. Rates of copper extraction and eh values from duplicate shake flask tests using low grade sulfide ore and On solution plus PEGM.
FIG. 4. Population densities of T. ferrooxidans (T. ferro.) and T. cuprinus in leach solutions from duplicate shake flask tests using a low grade copper sulfide ore and On solution plus PEGM.
FIG. 5. Rates of copper extraction from sulfide ore using pure bacterial cultures in growth media. T.c.=T. cuprinus, T.f.=T. ferrooxidans.
DETAILED DESCRIPTION OF THE INVENTION
The subject invention concerns new materials and methods for the efficient extraction of useful metals for ores, including low grade ores. Because the process of the subject invention reduces or eliminates the use of hazardous chemicals, it is advantageous from an environmental standpoint. The process of the subject invention utilizes bioremediation properties of microbes to liberate desired metals from ores. In a preferred embodiment the process of the subject invention utilizes microbes which exist naturally in the ore which is to be processed. The biooxidative properties of these indigenous microbes is activated, enhanced, or augmented by the administration of aqueous nutrient solutions. Specifically exemplified herein are nutrient solutions which are derived from potato and corn sources. These nutrient solutions are referred to herein as Potato Extract Growth Medium (PEGM) and Corn Extract Growth Medium (CGM).
As described herein, the nutrient mediums of the subject invention are administered directly to ores, such as in leach heaps, and advantageously and surprisingly, these nutrient sources are able to markedly increase the extraction of useful metals from even low grade ores. This enhanced extraction efficiency is observed even without seeding the ore with desired microbes and without adding agents which help to select for specific microbes.
The subject invention is specifically exemplified herein with reference to the extraction of copper from sulfides in ore. In a preferred embodiment PEGM or CGM is added to copper sulfite ore pries using sprinklers, hoses, or the like. The rate of delivery will depend on the particular setting but can be in the range of about 100 to about 500 gal/day and, preferably, about 250 gal/day. The concentration of the nutrient solution can be about 5 to about 25% in water and is preferably about 10%. The addition of PEGM or CGM was discovered to result in the recovery of useful quantities of copper from the ore. In further embodiments of the invention, the natural flora can be manipulated by either adding additional microbes or by adding agents which will preferentially select for certain desired microbes.
Although seeding of heap pries with microbes is not necessary when using the procedure of the subject invention, if addition of microbes is desired then a variety of microbes can be used which are known and available to those skilled in the art. In addition to the various microbes described herein, additional microbes are described in, for example, U.S. Pat. No. 5,055,130 (Bacillus polymyxa) and U.S. Pat. No. 5,221,327 (Bacillus MBX 69 and mutants thereof). These patents are incorporated herein by reference.
In conventional copper mining operations, ore is first treated with an "On" solution. This solution extracts copper sulfite from the sulfides in ore. The resulting copper sulfate is sent to a solvent extraction plant where purified copper is stripped from the solution.
Materials and Methods
Variables were evaluated in the composition of the solutions for effects on copper solubilization of copper sulfide ore. Variables evaluated included: The addition of nutrient supplements to the solution, seeding the solution with the microbes T. ferrooxidans or T. cuprinus, and comparisons of growth media. Unmodified On solutions were used as a baseline control. Nutrient supplements evaluated included supplements favoring the growth of either T. ferrooxidans (designated TFN), or supplements favoring the growth of T. cuprinus (designated TCN). TFN and TCN, or variations thereof, are known and available to the public from, for example, ATCC. A nutrient supplement designated as PEGM (U.S. Pat. No. 5,248,329) was also tested at a final concentration of 10%. Additives to the On solution that match concentrations found in growth Medium 64, described by ATCC (1989), or growth Medium 30 were evaluated.
As used herein, PEGM refers to the composition which is obtained when raw potatoes are cut up and heated in the presence of water. Typically, the potatoes will be boiled in water for about 15 to about 60 minutes, preferably about 30 minutes. The amount of water used can vary and the medium obtained can be diluted. The relative percentages of non-water constituents, however, will remain approximately the same. The composition of a PEGM is provided in Table 1.
TABLE 1______________________________________Composition of a PEGM Fresh.sup.1 Range.sup.1______________________________________Water 77 69-85Ash 1 0.08-1.2Protein 2.5 2.0-3.0Fat 0.1 0.08-0.13Fiber 0.4 0.2-0.6Carbohydrate 20.3 18-22Vitamin A trace traceAscorbic Acid 200 mg/kg (0.02%) 0.01-0.03Niacin 15 mg/kg (0.0015%) 0.0012-0.0010Thiamine 1.0 mg/kg (0.0001%) 0.00005-0.0003Riboflavin 0.4 mg/kg (0.00004%) 0.00002-0.00006Iron 0.001 0.01-0.0005Phosphorus 0.05 0.02-0.08Potassium 0.41 0.2-0.6Sodium 0.02 0.01-0.03Chloride 0.07 0.05-0.1Copper 4.1 mg/kg (0.00041%) 0.0002-0.0006Magnesium 0.03 0.02-0.04Manganese 9.6 mg/kg (0.00096%) 0.0007-0.002Calcium 0.01 0.05-0.02Sulfur 0.02 0.01-0.03______________________________________ .sup.1 Concentrations are in percent unless otherwise noted.
Corn Extract Growth Medium, or CGM, may also be used according to the subject invention. As used herein CGM refers to the extract obtained when corn cobs are chopped and boiled in water. Typically, the corn cobs are chopped into pieces of a couple to several inches, and boiled in water for about 15 to about 60 minutes, preferably about 30 minutes. The amount of water used can be varied and the medium obtained can be diluted. The relative percentages of non-water constituents, however, will remain approximately the same. The composition of a CGM is provided in Table 2.
TABLE 2______________________________________Composition of a CGM Composition (%) Range (%)______________________________________Ash 1.6 1.46-1.74Fiber 2.7 2.4-3.0Protein 12.1 10.9-13.3Fat 5.4 4.9-5.9Carbohydrate 84.4 76.0-92.8Vitamin A 310.0 IU 282-338Ascorbic acid 0.02 0.01-0.03Niacin 0.03 0.01-0.05Thiamine 0.0003 0.00027-0.00033Riboflavin 0.0013 0.0012-0.0014Iron 0.001 0.0009-0.0013Magnesium 0.13 0.116-0.144Phosphorous 0.34 0.2-0.4Sulfur 0.1 0.08-0.13Potassium 0.4 0.2-0.6Calcium 0.02 0.01-0.03Choline 0.6 0.5-0.7Pantothenic acid 0.007 0.0062-0.0078Pyridoxine 0.009 0.0079-0.01Arginine 0.6 0.5-0.7Cystine 0.1 0.07-0.2Glycine 0.5 0.4-0.6Histidine 0.2 0.1-0.3Isoleucine 0.5 0.45-0.55Leucine 1.3 1.17-1.43Lysine 0.2 0.15-0.25Methionine 0.2 0.1-0.3Phenylalanine 0.6 0.5-0.7Threonine 0.5 0.4-0.6Tryptophan 0.1 0.06-0.22Valine 0.5 0.46-0.56______________________________________
The following constituents of the PEGM and the CGM are the most critical for support of bacterial growth and to aid in the claimed processes: protein, carbohydrates, sulfur, niacin, thiamine, riboflavin, phosphorus, potassium and magnesium.
Thus, the PEGM used according to the subject invention can comprise the following ingredients:
TABLE 3______________________________________Ingredient Concentration Range (%)______________________________________Protein 2.0-3.0Carbohydrate 18-22Niacin 0.0012-0.0010Thiamine 0.00005-0.00003Riboflavin 0.00002-0.00006Phosphorous 0.02-0.08Potassium 0.2-0.6Magnesium 0.02-0.04Sulfur 0.01-0.03______________________________________
In a preferred embodiment the approximate concentrations of ingredients in the PEGM can be:
TABLE 4______________________________________Ingredient Approximate Concentration (%)______________________________________Protein 2.5Carbohydrate 20.3Niacin 0.0015Thiamine 0.0001Riboflavin 0.00004Phosphorous 0.05Potassium 0.41Magnesium 0.03Sulfur 0.2______________________________________
Similarly, the CGM of the subject invention can comprise the following ingredients:
TABLE 5______________________________________Ingredient Range of Concentration (%)______________________________________Protein 10.9-13.3Carbohydrate 76.0-92.8Niacin 0.01-0.05Thiamine 0.00027-0.00033Riboflavin 0.0012-0.0014Phosphorous 0.2-0.4Sulfur 0.08-0.13Potassium 0.2-0.6Magnesium 0.116-0.144______________________________________
In a preferred embodiment the approximate concentrations of the ingredients in the CGM can be:
TABLE 6______________________________________Ingredient Approximate Concentration (%)______________________________________Protein 12.1Carbohydrate 84.4Niacin 0.03Thiamine 0.0003Riboflavin 0.0013Phosphorous 0.34Sulfur 0.1Potassium 0.4Magnesium 0.13______________________________________
Medium 30 of the subject invention, contains the following per liter of distilled water:
TABLE 7______________________________________Ingredient Amount______________________________________NH.sub.4 Cl 1.25 gKCl 0.33 gK.sub.2 HPO.sub.4 0.14 gMgSO.sub.4.7H.sub.2 O 3.45 gMgCl.sub.2.6H.sub.2 O 2.75 gCaCl.sub.2.2H.sub.2 O 0.14 gKH.sub.2 PO.sub.4 0.14 gNaCl 0.50 gNiCl.sub.2.6H.sub.2 O 0.002 gyeast extract 0.50 gtrace element solution* 10 ml______________________________________ *Balch et al. (1979)
A 0.1% sodium solution was added to some control shake flasks to sterilize the On solution and ore. These sterile flasks were included to determine whether bacterial activity was actually contributing to the copper extraction from sulfide ore. In some cases, ore was sterilized by autoclaving (121° C., 15 min, 15 psi).
A 10% pulp density and minus200 mesh ore were used in all cases. Shake flasks were rotated at ≈130 rpm. Solution pH, Eh, solubilized copper, ferrous iron, and total iron were determined weekly. Soluble copper and iron were determined by atomic absorption (AA). Ferrous iron was determined by the Ferrozine method as described by Gibbs (1976). Midway in the test period, leach solutions were revitalized by replacing half the volume with fresh solution. Most Probable Number (MPN) enumeration of Thiobacillus sp. was determined at intervals using standard methods (APHA, 1989). Solution pH was adjusted with H 2 SO 4 or NaOH at each sampling period. For T. cuprinus, the target pH range was 2.5 to 4.0. For T. ferrooxidans, the target range was pH 1.6 to 2.4.
At the end of each test period, residual solids (tails) were washed three times with distilled water, dried, and weighed. Shake flask tails and heads were digested for AA analyses using aqua regia and perchloric acid. A metallurgical balance was calculated in each case.
All treatments were tested in duplicate. Statistical analyses were performed using one-way analysis of variance.
Following are examples which illustrate procedures, including the best mode, for practicing the invention. These examples should not be constructed as limiting. All percentages are by weight and all solvent mixture proportions are by volume unless otherwise noted.
EXAMPLE 1
Effects of Variations in the Leach Solutions on the Copper Extraction of Sample Ore A
Copper sulfide ore sample A had a head assay of 0.22% copper of which 22.7% was acid soluble. According to a mineralogical analysis, most of the copper was in the form of chalcopyrite having a minor quantity of digenite. The ore also contained 2.65% iron and 1.6% sulfur of which 97% was in the sulfide form.
Table 8 shows the effect that variations in the leach solutions have on copper extraction. As shown in Table 8, sterilization of the On solution and ore by the addition of 0.10% sodium benzoate to kill all native flora resulted in a significant decrease in copper extraction (p=0.011). The results of these studies attest to the importance of microorganisms for the leaching of such refractory sulfide compounds.
TABLE 8______________________________________Metallurgical balances for Ore Sample A.sup.1 Amount of Copper in MilligramsLeach Cu in Leached Calc. % CuSolution Solution Tails Head Extr.______________________________________Sterile On 6.05 15.8 21.8 27.6Soln. + OreOn Soln. 6.9 13.9 20.8 33.0On soln. + TFN 6.3 12.1 18.5 34.3On soln. + TCN 7.9 12.8 20.7 38.1On soln. + TCN + 7.8 12.5 20.3 38.5T. cuprinusOn soln. + PEGM 10.0 11.7 21.7 46.2Medium 64 7.7 11.0 18.7 41.1Medium 64- 8.3 12.2 20.6 40.5Medium 30 7.6 12.2 19.7 38.3Medium 64- + 8.4 11.7 20.1 41.7T. ferrooxidansMedium 30 + 7.2 14.0 21.2 33.9T. cuprinus.sup.2______________________________________ .sup.1 Head assay in all cases = 22.0 mg. .sup.2 Ore was sterilized by autoclave.
FIG. 1 shows rates of copper extraction achieved using unmodified On solution, On solution amended with 1.9% TFN nutrients, and On solution amended with 0.16% TCN nutrients. No significant increase in copper extraction resulted when TFN, known to enrich for T. ferrooxidans, was added to the On solution. However, the addition of TCN, known to enrich for T. cuprinus, resulted in a significant increase in copper extraction (p=0.011) as shown in Table 8.
Microbial seeding of On solution amended with TCN with T. cuprinus did not result in substantially more copper extraction than the addition of TCN alone as shown in Table 8. These results suggest that managing dump leach solutions in such a manner as to enhance the activity of the native microorganisms will result in increased copper extraction and that seeding of On solution is not necessary.
This conclusion was further supported by the results obtained when PEGM was added to the On solution. As shown in Table 8, the addition of PEGM resulted in a very significant increase in copper extraction compared to using the unmodified On solution (p=0.002). The effect of PEGM was most noticeable late in the study (see FIG. 2). Copper extraction results were equivalent through Day 21 and both curves appeared to have had "flattened out." However, by Day 28, the beneficial effect of PEGM began to make itself evident. By Day 70, when the study was terminated, the enhancement of copper extraction by the addition of PEGM was marked.
The effects of PEGM additions were very reproducible. The rates of copper extraction and Eh values in the duplicate shake flask tests are shown in FIG. 3. Except for an early temporary decrease, the Eh values remained high throughout the test. The ability of PEGM-amended On solutions to support populations of T. ferrooxidans and T. cuprinus was also very reproducible as shown in FIG. 4. Although these bacterial populations were initially low, they both exhibited a 4 log increase in numbers during the shake flask study. The numbers of native T. ferrooxidans were consistently 1 log lower in unmodified On solution than in On solution amended with PEGM. Although the PEGM nutrient contains an organic fraction, it surprisingly and advantageously enhanced the growth of T. ferrooxidans in the On solution.
In testing the effects of additives to the On Solution in concentrations equivalent to those of growth media, slightly more copper was extracted in the presence of Medium 64, however, the differences in extraction using Medium 64, Medium 64 without ferrous sulfate, (Medium 64-), or Medium 30 were not significant. Medium 64 enriches for iron-oxidizing bacteria such as T. ferroxidans and L. ferrooxidans while Medium 30 enriches for T. cuprinus and similar bacteria. Unlike T. ferrooxidans, T. cuprinus is able to use many forms of organic carbon including yeast extract as described by Huber and Stetter (1986, 1990). Thiobacillus cuprinus prefers a higher pH range (2.5-7.2) than T. ferrooxidans (1.3-4.5). Thiobacillus cuprinus is also dissimilar to T. ferrooxidans in that it is able to oxidize sulfides but not ferrous iron. In spite of this, the solution Eh results using Medium 64 and Medium 30 were similar with average values of 559 and 570 respectively.
In order to directly compare copper extraction by T. ferrooxidans and T. cuprinus, the ore was sterilized by autoclave prior to seeding Medium 64- and Medium 30 with pure log phase culture of T. ferrooxidans and T. cuprinus respectively.
Significantly more copper was extracted using Medium 64- seeded with T. ferrooxidans than by using Medium 30 seeded with T. cuprinus (Table 8). In this case, where the ore microcosm was eliminated, Eh values and rates of copper extraction were not equivalent in the two systems as shown in FIG. 5. These results indicated that T. ferrooxidans extracted copper more rapidly from sulfide ore A than T. cuprinus when competition and cooperation from native ore flora had been eliminated.
EXAMPLE 2
Effect of PEGM Enhancement on the Extraction of Copper from Sample Ore B
Similar enhancement of copper extraction by the addition of PEGM to On solution has also been demonstrated using another sulfide dump ore (Ore Sample B). The primary copper mineral in this ore was chalcopyrite. Metallurgical balances are shown in Table 9. The increased copper extraction achieved by the addition of PEGM was significant (p=0.043).
TABLE 9______________________________________Metallurgical Balances for Ore Sample B.sup.1Leach Cu in Cu in Calc. % CuSolution Solution Leached Tails Head Extr.______________________________________On Soln. 5.3 13.3 18.6 28.5On Soln. + PEGM 9.1 9.8 18.8 48.1______________________________________
We also found that the addition of TCN to the On solution and seeding with T. cuprinus enhanced copper extraction much more than the addition of TFN and seeding with T. ferrooxidans during shake flask tests utilizing Ore Sample B. Indeed, 64% of the copper was extracted using nutrient-amended On solution seeded with T. cuprinus. Equivalent concentrations of copper (42%) were extracted from the sulfide ore sample using T. ferrooxidans and T. cuprinus in appropriate laboratory growth media. These results have been described in detail by Rusin et al. (1993).
The addition of TCN and seeding with T. cuprinus can be beneficial for the extraction of copper from sulfide dump ores. However, the bacterial seeding may be unnecessary and the yeast extract present in TCN would not be commercially affordable. The addition of PEGM to On solution showed very reproducible results, growth enhancement of T. ferrooxidans, and significant increases in extraction of copper from two different sulfide dump ores.
It should be understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and the scope of the appended claims.
REFERENCES
APHA, AWWA, WPCF (1989) "Estimation of Bacterial Density," Standard Methods for the Examination of Water and Wastewater, eds. L. S. Cleseri, A. E. Greenberg, and R. R. Trussell, 17ed., pp. 9.77-9.79.
ATCC Catalogue of Bacteria & Bacteriophages (1989) 17th ed., P. 293.
Balch, W. E., G. E. Fox, L. J. Magrum C. R. Woese, and R. S. Wolfe (1979) "Methanogens: Reevaluation of a Unique Biological Group," Microbiological Reviews 43:260-296.
Colmer, A. R., and M. E. Hinkle (1947) Science 106:253-256.
Gibbs, C. R. (1976) "Characterization and Application of FerroZine Iron Reagent as a Ferrous Indicator, Analytical Chemistry 48:1197-1201.
Huber, G., H. Huber, and K. O. Stetter (1986) "Isolation and Characterization of New Metal-Mobilizing Bacteria," Biotechnology and Bioengineering 16:239-251.
Huber, H., and K. O. Stetter (1989) "Thiobacillus prosperus sp. nov., Represents a new Group of Halotolerant Metal-Mobilizing Bacteria Isolated from a Marine Geothermal Field,"0 Archives of Microbiology 151:479-485.
Huber, G., and K. O. Stetter (1990) "Thiobacillus cuprinus sp.; a Novel Facultatively Organotrophic Metal-Mobilizing Bacterium," Applied and Environmental Microbiology 56:315-322.
Manchee, R. (1979) "Microbial mining," TIBS April: 77-80.
Puhakka, J. P., and O. H. Tuovinen (1987) "Effect of Organic Compounds on the Microbiological Leaching of a Complex Sulphide Ore Material" MIRCEN Journal of Applied Microbiology and Biotechnology 3:436-442.
Rusin, P. A., L. Quintana, and J. Cassells (1993) "Enhancement of Copper and Molybdenum Bioextraction from Sulfide Ore through Nutrient Balance and the Addition of Thiobacillus cuprinus" Minerals Engineering 6:977-989.
Stevens, C. J., P. R. Dugan, and O. H. Tuovinen (1986) "Acetylene Reduction (Nitrogen Fixation) by Thiobacillus ferrooxidans" Biotechnology and Applied Biochemistry 8:351-359.
Torma, A. E., G. G. Gabra, R. Guay, and M. Silver (1976) "Effects of Surface Active Agents on the Oxidation of Chalcopyrite by Thiobacillus ferrooxidans," Hydrometallurgy 1:301-309.
Tuovinen, O. H., F. A. Panda, and H. M. Tsuchiya (1979) "Nitrogen Requirement of Iron-Oxidizing Thiobacilli for Acidic Ferric Sulfate Regeneration," Applied and Environmental Microbiology 37:954-958.
Tuttle, J. H., and P. R. Dugan (1976) "Inhibition of Growth, Iron, and Sulfur Oxidation in Thiobacillus ferroxidans by Simple Organic Compounds," Canadian Journal of Microbiology 22:719-730.
Rusin, Patricia A. and James E. Sharp (1993) U.S. Pat. No. 5,248,329.
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Materials and methods for the enhancement of the biooxidative acid leaching of heavy metals from sulfide ore are disclosed and claimed. The enhancement of bioleach solutions with a nutrient supplement selective for a particular sulfide oxidizing strain of bacteria significantly increases copper solubilization of chalcopyrite ore. Likewise, copper solubilization is enhanced by enriching bioleach solutions with a non-selective growth mediums.
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This application claims priority from U.S. Provisional Application No. 60/298,745 filed Jun. 16, 2001 incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
The present invention relates to treatment of nonwoven fabrics to impart desired properties. In particular, the invention provides relatively lightweight nonwoven fabrics with unique properties on opposing surfaces obtained by separate steps in a highly efficient and effective process. The invention also relates to resulting nonwovens having, for example, one surface that is alcohol repellent and the other that has antistatic properties suitable for use in the manufacture of infection control medical products including surgical gowns and sterilization wrap. Such nonwoven fabrics may also have excellent barrier properties as measured by hydrostatic head.
The manufacture of nonwoven fabrics for diverse applications has become a highly developed technology. Well known methods include spunbonding, meltblowing, carding, airlaying, and others. It is not always possible, however, to produce by these methods a nonwoven fabric having all desired attributes for a given application. As a result, it is often necessary to treat nonwoven fabrics by various means to impart such properties. For example, for medical applications such as surgeon's gowns, barrier to alcohol and blood penetration and bacteria is essential, and antistatic properties are very important. Unfortunately, treatments for barrier properties using fluorocarbons, for example, and treatments for antistatic properties using salts are detrimental to each other which makes it necessary to apply excessive amounts of one or both of the treatments. U.S. Pat. No. 5,178,931 addresses this concern by providing separately treated layers in a multi-ply construction. For lightweight fabrics or single component fabrics this is not always a satisfactory solution to efficiently and effectively providing a two sided nonwoven. European patent 0 546 580 B1 describes a printing process for treating one side only of a hydrophobic nonwoven with a wetting agent resulting in a two sided fabric with hydrophilic and hydrophobic properties. There remains a need, however, particularly for lightweight nonwovens, for improved means and methods for imparting two-sided properties of alcohol repellency and/or antistatic characteristics while maintaining hydrostatic head, all with reduced treatment chemical requirements.
SUMMARY OF THE INVENTION
The present invention addresses the difficulties and problems discussed above by providing a two-step treatment process for treating lightweight nonwovens and preserving desired properties of alcohol repellency on one side and/or antistatic characteristics on the other side. The resulting treated nonwoven also has good hydrohead properties. In one embodiment the process involves a saturation treatment for alcohol repellency using a minimum treatment amount followed by a single side spraying of a light amount of antistatic treatment composition. In a second embodiment each side is treated separately with printing forming light spray applications using a minimum of treatment composition resulting in imparting alcohol repellency and/or antistatic characteristics primarily to the respective treated sides only. Other application means are also contemplated. In these preferred embodiments the nonwoven has a basis weight in the range of from about 17 gsm to about 135 gsm and ideally for many applications, in the range of from about 34 to about 88 gsm. The alcohol repellency treatment will generally add only about 0.05 gsm to about 0.41 gsm to the fabric weight and ideally for many applications, within the range of from about 0.10 gsm to about 0.26 gsm. Similarly, the antistatic treatment composition will add only about 0.017 gsm to about 1.08 gsm to the fabric weight and ideally for many applications, within the range of from about 0.068 gsm to about 0.44 gsm. Despite these low add-on amounts, the treated nonwoven will have antistatic properties of less than about 0.50 sec by static decay test (described below) and ideally for many applications less than about 0.05 sec and will also have alcohol repellency of at least 3 to about 70% isopropyl alcohol and ideally for many applications, at least about 3 at 80% isopropyl alcohol. The treated nonwoven will also have a hydrohead of at least about 50 mB and ideally for many applications, at least about 70 mB. The resulting nonwoven is suited for use particularly as infection control products like a medical fabric especially when starting with a spunbond, meltblown or spunbond/meltblown laminate of polymers selected from thermoplastic polymers including polyolefins such as polypropylene, polyethylene as well as copolymers including propylene or ethylene monomer units.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of one treatment process embodiment of the present invention using a saturation treatment step followed by a spray treatment step.
FIG. 2 is a schematic of a second treatment process embodiment of the present invention using a foam applicator instead of a spray treatment step.
FIG. 3 is a schematic of the second step of the process of the invention using ink jet treating.
FIG. 4 is a schematic of a third treatment embodiment of the present invention applying antistat and repellent treatments to opposite sides.
DETAILED DESCRIPTION OF THE INVENTION
Test Procedures
Hydrohead: A measure of the liquid barrier properties of a fabric is the hydrohead test. The hydrohead test determines the height of water (in centimeters) which the fabric will support before a predetermined amount of liquid passes through. A fabric with a higher hydrohead reading indicates it has a greater barrier to liquid penetration than a fabric with a lower hydrohead. The hydrohead test is performed according to Federal Test Standard 191A, Method 5514.
Alcohol: Alcohol repellency was tested according to the test procedure described as follows. In this test, a fabric's resistance to penetration by low surface energy fluids is determined by placing 0.1 ml of a specified percentage of isopropyl alcohol (IPA) solution on the surface of the fabric and leaving the specimen undisturbed for 5 minutes. The grading scale ranges from 0 to 5, with 0 indicating the IPA solution wets the fabric and 5 indicating maximum repellency. This procedure is a modification of INDA Standard Test No. IST 80.9-74 (R-82).
Resistance to Blood Penetration (RBP): The blood strikethrough or resistance to blood penetration of a fabric is a measure of the amount of blood which penetrates the fabric at a particular pressure. The blood strikethrough is performed by weighing a blotter placed next to the fabric before and after the test which consists of applying 1 pound per square inch gauge (psig) pressure to the side of the fabric away from the blotter, which side has blood thereon.
The pressure is ramped up over approximately 10 seconds and removed when it reaches 1 psig. The difference in the weight of the blotter before and after the test in grams represents the amount of blood which has penetrated the fabric.
Grab Tensile test: The grab tensile test is a measure of breaking strength and elongation or strain of a fabric when subjected to unidirectional stress. This test is known in the art and conforms to the specifications of Method 5100 of the Federal Test Methods Standard 191A. The results are expressed in pounds or grams to break and percent stretch before breakage. Higher numbers indicate a stronger, more stretchable fabric. The term “load” means the maximum load or force, expressed in units of weight, required to break or rupture the specimen in a tensile test. The term “total energy” means the total energy under a load versus elongation curve as expressed in weight-length units. The term “elongation” means the increase in length of a specimen during a tensile test. The grab tensile test uses two clamps, each having two jaws with each jaw having a facing in contact with the sample. The clamps hold the material in the same plane, usually vertically, separated by 3 inches (76 mm) and move apart at a specified rate of extension. Values for grab tensile strength and grab elongation are obtained using a sample size of 4 inches (102 mm) by 6 inches (152 mm), with a jaw facing size of 1 inch (25 mm) by 1 inch, and a constant rate of extension of 300 mm/min. The sample is wider than the clamp jaws to give results representative of effective strength of fibers in the clamped width combined with additional strength contributed by adjacent fibers in the fabric. The specimen is clamped in, for example, a Sintech 2 tester, available from the Sintech Corporation, 1001 Sheldon Dr., Cary, N.C. 27513, an Instron Model TM, available from the Instron Corporation, 2500 Washington St., Canton, Mass. 02021, or a Thwing-Albert Model INTELLECT II available from the Thwing-Albert Instrument Co., 10960 Dutton Rd., Phila., Pa. 19154. This closely simulates fabric stress conditions in actual use. Results are reported as an average of three specimens and may be performed with the specimen in the cross direction (CD) or the machine direction (MD).
Antistatic properties were measured according to INDA Standard Test 40.2-92.
Porosity results were obtained by Frazier Porosity tests, ASTM Standard D737 “Air Permeability of Textile Fabrics,” also Method 5450 Federal Test Methods Standard No. 191A, except that the specimen size is 8 inches by 8 inches.
Definitions
As used herein and in the claims, the term “comprising” is inclusive or open-ended and does not exclude additional unrecited elements, compositional components, or method steps.
As used herein the term “nonwoven fabric or web” means a web having a structure of individual fibers or threads which are interlaid, but not in an identifiable manner as in a knitted fabric. Nonwoven fabrics or webs have been formed from many processes such as for example, meltblowing processes, spunbonding processes, and bonded carded web processes. The basis weight of nonwoven fabrics is usually expressed in ounces of material per square yard (osy) or grams per square meter (gsm) and the fiber diameters useful are usually expressed in microns or an equivalent but more recognized term, micrometers. (Note that to convert from osy to gsm, multiply osy by 33.91). As used herein the term “spunbonded fibers” refers to small diameter fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine, usually circular capillaries of a spinneret with the diameter of the extruded filaments then being rapidly reduced as by, for example, in U.S. Pat. No. 4,340,563 to Appel et al., U.S. Pat. No. 3,692,618 to Dorschner et al., U.S. Pat. No. 3,802,817 to Matsuki et al., U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartman, and U.S. Pat. No. 3,542,615 to Dobo et al. Spunbond fibers are generally not tacky when they are deposited onto a collecting surface. Spunbond fibers are generally continuous and have average diameters (from a sample of at least 10) larger than 7 microns, more particularly, between about 10 and 20 microns. The fibers may also have shapes such as those described in U.S. Pat. No. 5,277,976 to Hogle et al., U.S. Pat. No. 5,466,410 to Hills and U.S. Pat Nos. 5,069,970 and 5,057,368 to Largman et al., which describe fibers with unconventional shapes.
As used herein the term “meltblown fibers” means fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity, usually hot, gas (e.g. air) streams which attenuate the filaments of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 to Butin et al. Meltblown fibers are microfibers which may be continuous or discontinuous, are generally smaller than 10 microns in average diameter, and are generally tacky when deposited onto a collecting surface.
As used herein “multilayer laminate” means a laminate wherein some of the layers are spunbond and some meltblown such as a spunbond/meltblown/spunbond (SMS) laminate and others as disclosed in U.S. Pat. No. 4,041,203 to Brock et al., U.S. Pat. No. 5,169,706 to Collier, et al, U.S. Pat. No. 5,145,727 to Potts et al., U.S. Pat. No. 5,178,931 to Perkins et al. and U.S. Pat. No. 5,188,885 to Timmons et al. Such a laminate may be made by sequentially depositing onto a moving forming belt first a spunbond fabric layer, then a meltblown fabric layer and last another spunbond layer and then bonding the laminate in a manner described below. Alternatively, the fabric layers may be made individually, collected in rolls, and combined in a separate bonding step. Such fabrics usually have a basis weight of from about 0.1 to 12 osy (3 to 400 gsm), or more particularly from about 0.75 to about 3 osy. Multilayer laminates may also have various numbers of meltblown layers or multiple spunbond layers in many different configurations and may include other materials like films (F) or coform materials, e.g. SMMS, SM, SFS, etc.
As used herein the term “polymer” generally includes but is not limited to, homopolymers, copolymers, such as for example, block, graft, random and alternating copolymers, terpolymers, etc. and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term “polymer” shall include all possible geometrical configurations of the molecule. These configurations include, but are not limited to isotactic, syndiotactic and random symmetries.
As used herein the term “conjugate fibers” refers to fibers which have been formed from at least two polymers extruded from separate extruders but spun together to form one fiber. Conjugate fibers are also sometimes referred to as multicomponent or bicomponent fibers. The polymers are usually different from each other though conjugate fibers may be monocomponent fibers. The polymers are arranged in substantially constantly positioned distinct zones across the cross-section of the conjugate fibers and extend continuously along the length of the conjugate fibers. The configuration of such a conjugate fiber may be, for example, a sheath/core arrangement wherein one polymer is surrounded by another or may be a side by side arrangement, a pie arrangement or an “islands-in-the-sea” arrangement. Conjugate fibers are taught in U.S. Pat. No. 5,108,820 to Kaneko et al., U.S. Pat. No. 4,795,668 to Krueger et al., U.S. Pat. No. 5,540,992 to Marcher et al. and U.S. Pat. No. 5,336,552 to Strack et al. Conjugate fibers are also taught in U.S. Pat. No. 5,382,400 to Pike et al. and may be used to produce crimp in the fibers by using the differential rates of expansion and contraction of the two (or more) polymers. Crimped fibers may also be produced by mechanical means and by the process of German Patent DT 25 13 251 A1. For two component fibers, the polymers may be present in ratios of 75/25, 50/50, 25/75 or any other desired ratios. The fibers may also have shapes such as those described in U.S. Pat. No. 5,277,976 to Hogle et al., U.S. Pat. No. 5,466,410 to Hills and U.S. Pat. Nos. 5,069,970 and 5,057,368 to Largman et al., which describe fibers with unconventional shapes.
As used herein “thermal point bonding” involves passing a fabric or web of fibers to be bonded between a heated calender roll and an anvil roll. The calender roll is usually, though not always, patterned in some way so that the entire fabric is not bonded across its entire surface, and the anvil roll is usually flat. As a result, various patterns for calender rolls have been developed for functional as well as aesthetic reasons. One example of a pattern has points and is the Hansen Pennings or “H&P” pattern with about a 30% bond area with about 200 bonds/square inch as taught in U.S. Pat. No. 3,855,046 to Hansen and Pennings. The H&P pattern has square point or pin bonding areas wherein each pin has a side dimension of 0.038 inches (0.965 mm), a spacing of 0.070 inches (1.778 mm) between pins, and a depth of bonding of 0.023 inches (0.584 mm). The resulting pattern has a bonded area of about 29.5%. Another typical point bonding pattern is the expanded Hansen Pennings or “EHP” bond pattern which produces a 15% bond area with a square pin having a side dimension of 0.037 inches (0.94 mm), a pin spacing of 0.097 inches (2.464 mm) and a depth of 0.039 inches (0.991 mm). Another typical point bonding pattern designated “714” has square pin bonding areas wherein each pin has a side dimension of 0.023 inches, a spacing of 0.062 inches (1.575 mm) between pins, and a depth of bonding of 0.033 inches (0.838 mm). The resulting pattern has a bonded area of about 15%. Yet another common pattern is the C-Star pattern which has a bond area of about 16.9%. The C-Star pattern has a cross-directional bar or “corduroy” design interrupted by shooting stars. Other common patterns include a diamond pattern with repeating and slightly offset diamonds with about a 16% bond area and a wire weave pattern looking as the name suggests, e.g. like a window screen, with about a 19% bond area. Typically, the percent bonding area varies from around 10% to around 30% of the area of the fabric laminate web. As in well known in the art, the spot bonding holds the laminate layers together as well as imparts integrity to each individual layer by bonding filaments and/or fibers within each layer.
As used herein, the term “infection control product” means medically oriented items such as surgical gowns and drapes, face masks, head coverings like bouffant caps, surgical caps and hoods, footwear like shoe coverings, boot covers and slippers, wound dressings, bandages, sterilization wraps, wipers, garments like lab coats, coveralls, aprons and jackets, patient bedding, stretcher and bassinet sheets, and the like.
Composition percent amounts herein are expressed by weight unless otherwise indicated.
Turning to the drawings, FIG. 1 shows web 10 traveling from right to left. At saturation spray device 12 a fluorocarbon spray is applied to both sides. Squeeze nip rolls 14 remove excess fluorocarbon and vacuum extractor 16 removes additional treatment composition as web 10 travels over guide rolls 18 . At treatment station 20 antistat is applied to one side only of web 10 by spray device 22 and at a point preferably prior to full curing of the fluorocarbon. Web 10 is then dried by contact with steam cans 24 .
FIG. 2 shows a process using a foam applicator to apply the fluorochemical instead of an antistatic spray device 22 as in FIG. 1 . For FIG. 2, the system may be the same as FIG. 1 prior to the antistat spray 20 (FIG. 1) and is not shown. In FIG. 2, foam applicator 32 applies fluorocarbon composition as a foam. Excess is removed in the nip 34 between squeeze rolls 36 , and web 10 is directed over steam cans 24 for drying as in FIG. 1 .
FIG. 3 shows schematically the second inline treatment step applied to web 40 having been previously treated as, for example, using the saturation spray device 12 of FIG. 1 . In this embodiment web 40 is unwound from roll 42 and directed around guide roll 44 through printing station 46 including ink jet printhead 48 and web support platen/exhaust hood 50 . The web has applied to the surface facing the printhead a light application of the antistat. The web may then be directed by one or more drive rolls 52 and rewound into treated roll 54 or, optionally, otherwise processed.
FIG. 4 shows a third embodiment where the foam applicator 32 is used to apply fluorocarbon to one side of web 10 and spray 22 to apply antistat to the opposite side at steam can 24 . Otherwise the process is like that of FIG. 2 .
EXAMPLES
The present invention is further described by the examples which follow. Such examples, however, are not to be construed as limiting in any way either the spirit or the scope of the present invention.
For those examples using SMS fabric, the general process for forming the fabric and treating it was as follows:
A SMS (spunbond/meltblown/spunbond) laminate was formed all inline as described in U.S. Pat. No. 4,041,203 to Brock et al. After forming, the SMS laminate was thermally bonded with a bonding roll resulting in about 15% bond area in a wire weave pattern. The fabric produced had a basis weight of about 1.5 oz/yd2 (51 gsm) and was produced at about 760 ft/min. After bonding, the laminate was passed through a saturator where a partially fluorinated acrylic copolymer emulsion from DuPont (identified as Repellent 7700), and Zelec KC, an organic phosphate ester from Stepan Chemical, and a short chain alcohol (octanol) from Aldridge Chemical were applied as a mixture of about 2.85% in a ratio 2.5:0.1:0.25, respectively. The purpose of the fluorine containing compound is to give isopropanol repellency of 70% IPA or better to the finished, dried laminate. The amount in the bath was about 2.15% of the “as delivered” material. The purpose of the organic phosphate ester in this bath is to control the rate at which the fluorine containing material adheres to the fabric. The amount in the bath was about 0.05% of the “as delivered” material. The purpose of the alcohol is to aid in wetting out the laminate completely. As the water is dried off the laminate in a later step, the alcohol is volatilized also. The amount of octanol used was 0.25% of the chemical. After saturation, which results in about 300% wet pickup based on fabric weight, the fabric was run through a squeeze nip, resulting in a reduction in the wet pickup to about 100% and over a dewatering vacuum, apparatus, further reducing the wet pickup to about 40%. Next, additional organic phosphate ester was applied to one surface only of the fabric via an atomized spray apparatus resulting in an addition of about 0.05%, making the applied side of the fabric rich in phosphate ester antistatic agent on that surface, while the other surface had minimal phosphate ester. After drying using steam cans, the treated fabric was wound on cardboard cores.
Example 1
Attribute
Average
Range
Minimum
Maximum
St Dev.
Bloods (RPB) %
1.3
1.76
0.7
2.46
0.585
Tensile (lbs.)
15.49
5.7
11.9
17.6
1.568
Hydrohead (mbar)
71.09
30
57
87
7.711
Porosity (cfm)
37.1
6.5
34.2
40.7
2
Samples were tested for static decay and all had results of 0.01 sec. or less.
Control - Single Bath
Attribute
Average
Range
Minimum
Maximum
St Dev.
Bloods (RPB) %
1.25
2.54
0.49
3.03
0.647
Tensile (lbs.)
15.31
7.31
11.49
18.8
1.672
Hydrohead (mbar)
64.7
31.5
51.5
83
7.296
Porosity (cfm)
38.9
9.5
35.8
45.3
3.28
As shown, compared to the single bath control, hydrohead values are much improved in accordance with the invention.
Example 2
Sided Fluorochemical Atomized Spray Treatment
Formulation:
De-ionized Water
474.15
g
Repellant 9356H
24.6
g
1-octanol
1.25
g
Procedure:
De-ionized water was used. Repellent 9356H is a fluorinated acrylic copolymer dispersion from DuPont. Its purpose is to give alcohol repellency to the dried fabric. 1-octanol (99%) was used as received from Aldrich Chemical Company, Inc. The purpose of the octanol is to aid in wetting of the fabric. This will volatilize with the water during the drying procedure. Materials were added in the order shown under vigorous agitation with Ross high shear mixer and allowed to mix for at least 15 minutes to fully solubilize octanol.
The nonwoven fabric to be treated was a three-layer laminate having a basis weight of 51 gsm, comprised of spunbond/meltblown/spunbond (SMS) polypropylene at 35%/30%/35% respectively. The spunbond layers were composed of 35 melt flow polypropylene while the meltblown was 800 melt flow polypropylene. The laminate was pattern bonded by the application of heat and pressure in a wireweave pattern as described above.
The dispersion was applied to one side of the SMS at 100% wet pick-up (% WPU) via a handheld spray gun, model DH7500 from Campbell Hausfeld. % WPU was determined by weighing the sample before and after drying. % WPU=100*(Weight Wet-Weight Dry)/Weight Dry. 100% WPU correlates to approximately 1.0% dry fluorochemical add-on. After spraying, the fabric was run through a squeeze nip at a pressure of ˜25 PSI to ensure penetration into the first spunbond layer and dried in a laboratory oven for approximately 3 minutes at 95° C. to cure the fluoropolymer and remove moisture.
IPA Repellency Results:
Treated Side:
5 @ 80% IPA, 3 @ 90% IPA
Untreated Side:
5 @ 20% IPA, 0 @ 30% IPA
The results indicate that the treated side of the fabric displayed significantly higher alcohol repellency. In accordance with the invention the treated side was repellent at IPA of a percentage difference of 60% higher than the untreated side.
Example 3
Formulation:
De-ionized Water
14280
g
Unidyne S-1042
1680
g
1-octanol
40
g
Procedure:
De-ionized water was used Unidyne S-1042 is an experimental, proprietary fluoroalkyl acrylate copolymer emulsion from Daikin America, Inc. Its purpose is to give alcohol repellency to the dried fabric. 1-octanol (99%) was used as received from Aldrich Chemical Company, Inc. The purpose of the octanol is to aid in wetting of the fabric. This will volatilize with the water during the drying procedure. Materials were added in the order shown under vigorous agitation with Ross high shear mixer and allowed to mix for at least 15 minutes to fully solubilize octanol.
The nonwoven fabric to be treated was a three-layer laminate as in Example 1 comprised of spunbond/meltblown/spunbond (SMS) polypropylene at 35%/30%/35% respectively. The spunbond layers were composed of 35 melt flow polypropylene while the meltblown was 800 melt flow polypropylene. The laminate was pattern bonded by the application of heat and pressure in a wireweave pattern as described above.
The dispersion was foamed onto one side of the SMS via a Gaston CFS-6 Latex Foam Generator equipped with a parabolic applicator at a wet pick-up level of approximately 45% WPU was determined by weighing the sample before and after drying. % WPU=100*(Weight Wet-Weight Dry)/Weight Dry. 100% WPU correlates to approximately 1.8% dry fluorochemical add-on The fabric was then run through a squeeze nip as in Example 1 to ensure penetration into the first spunbond layer and dried in excess across steam cans to cure the fluoropolymer and remove moisture.
Alcohol repellency was then tested according to test procedure described above. The results indicate that the treated side of the fabric displayed significantly higher alcohol repellency.
IPA Repellency Results:
Treated Side:
5 @ 60% IPA, 3 @ 70% IPA
Untreated Side:
3 @ 30% IPA, 0 @ 40% IPA
In accordance with the invention the treated side was repellent at a percentage of IPA at least 30% higher than the untreated side.
Example 4
Sided Fluorochemical Foam Treatment
Formulation:
De-ionized Water
14993.6
g
Unidyne TG-573
966.4
g
1-octanol
40.0
g
Procedure:
De-ionized water was used. Unidyne TG-573 is a fluoroalkyl acrylate copolymer emulsion from Daikin America, Inc. Its purpose is to give alcohol repellency to the dried fabric. 1-octanol (99%) was used as received from Aldrich Chemical Company, Inc. The purpose of the octanol is to aid in wetting of the fabric. This will volatilize with the water during the drying procedure. Materials were added in the order shown under vigorous agitation with Ross high shear mixer and allowed to mix for at least 15 minutes to fully solubilize octanol.
The nonwoven fabric to be treated was a three-layer laminate as in the previous example comprised of spunbond/meltblown/spunbond (SMS) polypropylene at 35%/30%/35% respectively. The spunbond layers were composed of 35 melt flow polypropylene while the meltblown was 800 melt flow polypropylene. The laminate was pattern bonded by the application of heat and pressure.
The dispersion was foamed onto one side of the SMS via a Gaston CFS-6 Latex Foam Generator equipped with a parabolic applicator at a wet pick-up level of approximately 35%. % WPU was determined by weighing the sample before and after drying. % WPU=100*(Weight Wet-Weight Dry)/Weight Dry. 35% WPU correlates to approximately 0.7% dry fluorochemical add-on. The fabric was then run through a squeeze nip to ensure penetration into the first spunbond layer and dried in excess across steam cans to cure the fluoropolymer and remove moisture.
Alcohol repellency was then tested. The results indicate that the treated side of the fabric displayed significantly higher alcohol repellency.
IPA Repellency Results:
Treated Side:
5 @ 50% IPA
Untreated Side:
3 @ 30% IPA, 0 @ 40% IPA
Example 5
Formulation:
De-ionized Water
150
mL
Unidyne S-1042
5
mL
1-octanol
3
mL
Procedure:
De-ionized water was used as obtained from on-site system. Unidyne S-1042 is an experimental, proprietary fluoroalkyl acrylate copolymer emulsion from Daikin America, Inc. Its purpose is to give alcohol repellency to the dried fabric. 1-octanol (99%) was used as received from Aldrich Chemical Company, Inc. The purpose of the octanol is to aid in wetting of the fabric. This will volatilize with the water during the drying procedure. Materials were added in the order shown under vigorous agitation with Ross high shear mixer and allowed to mix for at least 15 minutes to fully solubilize octanol.
The nonwoven fabric to be treated was a three-layer laminate comprised of spunbond/meltblown/spunbond (SMS) polypropylene at 35%/30%/35% respectively. The spunbond layers were composed of 35 melt flow polypropylene while the meltblown was 800 melt flow polypropylene. The laminate was pattern bonded by the application of heat and pressure using the wireweave pattern described above.
The dispersion was ink-jetted onto one side of the SMS via an 8″ wide MARSH LCP/ML8 a inkjet system at approximately 50% wet pick-up (WPU). %WPU was determined by weighing the sample before and after drying. %WPU =100*(Weight Wet-Weight Dry)Weight. The swatches of fabric were dried on a flat screen dryer (Model F10, Noble & Wood Lab Mach. Co.).
Alcohol repellency was then tested. In this test, a fabric's resistance to penetration by low surface energy fluids is determined by placing 0.1 ml of a specified percentage of isopropyl alcohol (IPA) solution on the surface of the fabric and leaving the specimen undisturbed for 5 minutes. The grading scale ranges from 0 to 5, with 0 indicating the IPA solution wets the fabric and 5 indicating maximum repellency. For purposes of the present invention, a rating of at least 3 is needed to be considered repellent. This procedure is a modification of INDA Standard Test No. IST 80.9-74 (R-82). The results indicate that the treated side of the fabric displayed significantly higher alcohol repellency.
IPA Repellency Results:
Treated Side:
5 @ 60% IPA, 5 @ 70% IPA
Untreated Side:
3 @ 30% IPA, 0 @ 40% IPA
In accordance with the invention the treated side was repellent to an IPA percentage at least 30% higher than the untreated side.
While the invention has been described in detail with respect to specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily conceive of alterations to, variations of, and equivalents to these embodiments. Accordingly, the scope of the present invention should be assessed as that of the appended claims and any equivalents thereto.
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Described is an improved two-step process for treating lightweight nonwovens to impart single-sided anti-static and alcohol repellency properties while maintaining good barrier characteristics as measured by hydrostatic head values. The resulting nonwovens find particular uses as infection control product medical fabrics for sterilization wrap and surgical gowns, for example.
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[0001] This application is a continuation of International application No. PCT/EP2005/004060 filed on Apr. 16, 2005.
[0002] The present disclosure relates to the subject matter disclosed in International application No. PCT/EP2005/004060 of Apr. 16, 2005, which is incorporated herein by reference in its entirety and for all purposes.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to an implant for alleviating pressure on intervertebral disks, for restoring the height of and alleviating pressure on an intervertebral space of a human or animal spinal column, comprising at least two bearing elements for a spinous process each for abutting or securing the implant on one or two spinous processes of adjacent vertebra of the spinal column.
[0004] Furthermore, the present invention relates to a method for restoring the height of and alleviating pressure on an intervertebral space of a human or animal spinal column, using an implant for alleviating pressure on intervertebral disks comprising at least two bearing elements for a spinous process each for abutting and/or securing the implant on one or two spinous processes of adjacent vertebra of the spinal column.
[0005] During a prolapse of an intervertebral disk arranged between two vertebral bodies of the spinal column, nucleus material normally exits through the annulus of the intervertebral disk. One consequence of this is loss of the original height of the intervertebral disk, with the result that the bone structures of the foramen move closer and press on roots of nerve structures exiting from the spinal column. A patient often suffers from very considerable pain on account of this mechanical pressure.
[0006] If the sheath of the annulus, the so-called containment, is destroyed only in a locally limited manner, it is possible to restore the height of the nucleus and, therefore, of the entire intervertebral space again by injecting nucleus or cartilage cells into the nucleus. However, it is to be noted in this respect that the desired height is restored immediately as a result of the injection of a large cell volume but very great pressure also results in the interior of the intervertebral disk which can lead or even leads almost always to the cells dying off. This problem may be circumvented in that only a small cell volume is injected into the nucleus so that no increased pressure results. The volume within the intervertebral disk is not then increased until the extracellular matrix is formed by way of the injected cells. The disadvantage of this is that a patient can become free of pain only in the medium term or long term and several operations are very often required.
[0007] Therefore, it would be desirable to provide an implant for alleviating pressure on intervertebral disks and a method so that as far as possible only one single operation is required to restore the height of and alleviate pressure on the intervertebral space.
SUMMARY OF THE INVENTION
[0008] In accordance with the invention, it is suggested in an implant for alleviating pressure on intervertebral disks of the type described at the outset, that the implant is produced from a biocompatible, resorbable material.
[0009] Such an implant enables the required number of cells to be injected into the nucleus in order to restore the intervertebral space to the original height with a single operation. Any pressure within the intervertebral disk will be clearly reduced by the implant for alleviating pressure on intervertebral disks and so the injected cells do not die off. Since the implant is, in addition, produced from a biocompatible, resorbable material, the pressure on the restored intervertebral disk is increased only during the course of time. Sufficient time therefore remains for an adequate stabilization of the intervertebral disk with the injected cells. As a result of a corresponding selection of the material as well as shape of the implant, it is possible for an alleviation of pressure on the intervertebral space to be reduced successively over the course of several weeks, for example, during a period of time of two weeks to 18 months. The alleviation of pressure on the intervertebral space is reduced little by little as a result of the resorbability of the implant, in contrast to which it is eliminated completely in one step in the case of a non-resorbable implant as a result of the implant being removed. Furthermore, it is of advantage when the implant is resorbable at least partially, normally completely so that no additional operation is necessary to remove the implant for alleviating pressure on intervertebral disks again. The removal of an internal fixation device for alleviating pressure on the intervertebral space can, in particular, lead to undesired trauma. In addition, the implant can also be inserted into the body by way of a minimally invasive approach when it is shaped accordingly, whereby any operation trauma is minimized and, therefore, any postoperative affect on the patient is reduced.
[0010] It is favorable when at least one of the at least two bearing elements is designed in the form of a receptacle with an insertion opening for the insertion of a spinous process in a direction parallel or transverse to a preferred direction defined by the spinous process. As a result, the introduction of the implant into the body and the abutment on the spinous process or processes is simplified, on the one hand. On the other hand, additional fixing elements for securing the implant can, in certain circumstances, be dispensed with which reduces operating time, on the one hand, and, on the other hand, does not make any additional trauma to a spinous process necessary. In addition, movement of a spinous process can be limited by way of a stop, such as that defined, for example, by a fork-like receptacle, in a desired manner.
[0011] The construction of the implant becomes particularly simple when two receptacles are provided, the insertion openings of which point away from one another. For example, the implant could be designed in the form of a double T support which defines two fork-like receptacles for the insertion of two spinous processes. In addition, the implant can be designed in a particularly slim and elongated manner as a result of such a configuration which simplifies the insertion of the implant into the body through a minimally invasive approach. Moreover, a minimal distance between the two adjacent spinous processes is predetermined by the configuration of the implant.
[0012] The receptacle is preferably of a groove-like design. Such an implant can be moved towards the spinous processes parallel to the groove-like receptacle. In addition, it is, however, also possible to insert the spinous processes into the receptacle transversely to the groove direction.
[0013] The implant will be particularly light and is, in addition, very easy to produce when it is produced entirely or partially from a plastic material. An additional advantage of producing the implant from a plastic material is that the implant can be adapted in an optimum manner to an anatomical geometry, particularly when the plastic material has rubber elastic properties and traumata can be avoided in this way.
[0014] In order to be able to predetermine a resorbability of the implant within a desired period of time, it is advantageous when the plastic material is a polymer or contains a polymer. As a consequence of the resorption, polymer chains can be successively degraded, whereby the stability of the implant as a whole is reduced in a desired manner during the course of time.
[0015] The implant is particularly biocompatible when the polymer is polylactide or contains polylactide.
[0016] Furthermore, a resorbability, in particular, of the implant may be adjusted particularly well when the plastic material is a gelatin cross-linked three dimensionally or contains a gelatin cross-linked three dimensionally.
[0017] In order to prevent the implant from becoming detached from a spinous process out of a predetermined position relative thereto, it is favorable when the implant comprises at least one securing element for securing a spinous process to a bearing element. For example, the securing element may be a fixing element, with which the bearing element can be secured to a spinous process. It would, however, also be conceivable to provide a securing element which restricts the freedom of movement of the implant relative to a spinous process only conditionally, for example, by reducing the number of degrees of freedom of movement of the implant relative to a spinous process from two to one.
[0018] So that a spinous process cannot exit again from the receptacle through the insertion opening, it is advantageous when the insertion opening can be closed or locked.
[0019] A closure element is favorably provided for closing the insertion opening. The closure element can be an individual component or, however, also be designed in one piece with the rest of the implant.
[0020] So that the insertion opening can be closed in a simple manner, it is advantageous when the closure element is mounted on the receptacle so as to be movable. For example, it can be mounted, for example, via a film hinge such that it cannot become detached from the implant unintentionally.
[0021] The insertion opening may be closed in a particularly simple manner when the closure element is pivotally or displaceably mounted. In this way, the insertion opening can be closed, in particular, as a result of simple pivoting of the closure element, for example, after the implant has been inserted and abutted on a spinous process.
[0022] In accordance with one preferred embodiment of the invention, it may be provided for the closure element to be lockable or connectable in a snap-in manner to the receptacle in a closure position, in which the insertion opening is closed. It is thus possible in a simple manner to prevent the closure element from releasing the insertion opening unintentionally.
[0023] In order to be able to use the implant universally, in particular, for patients of different sizes, it is favorable when a distance between the at least two bearing elements is variable. This makes it possible to adapt the implant individually to a patient and also selectively predetermine a desired alleviation of pressure on the intervertebral space.
[0024] So that the bearing elements maintain a set distance between them, it is advantageous when the two bearing elements can be secured relative to one another at a predetermined distance.
[0025] The distance between the two bearing elements is advantageously variable in discrete steps. As a result, the construction of the implant is simplified, on the one hand, for example, by providing locking strips or teeth movable relative to one another; on the other hand, the handling capability as well as the stability of the implant are also improved.
[0026] In principle, it would be conceivable to design the implant in one piece. It is, however, favorable when the implant comprises at least two implant parts each having at least one bearing element and when the two implant parts can be secured to one another. As a result, a relative arrangement of the bearing elements can, for example, be determined individually and differently depending on the requirements of each patient. Moreover, a distance of the bearing elements from one another and, therefore, an alleviation of pressure on the intervertebral space can also be predetermined in a desired manner.
[0027] The two implant parts can preferably be secured relative to one another in different positions. This may be possible in the form of not only discrete but also non-discrete positions.
[0028] So that the implant can be secured to a spinous process in a reliable manner, it is favorable when the implant comprises at least one fixing element for securing the at least one bearing element to a spinous process.
[0029] In order to increase the stability of the implant and, in addition, ensure that the implant cannot become detached from a spinous process, it is advantageous when the implant has at least one fixing element receptacle for the at least one fixing element, that the fixing element can be driven into the spinous process or be secured to it and that the fixing element is held in the fixing element receptacle. For example, a bone pin or a bone screw could be guided through a bore in the implant forming a fixing element receptacle and be driven into the bone. Alternatively, a thread could also be guided through a bore and wound around the spinous process. It would, however, also be conceivable to design the fixing element in the form of a plug or a rivet.
[0030] In order to increase the stability of a connection between the implant and a spinous process, it is favorable when the at least one fixing element can be secured to the receptacle passing transversely through it.
[0031] Four fixing elements per bearing element are advantageously provided. As a result, a particularly secure connection between the implant and the spinous process can be achieved.
[0032] In accordance with one preferred embodiment of the invention, it may be provided for the at least one fixing element to be a bone pin, a bone screw or a thread. With such fixing elements, the implant may be secured to a spinous process in a simple manner. The at least one fixing element can, in addition, like the entire implant, be produced from a resorbable material, for example, from the same material as the rest of the implant. It would, however, also be conceivable to provide fixing elements which are produced from a material which is biocompatible but not resorbable.
[0033] Further, it is suggested in accordance with the invention, in a method of the type described at the outset, that the implant is produced from a biocompatible, resorbable material.
[0034] It is possible with the method according to the invention to restore the height of the intervertebral space, for example, due to injection of a cell volume required for this purpose into the nucleus of the intervertebral disk in a single surgical operation without having to run the risk of the injected cells dying off on account of an increased internal pressure in the nucleus. Furthermore, the suggested procedure allows an implant to be selected which decreases its pressure alleviating function little by little during a specific period of time.
[0035] It is advantageous when at least one of the at least two bearing elements is designed in the form of a receptacle with an insertion opening for the insertion of a spinous process in a direction parallel or transverse to a preferred direction defined by the spinous process. As a result, the operation can be carried out considerably more quickly since a spinous process can be introduced into the receptacle in a simple manner.
[0036] Two receptacles are preferably provided, the insertion openings of which point away from one another. As a result, it is possible to prevent spinous processes inserted into the receptacles from being held at a minimal distance from one another.
[0037] A spinous process can be inserted into the receptacle particularly easily when this is of a groove-like design.
[0038] An implant can be introduced into a human body through a minimally invasive approach particularly easily when the implant is produced entirely or partially from a plastic material; for example, this plastic material can have a certain elasticity so that the implant can be pressed together somewhat during insertion into the body.
[0039] A plastic material is preferably used which is a polymer or contains a polymer. A resorption time of the implant can be predetermined in a desired manner as a result.
[0040] An implant will be particularly biocompatible when a polymer is used which is polylactide or contains polylactide.
[0041] A plastic material is preferably used which is a gelatin cross-linked three dimensionally or contains a gelatin cross-linked three dimensionally. The use of gelatin as material for the production of the implant enables a desired resorption time of the implant and, therefore, a successive alleviation of pressure on the intervertebral space during a specific period of time to be predetermined by adjusting a degree of cross-linking of the gelatin.
[0042] In order to prevent the implant being able to detach from a spinous process in an undesired manner, it is favorable when the implant comprises at least one securing element and when a bearing element is secured to a spinous process with the at least one securing element. For example, a fixing element already described above in greater detail can be used as securing element. Alternatively, it would also be conceivable to provide a closure element for the insertion opening, whereby a spinous process is prevented from being able to exit from the receptacle.
[0043] In order to prevent a spinous process from exiting from the receptacle, it is advantageous when the insertion opening is closed once the spinous process has been inserted into the receptacle.
[0044] The insertion opening may be closed particularly easily when it is closed with a closure element. A closure element specially provided for the closure of the insertion opening helps to ensure that the length of an operation is minimized.
[0045] The insertion opening may be closed with the closure element particularly easily when the closure element is mounted on the receptacle so as to be movable. After insertion of the spinous process into the receptacle, the closure element need then be moved, for example, by a surgeon only from an insertion position, in which the insertion opening is free, into a closure position, in which the insertion opening is closed.
[0046] The closure element may be transferred into the closure position in a particularly fast and simple manner when the closure element is pivotally or displaceably mounted.
[0047] So that a secure connection between the implant and the spinous process can be brought about, it is advantageous when the closure element is locked or connected in a snap-in manner to the receptacle in a closure position, in which the insertion opening is closed.
[0048] A distance between the at least two bearing elements is favorably altered in a desired manner prior to or following the insertion of the implant. In this way, the implant can be adapted individually to the respective patient, in particular, to situations, in which distances between spinous processes vary considerably.
[0049] In order to prevent a distance between the two bearing elements from being able to change after insertion into the human body and termination of the operation, it is favorable when the two bearing elements are secured relative to one another at a predetermined distance prior to or following the insertion of the implant.
[0050] For a surgeon, a distance between the two bearing elements may be brought about in an advantageous manner without additional tools when, for example, the distance between the two bearing elements is altered in discrete steps prior to or following the insertion of the implant. For example, this can be brought about via the provision of locking strips which can be displaced relative to one another or corresponding teeth.
[0051] In order to make an individual adaptation of the implant to a patient possible, it is favorable when the implant comprises at least two implant parts each having at least one bearing element and when the two implant parts are secured to one another prior to or following the insertion of the implant. As a result, a distance between the two bearing elements can, for example, be adjusted and, therefore, a desired alleviation of pressure on the intervertebral space predetermined.
[0052] The two implant parts can advantageously be secured relative to one another in different positions and are secured to one another in a predetermined position. As a result, the implant can be prepared during the operation in accordance with the requirements on account of an orthopedic situation.
[0053] It is advantageous when the implant comprises at least one fixing element and when the at least one bearing element is secured to a spinous process with the at least one fixing element. The implant may thus be secured to a spinous process in a simple and reliable manner.
[0054] It is favorable when the implant has at least one fixing element receptacle for the at least one fixing element and when the fixing element is inserted into the fixing element receptacle and driven into the spinous process or secured to it. For example, the implant can be held securely on a spinous process as a result of a bone pin being knocked in or a bone screw screwed in and prior guidance of these fixing elements through a corresponding fixing element receptacle of the implant, for example, a bore. Alternatively, the implant can also be secured to a spinous process with a thread which has been guided through a bore, wound around the spinous process and tied to it.
[0055] In accordance with a preferred variation of the method according to the invention, it may be provided for the at least one fixing element to be secured to the receptacle passing transversely through it. A connection between the implant and the spinous process is thus secured in a particularly good manner. In particular, it may also be provided for the spinous process to likewise be provided with a corresponding receptacle for the fixing element, for example, one or more bores prior to the insertion of the fixing element.
[0056] In order to ensure a particularly good securing of the implant on a spinous process, four fixing elements are used per bearing element.
[0057] The method may be carried out particularly easily and, therefore, the implant secured to a spinous process when a bone pin, a bone screw or a thread is used as fixing element and when the bearing element is securely pinned, securely screwed or securely tied to a spinous process.
[0058] In accordance with a further, preferred variation of the method according to the invention, it may be provided for a minimally invasive approach to the human or animal body to be opened, for the implant to be guided to the spinous processes of the vertebra through the minimally invasive approach and for cartilage cells to also be injected into a nucleus of a deformed or damaged intervertebral disk during this operation. This procedure makes it possible for the intervertebral space to be adjusted to its original height and alleviated of pressure with the implant with only one surgical operation and simultaneous minimalizing of operation trauma.
[0059] An implant is preferably used which is completely resorbed in a period of three weeks to six months. In this way, the injected cells are given sufficient time to restore the stability of the intervertebral disk in a desired manner.
[0060] The following description of preferred embodiments of the invention serves to explain the invention in greater detail in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] FIG. 1 : shows a first embodiment of an implant according to the invention secured to spinous processes of a spinal column;
[0062] FIG. 2 : shows an enlarged view of the implant from FIG. 1 ;
[0063] FIG. 3 : shows a perspective view of a second embodiment of an implant according to the invention; and
[0064] FIG. 4 : shows a perspective view of a third embodiment of an implant according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0065] An implant 10 for alleviating pressure on intervertebral disks according to the invention and provided with the reference numeral 10 is illustrated in FIGS. 1 and 2 and this implant will be designated in the following only as implant for the sake of simplicity.
[0066] The implant 10 is formed by an elongated, basic member 12 which is essentially in the shape of a parallelepiped and has an approximately square cross section. Proceeding from oppositely located end faces of the basic member 12 , two groove-like receptacles, which point away from one another, are provided for spinous processes 14 and 16 , respectively, of adjacent vertebra 18 and 22 of a spinal column 22 in the form of groove-like recesses 24 and 26 . The recesses 24 and 26 are each limited by a curved groove base 28 and 30 , respectively, as well as two wall sections 32 and 34 or 36 and 38 , respectively, which extend parallel to one another away from the groove base 28 and 30 , respectively, and are aligned parallel to one another. Four transverse bores 40 and 42 , which are aligned coaxially to one another and approximately define a square, are provided in each of the wall sections 32 and 34 . In an analogous way, four transverse bores 44 and 46 , which are aligned coaxially to one another, are also provided in each of the wall sections 36 and 38 . The wall sections 32 , 34 , 36 and 38 are at somewhat of an angle on their outer sides proceeding from their free ends so that a wall thickness increases continuously proceeding from their respectively free ends up to a maximum wall thickness and, therefore, inclined surface sections 48 , 50 , 52 and 54 are formed.
[0067] In the same way as the transverse bores 40 , 42 , 44 and 46 can be provided in the wall sections 32 , 34 , 36 and 38 only optionally or in a small number or also only in one of the two recesses 24 and 26 , the implant 10 also comprises only optionally a total of eight identical, essentially cylindrical locking pins, namely four locking pins 56 and four locking pins 58 , respectively. An external diameter of the locking pins 56 and 58 is adapted to an internal diameter of the transverse bores 40 and 42 or 44 and 46 , respectively, so that the locking pins 56 and 58 can be pushed into the transverse bores 40 and 42 or 44 and 46 , respectively, and held in a clamped manner in them.
[0068] Both the basic member 12 and the locking pins 56 and 58 are preferably produced from a resorbable plastic material, for example, a polymer such as polylactide.
[0069] The operative procedure for restoring the height of an intervertebral space 60 formed between two vertebral bodies 62 and 64 will be explained in greater detail in the following in conjunction with FIG. 1 .
[0070] As a result of a prolapse of an intervertebral disk 66 arranged in the intervertebral space 60 between the vertebral bodies 62 and 64 , nucleus material can exit through the annulus of the intervertebral disk 66 . As a result, a distance between the intervertebral bodies 62 and 64 is reduced. In order to compensate for this loss in height, a cell volume sufficient to restore the height of the intervertebral disk 66 is injected into the annulus of the spinal column 22 alleviated of pressure after a minimally invasive approach has been opened. Subsequently or also already prior to injection of the cells, the implant 10 is inserted through the minimally invasive approach and pushed between the spinous processes 14 and 16 proceeding from the dorsal side, i.e., in the direction of arrow 68 . Alternatively thereto, it would also be conceivable to push each of the spinous processes 14 and 16 into the recesses 24 and 26 , respectively, transversely to a direction defined by the spinous processes which extends essentially parallel to a direction specified by the arrow 68 , i.e., the spinous process 14 , for example, into the recess 24 in the direction of arrow 70 .
[0071] In a next step, if the implant has transverse bores 40 , 42 , 44 and 46 in the sections 32 , 34 , 36 or 38 , transverse bores can be optionally made in the spinous processes 14 and 16 coaxially to the transverse bores 40 , 42 , 44 and 46 so that the locking pins 56 and 58 can be pushed not only through the transverse bores 40 , 42 , 44 and 46 but also through the transverse bores now provided in the spinous processes 14 and 16 . The implant 10 can be secured in the manner described to one or also to both spinous processes 14 and 16 , respectively. It is ensured by this securing in place that the implant 10 cannot become detached from the respective spinous process 14 or 16 secured thereto. Without the securing in place with the locking pins 56 and 58 as described, only movement of the two spinous processes 14 and 16 towards one another would be limited but not movement of the two spinous processes 14 and 16 away from one another.
[0072] The intervertebral disk 66 restored to its height again by the injection of cells is alleviated of pressure by the implant 10 and so the pressure in the intervertebral disk 66 cannot become so great that the injected cells die off.
[0073] Following the optional securing in place of the implant 10 in the spinous processes 14 and 16 , the minimally invasive approach can be closed again. The body of the patient can, of course, also be opened with a larger approach for carrying out the operation described.
[0074] The movability of the intervertebral space 60 is limited by the implant 10 until the implant 10 is resorbed to such an extent that it can be destroyed by forces acting on the implant 10 on account of movement of the spinal column 22 . Until this point of time of the resorption of the implant 10 , the injected cells have the possibility of filling out the intervertebral space 60 with load-resistant cartilage tissue.
[0075] A second implant provided altogether with the reference numeral 110 will be described in greater detail in the following in conjunction with FIG. 3 . It has a basic member 112 which is formed in an analogous way to the basic member 12 and is provided with recesses 124 and 126 which correspond in their shape to the recesses 24 and 26 .
[0076] The wall sections 132 , 134 or 136 and 138 , respectively, of the recesses 124 and 126 are not, however, provided with transverse bores. By comparison, two covers 142 and 144 are mounted on free ends of the wall sections 132 and 136 so as to be pivotable about pivot axes 140 and 142 , respectively, which extend parallel to one another. The covers 142 and 144 are of an identical design and so their mounting will be described in greater detail in the following only in conjunction with the cover 142 .
[0077] The free end of the wall section 132 supports a bearing bracket 146 which is bored through parallel to the pivot axis 140 and through which a bearing shaft 148 extends. Free ends of the bearing shaft 148 projecting out of the bearing bracket 146 on both sides engage in bearing rings 150 of the cover 142 which border on the bearing bracket 146 on both sides so that the cover 142 can be pivoted relative to the base member 112 about the pivot axis defined by the bearing shaft 148 . A free end of the cover 142 supports a snap-in projection 152 which has a locking groove 154 pointing in the direction towards the pivot axis 140 . A snap-in nose 156 with an inclined slide-on surface 158 is integrally formed on the wall section 134 on an outer side, pointing away from the pivot axis 140 .
[0078] If the free end of the cover 142 is moved in the direction towards the snap-in nose 156 , an outer surface of the snap-in projection 152 slides first of all along the slide-on surface 158 , whereby the cover 142 is deformed somewhat. If the cover 142 is pivoted further, the snap-in nose 156 snaps into the locking groove 154 , whereby the recess 124 is closed on the end side. FIG. 3 illustrates at the bottom how the cover 144 closes the recess 126 in the manner described.
[0079] The implant 110 is inserted between the spinous processes 14 and 16 in a similar manner to the implant 10 . The recesses 124 and 126 are dimensioned such that the spinous processes 14 and 16 can be introduced into them and secured in them as a result of the end-side closure of the recesses 124 and 126 . The covers 142 and 144 can be closed either prior to or following the insertion of the spinous processes 14 and 16 , respectively.
[0080] A third embodiment of an implant provided altogether with the reference numeral 210 is illustrated in FIG. 4 . It corresponds essentially to the implant 10 in its basic form. However, the implant 210 is designed in two parts, i.e., the basic member 212 is divided into an upper part 270 and a lower part 272 . The upper part 270 has a recess 224 corresponding to the recess 24 , the lower part 272 has a recess 226 corresponding to the recess 26 .
[0081] In order to connect the two parts 270 and 272 , a snap-in connection 274 is provided which comprises a toothed groove 276 and a projection 278 which can be inserted into the toothed groove. The groove 276 is provided so as to extend parallel to the recess 224 on the upper part 270 . The projection 278 , on the other hand, projects away from the recess 226 on the lower part 272 . Side surfaces of the groove 276 as well as the projection 278 which abut on one another are provided with rows of teeth 280 which correspond to one another and allow movement of the two parts 270 and 272 towards one another as a result of individual teeth of the rows of teeth 280 sliding along one another but not any movement of the parts 270 and 272 away from one another.
[0082] A distance between the recesses 224 and 226 can be altered prior to the implant 210 being introduced into the body or even after its introduction. In the case of the embodiment described, it is possible to increase the distance between the recesses 224 and 226 only with difficulty. Therefore, the implant 210 is preferably introduced into the body of the patient with a maximum possible distance between the recesses 224 and 226 and the distance reduced as required by way of movement of the two parts 270 and 272 towards one another.
[0083] One or more transverse bores may be optionally provided in the implant 210 , as in the case of the implant 10 , or one or two covers, as in the case of the implant 110 .
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In order to improve an implant ( 10 ) for alleviating pressure on intervertebral disks, for restoring the height of and alleviating pressure on an intervertebral space of a human or animal spinal column, comprising at least two bearing elements ( 24, 26 ) for a spinous process ( 14, 16 ) each for abutting and/or securing the implant on one or two spinous processes of adjacent vertebra of the spinal column, such that as far as possible only one single operation is required to restore the height of and alleviate pressure on the intervertebral space it is suggested that the implant ( 10 ) be produced from a biocompatible, resorbable material. Furthermore, a method for restoring the height of and alleviating pressure on an intervertebral space of a human or animal spinal column is suggested.
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This is a continuation of copending application Ser. No. 762,422 filed on Sep. 19, 1991 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to abrasive tools.
There are a variety of abrasive tools available which use ultra-hard abrasives such as diamond and cubic boron nitride (CBN) as the abrasive. Such tools include grinding wheels and saws.
Grinding wheels comprise a hub, typically made of a material such as bakelite, phenol-aluminium or aluminium, and a working rim secured to the periphery of the hub. The working portion will typically comprise a mass of ultra-hard abrasive particles dispersed in a metal matrix, vitreous matrix or in a thermosetting resin such as a phenol formaldehyde, urea formaldehyde or melamine formaldehyde resin. The hub may take the form of a flat disc or a cup.
One type of known saw comprises a flat circular blank or disc having a working portion bonded to the periphery thereof. The working portion may comprise a plurality of individual segments or a continuous rim. The working portion comprises a mass of ultra-hard abrasive particles dispersed in a metal bonding matrix. An example of a suitable metal bonding matrix is cobalt/bronze.
Another type of saw is a wire saw which comprises a wire having a plurality of annular segments bonded or secured to the wire in spaced relationship.
The manufacture of grinding wheels using thermosetting resins is ponderous and slow, the materials have poor heat conductivity and it may be necessary to heat a powder mix of such a material for four hours or more in an oven to set it.
In the literature there are described polishing materials comprising a flexible or similar support having a layer of abrasive particles in a binder resin bonded to a surface thereof. One such polishing material is described in U.S. Pat. No. 4,927,432. This polishing pad material comprises a porous thermoplastic resin matrix reinforced with a fibrous network and optionally containing abrasive particles such as silicon carbide, cerium oxide, titanium dioxide or diamond. The material is used for polishing silicon wafers by chemical attack, the pores being necessary to accommodate the liquid chemical reagent. The porous nature of the thermoplastic resin matrix renders the pad unsuitable for grinding and sawing operations where abrasion and not chemical attack of a workpiece occurs.
SUMMARY OF THE INVENTION
According to the present invention, an abrasive tool comprises a support and a working portion secured to the support, the working portion comprising a mass of ultra-hard abrasive particles dispersed in a non-porous thermoplastic polymer matrix, the abrasive particle content of the working portion being at least 4 volume percent.
Further according to the invention, a segment for use in manufacturing the working portion of a tool as described above comprises a mass of ultra-hard abrasive particles dispersed in a non-porous thermoplastic polymer matrix, the abrasive particle content being at least 4 volume percent.
DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a perspective view of a typical cup grinding wheel;
FIG. 2 illustrates a side view of a typical disc or peripheral grinding wheel;
FIG. 3 illustrates a sectional side view of a typical wire saw;
FIG. 4 shows an exploded perspective view of an abrasive segment according to the invention and a saw blade disc;
FIG. 5 shows a side view of the saw blade disc having a plurality of abrasive segments of FIG. 4 secured thereto;
FIG. 6 is a section on line 6--6 of FIG. 5; and
FIG. 7 shows a side view of an insert retainer to receive a moulded insert shown in FIG. 4.
DESCRIPTION OF EMBODIMENTS
The abrasive tool of the invention may be a saw or a grinding wheel.
An example of a cup grinding wheel is illustrated by FIG. 1. Referring to this figure, the grinding wheel comprises a flared cup hub 10 having a base 12 with a hole 14 formed therein. The grinding wheel is mounted on a suitable shaft for rotation by means of the hole 14. Bonded to the periphery 16 of the hub is a working portion or rim 18.
An example of a peripheral grinding wheel is illustrated by FIG. 2. Referring to this figure, the grinding wheel comprises a disc-shaped hub 20 having a rim 22 bonded to the periphery 24 of the hub. The hub has a centrally located hole 26 for mounting the wheel on a suitable shaft.
An example of a saw is one wherein the support is a circular blank and the working portion comprises a plurality of segments secured to the periphery of the blank or a continuous rim which is secured to the periphery of the blank.
A wire saw is one wherein the support is a wire and the working portion comprises a plurality of annular segments secured in spaced relationship with the wire. The wire will typically be made of a metal or a tough polymer such as Kevlar®. An example of a typical wire saw is illustrated by FIG. 3 of the accompanying drawings. Referring to this figure, the wire saw comprises a wire 30 having a plurality of cutting elements 32 secured to the wire in spaced relationship. Each cutting element 32 comprises an annular sleeve 34 which is secured to the wire and an annular working portion or segment 36 secured to the sleeve 34. Spacers (not shown) may be provided between adjacent cutting elements 32.
The ultra-hard abrasive particles used in the invention may be single crystal or polycrystalline diamond, or single crystal or polycrystalline CBN. Polycrystalline diamond or CBN may be produced by crushing a diamond or cubic boron nitride abrasive compact. Such compacts are well known in the art.
The ultra-hard abrasive particles will be dispersed in the polymer matrix. Generally these particles will be uniformly dispersed in the polymer matrix, at least in the region of the working portion which, in use, does the abrading.
The ultra-hard abrasive particles may be provided with a suitable metal coating to improve the retention of the particles in the thermoplastic matrix. For grinding wheels, the coating will typically be a coating such as nickel or copper. For saws, the coating will typically be a metal such as titanium.
The thermoplastic polymer is preferably selected from one of the following polymers: Polyetheretherketone (PEEK) and polyetherketone (PEK) such as that marketed by ICI under the trade name VICTREX®. Polyaryletherketone such as that marketed by BASF under the trade name ULTRAPEK®. Poly (amide-imide) such as that marketed by Amoco under the trade name TORLON®. Polyphenylene sulphide (PPS) such as that marketed by Phillips under the trade name RYTON®. Liquid Crystal Polymer (LCP) such as that marketed by Hoechst under the trade name VECTRA®.
Two, or more polymers may be used simultaneously in the polymer matrix in order to use the beneficial characteristics of each polymer. For instance, liquid crystal polymer (LCP) may be used in conjunction with polyetheretherketone (PEEK) in order that the low melt viscosity of the LCP may assist in the free flowing characteristics of the relatively highly viscous PEEK. This will be particularly important where there are high levels of fillers used in the matrix which make the matrix very viscous and difficult to process in conventional moulding equipment.
Other materials may be added to the polymer matrix to improve the properties of the working portion of the tool or segment of the invention. For example, carbon fibres or particles may be added to give strength, bronze powder added to improve thermal conductivity, silica powder added for abrasion resistance, alumina added for wear resistance or PTFE or silicon added to improve lubricity.
The thermoplastic polymer may be a so-called "filled" polymer. Such polymers will contain a particulate or fibre filler in an amount of up to 40 percent by volume. Examples of suitable particulate fillers are silicon carbide, alumina, glass and graphite. Examples of suitable fibres are graphite fibres, steel fibres and PTFE fibres.
In the case of saws, the abrasive particle content of the working portion is preferably in the range 4 to 20 volume percent. In the case of grinding wheels, the abrasive particle content is preferably in the range 15 to 30 volume percent.
The ultra-hard abrasive particles will typically have a size in the range 1 to 1000 microns. For saws, these particles will preferably have a size in the range 100 to 1000 microns. For grinding wheels, these particles will preferably have a size in the range 1 to 500 microns.
The working portion, as mentioned above, may comprise a plurality of segments, or a continuous rim. In the case of the continuous rim, it may be produced as an integral single entity or it can be formed by producing a plurality of segments which are then bonded together to form a rim.
The segments will typically be made by injection moulding, compression moulding or powder spraying. Injection moulding requires that the polymer matrix, including the ultra-hard abrasive and fillers, be heated in the barrel of an injection moulding machine and injected into a purpose built mould. Typical moulding machine barrel temperatures would range from 280° C. to 400° C.; typical injection pressures would range from 70 MPa to 150 MPa; holding pressures of 35 MPa to 70 MPa over a period of 2 seconds to 10 seconds may be used. It is preferred that the mould is heated to typical temperatures of between 150° C. and 200° C.
Compression moulding requires the polymer matrix to be loaded as a mixture together with the fillers and ultra-hard abrasive, into a purpose built mould. The mixture should then be pressurised to typically 1 MPa to expel air. The mould should then be heated to typically 280° C. to 400° C. for up to 2 hours. At the end of this period, the mixture should then be pressure cycled thus: 1 minute at 3,5 MPa, 1 minute at 7,0 MPa and finally 10 minutes at 14 MPa. The final pressure should be held whilst cooling takes place, over a period of typically 10 minutes.
Spraying may be carried out by conventional electrostatic spraying techniques. The polymer matrix, together with the fillers and ultra-hard abrasive may be sprayed directly onto a surface. The surface should be typically heated to 400° C. to 450° C. After coating, the surface should be re-heated for typically 2 minutes in an oven to improve the "flow-out" of the polymer. Typically, coatings up to 2 mm may be applied by a series of sprayings.
An example of an abrasive segment of the invention and the manner in which it may be secured to a saw blank is illustrated diagrammatically by FIGS. 4 to 7 of the accompanying drawings. Referring to these drawings, an injection moulded insert 50 comprises a base portion 52 and a cutting portion 54. The cutting portion 54 has a top cutting surface 56, a leading cutting edge 58 and a front surface 60. The base portion 52 comprises a generally cylindrical spine 62, a connecting web 64 and a cutting portion supporting section 66. The section 66 has a leading surface 66a and the spine 62 has a leading surface 62a, both of which are flush with the surface 60.
The cutting element 50 is received by retainer 70 which has a bore 72 for receiving the spine 62 and a slot 74 for receiving the web 64. The slot 74 extends the full length of the retainer 70, while the slot 72 stops short of the end 76 of the retainer. This can be seen clearly from FIG. 7. The insert 50 is engaged with the retainer so that the front surfaces 60, 62a and 66a of the insert are flush with the front surface 78 of the retainer.
The retainer 70 may be formed of a material such as stainless steel which can be secured by welding or brazing to the peripheral edge 80 of a circular saw blade disc 82 used as a circular saw. The edge 80 has spaced recesses 84 formed therein for accommodating cooling fluid, in use. The edge 80 of the disc is accommodated in the slot 86 formed in the retainer 70.
The inserts 50 are preferably formed of PEEK® and moulded in two sections or portions, as illustrated. The base portion 52 will be of the base polymer itself, with whatever additional fillers may be required but without ultra-hard abrasive, while the cutting portion 54 will be moulded on to the base section and will contain ultra-hard abrasive dispersed in the polymer. It is possible to make the entire insert 50 of the same ultra-hard abrasive containing polymer, but this will then lead to sections of the insert which will contain expensive ultra-hard abrasive, but will effect no abrasive action.
In use, it will be the surfaces 56 and 60 and edge 58 of the cutting portion 54 which will effect a cutting action on a hard material such as granite.
In order to restrain the insert 50 from movement out of the retainer 70, the spine 62 is provided with an inwardly directed slot 90 and an outwardly extending stop formation 92. As the insert is slid into the retainer, the end of the spine 62 may be depressed inwards in the region of the slot 90 until the stop formation 92 engages the hole 94 in the retainer 70. Removal of the inserts can be achieved by depressing inwards the spine 62 in the region of the slot 90 thereby releasing the locking effect of the stop formation 92.
Thus, it will be seen that the effective life of a saw blade can be extended by providing it with removable inserts of abrasive segments which can be replaced very much more easily and cheaply than replacing a complete saw blade.
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An abrasive tool such as a grinding wheel or a saw is characterized by the working portion comprising a mass of ultra-hard abrasive particles dispersed in a non-porous thermoplastic polymer matrix. Examples of suitable thermoplastic polymers are polyetheretherketone, polyaryletherketone, poly (amide-imide), polyphenylene sulphide, liquid crystal polymer and mixtures thereof.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to improvements in image processing techniques, and more particularly to an efficient, rapid, lossless method of compressing, processing and storing grayscale bitmaps using algorithms that are designed for binary images.
2. Technical Background
In the field of image processing, particularly in reprographic reproduction of an image or in the facsimile transmission of an image, the need for providing grayscale resolution of the image data is becoming of increased importance. Also, recently, with improvements in microprocessors and microcontrollers, and in digital information handling technologies, image data has been read and stored in digital form for processing.
Thus, typically, digital reprographic and image storage systems use a scanner to convert an input document to digital form. Such scanners, in their simplest form, compare the input image on a pixel-by-pixel basis to a predetermined threshold, such that pixels with brightness below the threshold are mapped to "1" (black) and pixels with brightness above the threshold are mapped to "0" (white). In more sophisticated systems, the scanners are capable of discerning various levels of gray in the image, and have a grayscale output, typically 4, 6, or 8 bits per pixel.
While the extension of binary scanners to images having grayscale values intermediate black and white can be realized with only modest technical and cost differences, the differences are much more substantial between binary output devices, such as displays and hard copy producing apparatuses, and those capable of reproducing gray-levels. This is especially true in such hard copy output devices as laser, ionographic, or inkjet printers. Until recently, most such devices were capable of rendering only binary bitmaps. For this reason, continuous-tone images, such as a photograph would be rendered as binary bitmaps for printing using halftoning techniques. For example, if the original were scanned at 300 spi×4 bit (16 level) gray, the image could be divided into 4 pixel×4 pixel cells, the gray values of the pixels within the cell averaged, and then the 16 pixels in the cell turned on in proportion to the average gray value over the cell; for instance, a gray-level 8 out of 16 would be represented by blacking 8 of the 16 pixels in the cell.
While grayscale hard copy output devices are relatively rare, it has long been known in the bitmap display art that the legibility and apparent image quality of an arbitrarily-shaped image (such as typed characters, lineart, etc.) is improved by the technique of anti-aliasing. Anti-aliasing provides a method of presenting bi-level images on finite-resolution bit-mapped printers or displays with improved image quality by using intermediate graylevels for pixels at the edges of features. More particularly, by this technique, an image can be rendered to a grayscale display of 50 spi×5 levels of gray by calculating what the text or image would look like at 200 spi, grouping pixels into 2×2 cells, counting up the number of pixels which are on, and mapping this to the gray-value of the 50 spi image. When the image to be rendered is not in vector form (such as typed characters or line-art) but rather is already in high-resolution binary bitmap form, this high-resolution binary to low-resolution grayscale rendering is called inverse halftoning.
Now, recently, hardcopy output devices have begun to appear that are capable of reproducing a few levels of gray, rather than just black or white. One example is a copier/fax that has an 8 bit (256 level) scanner and can reproduce 6 levels of gray in its printout. Even if the original image scanned has no regions of intermediate gray, only black marks on white paper, for example, the apparent image reproduction quality is still improved by grayscale printing because the "jaggies" introduced by the finite spatial resolution of the scanner are softened using gray on partially occluded pixels. If the region does have regions of intermediate gray (such as a photograph or the like), these regions are usually better reproduced by halftone techniques than just mapping each pixel into the limited number of printable gray values. Thus, such digital reprographic systems might be thought of as printing anti-aliased images, whether the input image is monochrome or continuous-tone.
A key problem faced by systems such as the digital copier/fax mentioned above is how to efficiently store the scanned images of pages to support fax or electronic collation functionality. While compression techniques such as CCITT Groups 3 or 4 [G3 or G4] are both lossless and efficient for compressing binary images (i.e., the bitmap produced from a thresholded or half-toned scanned image), they are much less efficient at compressing grayscale data. In typical compression techniques, such as in CCITT G4, the most significant bit of the binary word represents the gray-level of each image pixel. However, such techniques do not efficiently compress the less significant bits that are important in grayscale applications. For these, special techniques exist (e.g., JPEG) which tend to be complex, slow, and sometimes lossy. Custom hardware accelerator ASICs for G4 are far more wide-spread and far less expensive than JPEG.
For example, considering a 2-bit gray printing process, when a multipage document is being copied, it is desirable for the compressed bitmap to be stored in system RAM. If gray-level 3 "11" is black and gray-level 0 "00" is white, then the most-significant-bit will look like the old binary image, and will compress well. However, the least-significant-bit will look like the regular image with a white line drawn around character outlines. This LSB bitmap will not compress as well. Thus, storing the 400×2 G3/G4 image takes more than twice the space of the 400×1 (MSB) bit image.
The compressed version of the second most significant bitplane is 2 to 3 times as large as the most significant bit plane because the transition from white to black in the original image, once sampled by the scanner, involves the transition from gray-level 0 (binary 00xxx) to gray-level 1 (binary 01xxx), then 2 (binary 10xxx), then gray-level 3 (binary 1xxx). Thus the most-significant bit is 0, then 0, then 1, then 1, while the 2nd-most significant bit is 0, then 1, then 0, then 1 as the scanner sweeps across the white to black edge. The G4 technique uses 1 Huffman code per transition from pixel-on to pixel-off or vice versa, and the 2nd-most-significant bit map has 3 times as many transitions as the edge is swept across.
Other grayscale compression approaches exist. For example, one approach is the so-called "Gray codes" (see, for example, Logic Design with Integrated Circuits, William E. Wickes, (John Wiley & Sons, New York, 1968) p. 14). Another approach is described in the JPEG/MPEG standards. Gray codes have the advantage of being lossless, but would not enable standard G4 compressor/decompresor algorithms/chips to be used without special adaptations; JPEG/MPEG are, in general, lossy and often introduce unwanted artifacts in images of fine text.
Techniques for up-conversion of low-resolution gray to high-resolution binary are also known, and used in products of the Xerox Corporation, like the Docutech or the 7650 scanner, in which the scanner actually scans at 400 spi gray and interpolates to 600 spi binary.
Reference is also made to K. Y. Wong and B. Schatz, in Graphical and Binary Image Processing and Applications, J. C. Stoffel, ed., (Artech House, Dedham Mass., 1982); B. R. Schatz and K. Y. Wong, "Method for improving print quality of coarse-scan/fine-print character reproduction," U.S. Pat. No. 4,124,870, Issued Nov. 7, 1978, assigned to the assignee hereof.
SUMMARY OF THE INVENTION
In light of the above, it is an object of the invention to provide an efficient, rapid, lossless method for compressing, processing, and storing grayscale bitmaps using algorithms that are designed for binary images.
It is another object of the invention to provide an improved technique for enabling the efficient compression of the less significant bits in grayscale bitmap applications.
It is another object of the invention to provide an improved method for compressing successive bit-planes when operating on anti-aliased images, particularly in facsimile and reprographic applications.
It is another object of the invention to provide a lossless means for storing grayscale bit maps using compression algorithms which are typically used for binary images, such as G3 or G4.
It is yet another object of the invention to provide a method for transmitting data or storing data that requires essentially half the transmission time or memory space than prior data storing and transmitting techniques.
These and other objects, features, and advantages will become apparent to those skilled in the art from the following detailed description when read in conjunction with the accompanying drawings and appended claims.
In accordance with a broad aspect of the invention, a method for image processing is presented that includes the steps of scanning an image within a first grid of pixels, determining a grayscale value for each pixel scanned in the first grid of pixels, and, for each pixel scanned, activating a number of pixels of a second grid of pixels corresponding to the grayscale value determined.
Data representing the second grid of pixels can be compressed, and stored for use in facsimile transmission or reprographic image production.
In accordance with another broad aspect of the invention, a method is presented for image processing. The method includes scanning an image to produce a digital representation of the image at a first resolution and with a predetermined number of grayscale values. The digital representation of the image is converted to a digital representation of an image having an increased resolution at least as great as the first resolution times the base-2 logarithm of a predetermined number of grayscale values, and having only 2 grayscale values. The converted digital representation is then compressed and stored. The stored data can be used in facsimile transmission or reprographic image production.
BRIEF DESCRIPTION OF THE DRAWING
The invention is illustrated in the accompanying drawing, in which:
FIG. 1 is a diagram of four grayscale values and their binary representations in forming grayscale images thereof.
FIG. 2 is an image having the four grayscale values of FIG. 1 that is desired to be stored and processed.
FIG. 3A is a binary image produced using the least significant bit values of the grayscale values of the image of FIG. 2, using prior art techniques.
FIG. 3B is a binary image produced using the most significant bit values of the grayscale values of the image of FIG. 2, using prior art techniques.
FIG. 4A is a grayscale image having a resolution of 400 spi×2 bits (4 grayscale levels), that is desired to be stored and processed.
FIG. 4B is a binary image formed of the image of FIG. 4A, having a resolution of 800 spi×1 bit (2 grayscale levels), produced in accordance with the method of the invention.
And FIG. 5 is a block diagram illustrating the steps of processing a grayscale image in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As will become apparent, the invention is particularly useful in processing an image that has multiple grayscale values. An arbitrary image having the four grayscale values shown in FIG. 1 is depicted in FIG. 2. The image of FIG. 2 is depicted as it might be processed by a scanner or other device known in the art, and is partitioned into pixels 12, each of which having a particular grayscale value.
The four grayscale values shown in FIG. 1 are numbered 0-3, representing increasing levels of black from white. Thus, the first level 0 is white, and, when mapped to a two-bit binary value, has a grayscale value of "00". The black level maps to the two-bit binary value "11", and the two intermediate gray-levels map to binary values "01" and "10". Of course, any number of grayscale values can be defined, four being described as being merely exemplary.
As mentioned above, in the past, one technique that has been employed in the processing of an image such as that of FIG. 2 has been to generate a plurality of bit planes, each comprising the values at respective bit levels of grayscale information. Thus, in accordance with the prior art, as shown in FIGS. 3A and 3B, the image of FIG. 2 would be mapped into the respective least significant bit plane shown in FIG. 3A and most significant bit plane shown in FIG. 3B. It is noted that the least significant bit map of FIG. 3A has a "ghost halo" surrounding the image, and that the black values and an intermediate gray value map to the same black level. The combination of the bit maps of FIGS. 3A and 3B do not compress efficiently, using standard image compression techniques such as CCITT techniques G3 and G4.
On the other hand, the present invention provides a novel, substantially lossless method for storing grayscale bitmaps using compression algorithms that are normally used for binary images, such as G4. In the case of G4, it is twice as efficient as the technique of compressing successive bit-planes (i.e., the binary bitmaps of the most-significant bit, next-most-significant bit, etc.) when operating on anti-aliased images. This halving of memory requirements maps to halving the telephone charges for facsimile transmissions or halving the required RAM or disk space for digital copiers or image storage systems.
With reference now to FIGS. 4A and 4B, an image 20 to be processed is shown in FIG. 4A. Again, the image is an arbitrary image, and, in the embodiment illustrated, has four grayscale levels as defined in FIG. 1, but any number of grayscale values could be employed. The pixels 22 of the image 20 have a resolution of, for example, 400 spi. Thus, the resolution of the image 20 of FIG. 4A is referred to herein as 400 spi×2, representing, therefore, a resolution of 400 spi having four grayscale levels.
In accordance with the invention, as explained in conjunction with the flow chart of FIG. 5, the image 20 is scanned (Step 50). The grayscale value of each pixel is determined (Step 52). Then, the image 20 is mapped onto a binary grid of increased resolution (Step 53), to produce an image 20' as that shown in FIG. 4B. The image 20' of increased resolution, in the embodiment shown, is twice that of the image 20 of FIG. 4A. Thus, for each pixel 22 of the image 20 of FIG. 4A, four pixel portions 25 of the image 20' exist.
As each of the pixels 22 of the image 20 of FIG. 4A is mapped to the grid of higher resolution to form the image 20' of FIG. 4B, the binary values of each of the pixels 22 of the image 20 are used to determine the number of pixels in the image 20' that are blackened. Thus, for example, a black image having a two bit binary value of 11 is represented by all four pixel portions of the image of increased resolution 20' being blackened. A graylevel having a two bit binary grayscale value of "10" maps to three of the four pixel portions of the image of increased resolution being blackened. A grayscale level having a two bit binary grayscale value of "01" is mapped to blacken only one of the four pixel portions of the image 20' of increased resolution. A grayscale value of white, represented by the two bit binary number "00" maps to no pixel portions of the grid of FIG. 4B being blackened. It will be appreciated that although a two bit binary value representing four grayscale values has been illustrated in FIGS. 4A and 4B, any number of grayscale values can be mapped to a higher resolution grid. In such case, the mapping requires that each pixel of the original image map to a number of pixel portions that correspond to or are larger than the number of grayscale levels in the original image.
Thus, the image 20' of increased resolution as a binary image that can easily be compressed (Step 54) using standard CCITT techniques such as G3 or G4, or other compression technique. The compressed image can then be stored (Step 55) for subsequent use, such as to produce reprographic copies or facsimile transmission, or the like, or immediately transmitted (Step 56) for decompression (Step 58) and processing (Step 59). In the stored image case, the stored image merely needs to be retrieved (Step 57) and decompressed (Step 58) and processed (Step 59), as desired.
When the image is to be decompressed, for example, an 800 spi image can be decompressed 2 lines at a time, grouped into 2×2 cells. The printer gray-level is then established by mapping the counted density in the cell (5 possible levels for a 2×2 cell) into the printable levels (4 in the embodiment illustrated).
More particularly, in a system having a 400 spi scanner whose output is used to compose a 400 spi×2 bit anti-aliased image for processing, the image can be stored most efficiently in memory for reproduction, facsimile, or network transmission by first up-converting it to 800 spi×1 and then compressing it, using, for example a G4 technique. If the image is to be printed, for example, as a part of a reprographic process, the higher resolution image can be retrieved from memory, decompressed and inverse halftoned down to the print resolution of the particular machine employed. Or, for example, if the image is to be transmitted via facsimile, the compressed image can be retrieved from memory, transmitted, then decompressed for display or hard copy generation.
The method of the invention, furthermore, can be used to enhance the image reproduction capabilities of reprographic machines that have different resolution scanning and copy or printing reproduction capabilities. For example, if a particular hard copy device has a scanning and reproduction resolution of 400×3, a digital representation of the image can be converted to a higher resolution, for instance of 1200×1. If another copier, or printer, has, for instance, a different resolution, such as 600×1, then interchange from the lower (400, gray) to higher (600, binary) resolution machine can be made by decompressing the intermediate (1200) very-high-resolution image with every other pixel and every other line used to compose the 600×1 image for the higher resolution machine, thereby introducing minimal image distortion.
It will be appreciated that the method of the invention is not limited to reprographic or facsimile systems. It is useful wherever images are intended to be rendered on a grayscale output device, such as a grayscale display of an image-retrieval system, or the like.
It will be also appreciated that the technique of the invention is most efficient for anti-aliased images, that is, images where gray valued pixels are only found in the sweep between black and white. This technique would not be as efficient if the region were, say, uniformly at gray-level 2 (binary "01") out of 4 grayscale levels.
Although the invention has been described and illustrated with a certain degree of particularity, it is understood that the present disclosure has been made only by way of example, and that numerous changes in the combination and arrangement of parts can be resorted to by those skilled in the art without departing from the spirit and scope of the invention, as hereinafter claimed.
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A method for image processing includes the steps of scanning an image within a first grid of pixels, determining a grayscale value for each pixel scanned in the first grid of pixels, and, for each pixel scanned, activating a number of pixels of a second grid of pixels corresponding to the grayscale value determined. Data representing the second grid of pixels can be compressed, and stored for use in facsimile transmission or photoreprographic image production.
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CROSS REFERENCE TO RELATED APPLICATION
The present application is a continuation-in-part of application Ser. No. 10/378,103, filed Feb. 27, 2003 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to fasteners employed to fasten a covering material to an underlying substrate. More particularly, the invention relates to a plastic/metal composite stress plate with a fastener for fastening a membrane, such as a roof membrane or roofing insulation, to a roof deck, a wall, concrete, stone, plaster, or wood.
2. Reported Development
Fasteners are conventionally employed in the building industry for fastening or clamping a flexible membrane, such as an insulation membrane to a substrate, such as a roof deck. The fasteners typically comprise a large head portion and a shank portion. In use, the shank portion is driven through the membrane into the underlying substrate to anchor the fastener thereinto, while the head portion holds the membrane against the substrate and prevent removal thereof by wind lift. The undersurface of the head portion is typically provided with gripping means so that the membrane is prevented from moving or sliding under the fastener. The gripping means are designed not to penetrate the membrane in order to prevent atmospheric moisture from entering into the substrate through the holes which tend to be made by the gripping means. It is also important that the gripping means are spread/distributed in the undersurface of the head portion of the stress plate in order prevent tearing of the membrane. Conventional fasteners are illustrated by the following references.
U.S. Pat. No. 4,787,188 discloses a stress plate for securing a roof membrane to a roof deck. The stress plate is circular having a top surface and a bottom surface with a central circular opening for receiving a screw for fastening the stress plate over a roof membrane and to the roof deck. The stress plate is equipped with four gripping prongs of triangular shape which are circumferentially spaced from each other by 90°.
In use a first membrane is applied to a roof deck surface, then the membrane is secured to the roof deck surface with the stress plate and the screw. A top sheet or membrane is lapped over the first membrane to cover the stress plate and welded to the first membrane. The four gripping prongs in the stress plate grip the first sheet and hold the same on top of the roof deck without tearing.
U.S. Pat. No. 5,049,018 discloses a fastener for gripping a substrate material. The fastener is of a unitary piece comprising a head portion, a shaft portion, and a hook portion at the end of the shaft portion, wherein the hook portion has an outwardly and upwardly extending resilient end portion. The end portion has an end surface which provides gripping contact with a wall of a hole in a substrate into which the fastener is inserted.
U.S. Pat. No. 5,163,798 relates to a fastener assembly which is employed to secure plies or membranes of roofing, felt and paper to prevent the materials from being blown off the base roofing material before the base material is sufficiently hardened.
The assembly comprises a fastener and a retainer plate. The assembly includes a fastener plate which defines a substantially rectangular opening. The fastener includes a head and a pair of legs which are integrally hingably connected to the head. The legs have a contoured distal portion and an angular side configuration so that at least one of the legs is forced apart as the fastener is driven into the base material.
We have observed that under windy conditions the prior art fasteners need improvement in securely holding a flexible membrane on a substrate without the gripping means penetrating the flexible membrane, and without tearing the flexible membrane.
Accordingly, an object of the present invention is to provide a new and improved stress plate with a fastener to allow attachment of one or more flexible membranes to an underlying substrate without tearing the flexible membrane or allowing it to slip out from under the stress plate.
In another aspect, the present invention relates to a method for securing thermoplastic roof membranes to a roof deck using a stress plate and fastener and fusing overlapping portions of two roof membranes to provide a waterproof covering over a roof deck.
Asphalt roof membranes to prevent moisture from entering into an underlying roof deck are being replaced by thermoplastic sheet materials which offer a superior, longer-lasting roof at a lower cost. In the process of installing thermoplastic sheet materials over a roof deck, the typical steps are as follows. A first sheet is laid adjacent to the lower edge of the roof and running parallel thereto. Fastening means, such as batten bar or a line of stress plates are positioned neat the upper edge of the first sheet. Fasteners are inserted through the batten bar or stress plates and into the roof deck to securely hold the first sheet to the roof deck. Then a second sheet is laid over the roof deck in a marginally overlapping relationship with the first sheet. The second sheet also overlaps the batten bar or the line of stress plates. The overlapping edge area of the second sheet overlaps the area of the first sheet on both sides of the batten bar or line of stress plates. A weld is then applied between the first sheet and the second sheet resulting in the fusion of the two sheet on both sides of the batten bar or the line of stress plates. The weld is applied by the use of a welding machine or tool which softens the thermoplastic sheets and, after cooling, solidifies and forms a continuous sheet. The steps are repeated until the roof deck is completely covered by the thermoplastic sheets.
It has been observed that stress plates having a high profile create bumps in the weld area. It has also been observed that stress plates made of metals do not adhere to the second or overlapping thermoplastic sheet thereby creating bubbles in the weld. Accordingly, it is another object of the present invention to provide a low profile stress plate which substantially remains in the plane of the thermoplastic sheets and which is coated with a thermoplastic material so that the second or overlapping sheet is also welded to the stress plate.
U.S. Pat. No. 6,640,511 discloses an anchor plate with a fastener. The plate has an elevated bonding platform and a countersink. The bonding platform is coated with a heat activable adhesive. The other top surfaces are not coated with the adhesive.
The reference uses an electromagnetic induction heater for attaching a thermoplastic membrane to the anchor plate and the underlying roof structure.
Attaching thermoplastic membranes to a roof surface by using electromagnetic induction heat is cumbersome.
These and other aspects will be addressed as the description of the invention proceeds.
SUMMARY OF THE INVENTION
In the device aspect, the present invention comprises two non-integral components: a metal stress plate and a fastener. The stress plate has a top surface and a bottom surface and includes an opening in its center portion to allow a fastener, such as a screw, therethrough for attachment of the stress plate to an underlying substrate, such as a roof deck. The opening may be circular or rectangular. The top surface of the stress plate is coated with a thermoplastic coat, such as polyvinyl chloride, thermoplastic olefins, chlorinated polyethylene, chlorosulfonated polyethylene, nylon and ethylene propylene diene rubber. The stress plate has a low height profile so that on installation a thermoplastic sheet will not produce bumps therein. To achieve this objective, the total height of the stress plate will be of from about 0.026″ to about 0.100″ and preferably about 0.050″ to 0.070″. It is to be noted that the metal and thermoplastic components are integral with each other in the stress plate, and that the circumferential portions form ridges or protuberances designed to provide strength and adhesive properties to the thermoplastic sheets when laid over the stress plate.
In the method aspect, the present invention comprises the steps of:
a) laying a first thermoplastic sheet or membrane on a portion of the roof deck; b) laying a line of stress plates near the edge of the thermoplastic sheet or membrane parallel to the edge; c) securing the thermoplastic sheet or membrane on the roof deck by inserting fasteners through the stress plates, the first thermoplastic sheet or membrane and into the roof deck; d) laying a second thermoplastic sheet or membrane on the roof deck in an overlapping relationship to the line of stress plates and the first thermoplastic sheet or membrane; and e) applying heat and pressure to the overlapped portion of the thermoplastic sheets or membranes on both sides of the line of stress plates and over the line of stress plates thereby causing a fusion of the thermoplastic sheets or membranes and to the line of the stress plates.
The heat weld may be accomplished by a welding machine known in the art, such as described in U.S. Pat. Nos. 4,259,142, 4,289,552, 4,440,588, 4,533,423, 4,861,412, 4,894,112, 5,110,398, and 5,935,357. However, we prefer to use a welding machine which is disclosed in U.S. Pat. No. 6,536,498, and is incorporated by reference in its entirety. The welding machine comprises a pressure roller and a heating element for a welding apparatus for producing a weld simultaneously on each side of a line of fasteners and over the fasteners. The pressure roller is integral with an axle designed to be connected to a driving means at one end thereof, at the other end of the axle the pressure roller comprises a distal end, a proximal end and a center portion which defines a groove between the proximal and distal ends. The groove of the pressure roller carries an elastomeric cushion designed to smoothly ride over a line of fastening means.
The pressure roller is used in combination with a heating element containing a blower which forces heated air through a nozzle. The nozzle having an outlet therein comprises three portions: two large opening portions and a restricted opening portion therebetween. In use, the large opening portions allow delivery of the major portion of the hot air produced by the heating element while the restricted opening still allows delivery of sufficient amounts of the heated air to soften the overlapping portions of the thermoplastic sheet over and under the fastening means.
The stress plate of the present invention may be of circular, ellipsoidal, square, or rectangular configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top, perspective view of the circular plastic/metal composite stress plate with a fastener;
FIG. 2 is a side elevational view thereof, all other sides being identical thereto;
FIG. 3 is a top plan view thereof;
FIG. 4 is a bottom perspective view thereof;
FIG. 5 is a top perspective view of the ellipsoidal plastic/metal composite stress plate with a fastener;
FIG. 6 is a side elevational view thereof;
FIG. 7 is another side elevational view thereof;
FIG. 8 is a top plan view thereof;
FIG. 9 is a bottom perspective view thereof;
FIG. 10 is a top perspective view of the square plastic/metal composite stress plate with a fastener;
FIG. 11 is a side elevational view thereof, all other sides being identical thereto;
FIG. 12 is a top plan view thereof;
FIG. 13 is a bottom perspective view thereof;
FIG. 14 is a top perspective view of the rectangular plastic/metal composite stress plate with a fastener;
FIG. 15 is a side elevational view thereof;
FIG. 16 is another side elevational view thereof;
FIG. 17 is a top plan view thereof;
FIG. 18 is a bottom perspective view thereof;
FIG. 19 is a is a cross-sectional view illustrating the use of the stress plate and the fastener for attaching roof membranes to a roof deck;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference is now being made to the drawings wherein like numerals represent like parts throughout the figures showing the various embodiments of the present invention.
First Embodiment
Circular Stress Plate with Fastener
FIGS. 1-4 relate to the first embodiment of the present invention in which the circular stress plate is generally designated at 10 and the fastener is generally designated at 12 . The components are non-integral and, when put together, constitute the invention. The circular stress plate 10 has a round or rectangular opening 14 in its center portion through which the fastener is inserted when the stress plate is employed for attaching and firmly holding a roof membrane to an underlying roof deck. The stress plate has a circular body with a top surface and a bottom surface and characterized by
a) a diameter of from about 1″ to about 4″ or more, and preferably about 2″; b) an opening 14 in its center portion the diameter of which is about 0.25″; c) a first flat surface 16 surrounds the opening having a width W 1 of about 0.25″ which is designed to receive the head portion 18 of fastener 12 without passing through said opening 14 ; d) a second flat surface 20 adjacent to the circumferential edge 28 having a width W 2 of from about 0.12″ to about 0.25″, and preferably about 0.20″; e) a third flat surface 22 extends between the first flat surface 16 and the second flat surface 20 having a width W 3 of from about 0.25″ to about 1.0″, and preferably about 0.50″; f) connecting the second flat surface 20 with third flat surface 22 , a first circumferential portion 24 in the form of a ridge or protuberance extends above the second flat surface and towards third flat surface at an angle of from about 25° to about 70°, and preferably at about 45°; and g) connecting the first flat surface 16 and the third flat surface 22 a second circumferential portion 26 in the form of a ridge or protuberance extends above the first flat surface and towards the third flat surface at an angle of from about 25° to about 70°, and preferably at about 45°.
The distance between the first flat surface 16 and the third flat surface 22 is of from about 0.026″ to about 0.100″, and preferably about 0.050″ to 0.070″. The distance between the second flat surface 20 and the third flat surface 22 is also of from about 0.026″ to about 0.100″, and preferably about 0.050″ to about 0.070″.
The composition of the stress plate consists of a metal, such as steel or galvanized metals, having a thickness of about 1 to 3 mm; and a thermoplastic layer 29 coated on and being integral with the top surface of the metal plate having a thickness of about 0.5 mm to 2 mm. The thermoplastic coat completely covers the top surface of the stress plate, namely the first, second, and third flat surfaces and the first and second circumferential portions which connect the first, second and third flat surfaces. The total height H of the stress plate is preferably about 0.050″ to 0.070″.
Second Embodiment
Ellipsoidal Stress Plate with Fastener
FIGS. 5-9 relate to the second embodiment of the present invention in which the ellipsoidal stress plate is generally designated at 10 ′ and the fastener is generally designated at 12 ′ The two components are non-integral and, when put together, constitute the invention. The ellipsoidal stress plate 10 ′ has a round or rectangular opening 14 ′ in its center portion through which the fastener is inserted when the stress plate is employed for attaching and firmly holding a roof membrane to an underlying roof deck. The stress plate has an ellipsoidal body with a top surface and a bottom surface and is characterized by:
a) a larger diameter of from about 1″ to about 4″ or more, and preferably about 2″; b) a smaller diameter of from about 0.5″ to about 2″, and preferably about 1.5″; c) an opening 14 ′ in its center portion the diameter of which is about 0.25″; d) a first flat surface 16 ′ surrounds the opening having a larger radius of about 0.25″ and a smaller radius of about 0.15″ which is designed to receive the head portion 18 ′ of the fastener 12 ′ without passing through said opening 14 ′; e) a second flat surface 20 ′ adjacent to the circumferential edge 28 ′ having a larger radius of from about 0.12″ to about 0.25″, and preferably about 0.20″, and a smaller radius of about 0.15″ to 20″; f) a third flat surface 22 ′ extends between the first flat surface 16 ′ and second flat surface 20 ′ having a larger radius of from about 0.25″ to about 0.75″, and preferably about 0.50″ and a smaller radium of about 0.15″; g) connecting the second flat surface 20 ′ with the third flat surface 22 ′, a first circumferential portion 24 ′ in the form of a ridge or protuberance extends above the second flat surface and towards the third flat surface at an angle of from about 25° to about 70°, and preferably at about 45°; and h) connecting the first flat surface 16 ′ and the third flat surface 22 ′, a second circumferential portion 26 ′ in the form of a ridge or protuberance extends above the first flat surface and towards the third flat surface at an angle of from about 25° to about 70°, and preferably at about 45°.
The distance between the first flat surface 16 ′ and the third flat surface 22 ′ is of from about 0.026″ to about 0.100″, and preferably about 0.050″ to 0.070″. The distance between the second flat surface 20 ′ and the third flat surface 22 ′ is also of from about 0.026″ to about 0.100″, and preferably about 0.050″ to about 0.070″.
The composition of the stress plate consists of a metal, such as steel or galvanized metals, having a thickness of about 1 to 3 mm; and a thermoplastic layer 29 ′ coated on the top surface of the metal plate having a thickness of about 0.5 mm to 2.0 mm. The thermoplastic coat completely covers the top surface of the stress plate, namely the first, second, and third flat surfaces and the first and second circumferential portions which connect the first, second and third flat surfaces. The total height of the stress plate is preferably about 0.050 to 0.070″.
Third Embodiment
Square Stress Plate with Fastener
FIGS. 10-13 relate to the third embodiment of the present invention in which the square stress plate is generally designated at 30 and the fastener is generally designated at 32 . The components are non-integral and, when put together, constitute the invention. The square stress plate 30 has a round or rectangular opening 34 in its center portion through which the fastener is inserted when the stress plate is employed for attaching and firmly holding a roof membrane to an underlying roof deck. The stress plate has a square body with a top surface and a bottom surface and is characterized by:
a) a larger diameter of from about 1″ to about 4″ or more, and preferably about 2″; b) an opening 34 in its center portion the diameter of which is about 0.25″; c) a first flat surface 36 surrounds the opening having a radius of about 0.25″ which is designed to receive the head portion 38 of the fastener 32 without passing through said opening 34 ; d) a second flat surface 40 adjacent to the parametrical edge 48 having a radius of from about 0.12″ to about 0.25″, and preferably about 0.20″; e) a third flat surface 42 extends between the first flat surface 36 and second flat surface 40 having a radius of from about 0.25″ to about 0.75″, and preferably about 0.50″; f) connecting the second flat surface 40 with the third flat surface 42 , a first circumferential portion 44 in the form of a ridge or protuberance extends above the first flat surface and towards the third flat surface at an angle of from about 25° to about 70°, and preferably at about 45°; and g) connecting the second flat surface 40 and the third flat surface 42 ′, a second parametrical portion 46 in the form of a ridge or protuberance extends above the second flat surface and towards the third flat surface at an angle of from about 25° to about 70°, and preferably at about 45°.
The distance between the first flat surface 36 and the third flat surface 42 is of from about 0.026″ to about 0.100″, and preferably about 0.050″ to 0.070″. The distance between the second flat surface 40 and the third flat surface 42 is also of from about 0.026″ to about 0.100″, and preferably about 0.050″ to about 0.070″.
The composition of the stress plate consists of a metal, such as steel or galvanized metals, having a thickness of about 1 to 3 mm; and a thermoplastic layer 49 coated on the top surface of the metal plate having a thickness of about 0.5 mm to 2.0 mm. The thermoplastic coat completely covers the top surface of the stress plate, namely the first, second, and third flat surfaces and the first and second parametrical portions which connect the first, second and third flat surfaces. The total height of the stress plate is preferably about 0.050″ to 0.070″.
Fourth Embodiment
Rectangular Stress Plate with Fastener
FIGS. 14-18 relate to the fourth embodiment of the present invention in which the rectangular stress plate is generally designated at 30 ′ and the fastener is generally designated at 32 ′. The components are non-integral and, when put together, constitute the invention. The stress plate 30 ′ has a round or rectangular opening 34 ′ in its center portion through which the fastener is inserted when the stress plate is employed for attaching and firmly holding a roof membrane to an underlying roof deck. The stress plate has a rectangular body with a top surface and a bottom surface and is characterized by:
a) a larger diameter of from about 1″ to about 4″ or more, and preferably about 2″; b) a smaller diameter of from about 0.5″ to about 2″, and preferably about 1.5″; c) an opening 34 ′ in its center portion the diameter of which is about 0.25″; d) a first flat surface 36 ′ surrounds the opening having a larger radius of about 0.25″ and a smaller radius of about 0.15″ which is designed to receive the head portion 38 ′ of the fastener 32 ′ without passing through said opening 34 ′; e) a second flat surface 40 ′ adjacent to the parametrical edge 48 ′ having a larger radius of from about 0.12″ to about 0.25″, and preferably about 0.20″, and a smaller radius of about 0.15″ to 20″; f) a third flat surface 42 ′ extends between the first flat surface 36 ′ and second flat surface 40 ′ having a larger radius of from about 0.25″ to about 0.75″, and preferably about 0.50″ and a smaller radius of about 0.15″ to 20″ g) connecting the second flat surface 40 ′ with the third flat surface 42 ′, a first parametrical portion 44 ′ in the form of a ridge or protuberance extends above the first flat surface and towards the third flat surface at an angle of from about 25° to about 70°, and preferably at about 45°; and h) connecting the second flat surface 40 ′ with the third flat surface 42 ′, a second parametrical portion 46 ′ in the form of a ridge or protuberance extends above the second flat surface and towards the third flat surface at an angle of from about 25° to about 70°, and preferably at about 45°.
The distance between the first flat surface 36 ′ and the third flat surface 42 ′ is of from about 0.026″ to about 0.100″, and preferably about 0.050″ to 0.070″. The distance between the second flat surface 40 ′ and the third flat surface 42 ′ is also of from about 0.026″ to about 0.100″, and preferably about 0.050″ to about 0.070″.
The composition of the stress plate consists of a metal, such as steel or galvanized metals, having a thickness of about 1 to 3 mm; and a thermoplastic layer 49 ′ coated on the top surface of the metal plate having a thickness of about 0.5 mm to 2.0 mm.
Softer metals such as copper and aluminum may also be used, however, the thickness of the stress plate should be larger to provide sufficient integrity to the stress plate. The fastener is typically a screw of 2 to 3 inches long having threads thereon.
The thermoplastic coat completely covers the top surface of the stress plate, namely the first, second and third flat surfaces and the first and second parametrical portions which connect the first, second and third flat surfaces. The total height of the stress plate is preferably about 0.050″ to 0.070″.
In all of the embodiments of the present invention the ridge or protuberance connecting the flat surface serves the dual purpose of providing strength and rigidity to the stress plate, and firmly grips the second thermoplastic membrane in the marginal overlapping of the first thermoplastic membrane.
The low profile of the four embodiments of the present invention insures that when a second membrane covers the line of stress plates, no objectionable bumps are created, to wit, the stress plates substantially remain in the plane of the membranes.
FIG. 19 is a cross-sectional view illustrating the use of the stress plate and the fastener for attaching a roof membrane to a roof deck. Lower thermoplastic membrane 50 is positioned over insulation 52 which is over the roof deck surface 54 . The fastener 56 is then inserted through stress plate 58 , insulation 52 , and into roof deck 54 . Upper thermoplastic membrane 60 is then lopped over the marginal portions of the lower membrane covering the stress plate 58 . Upper membrane 60 is secured to the stress plate and the lower membrane by welded seam 62 .
Wind Uplift Test
Comparative wind uplift tests were conducted on a 2″ diameter circular composite stress plate versus a standard 2″ diameter circular metal plate without thermoplastic coating thereon. The wind uplift test measures the resistance of the roofing system to high wind currents. For example, a three second burst of wind at 175 miles per hour can exert a negative pressure of 90 pounds per square foot on the roof system.
The composite circular stress plate consisted of a stainless steel plate coated with polyvinyl chloride; while the standard metal stress plate had no coating thereon.
A) Composite Stress Plate
The roofing system consisted of: a roof deck, an insulating layer placed on the roof deck, and a thermoplastic roof membrane placed on the top of the insulating layer. A line of composite stress plates was placed on the marginal area of the thermoplastic layer spaced 6″ apart from each other. The composite stress plates were then attached to the roof system by inserting the fasteners through the stress plates, the roofing membrane, and insulating layer and into the roof deck. A second roofing membrane was then placed on the first roofing membrane in a marginally overlapping position to the first roofing membrane and the line of stress plates. The overlapping portions of the first and second membranes were about 3″ wide. The welding was accomplished by subjecting the overlapped portions to heat, softening them to a weldable consistency and pressing them together by an apparatus having a heat and pressure means. After the overlapped portions of the membranes cooled, a solid seal was formed and the welded are was subjected to wind uplift test. The wind uplift test at 60 seconds showed 180 pounds of pressure per square foot.
The testing was repeated using the same materials, conditions and processes except that the composite stress plates were spaced every 12″ apart from each other. The wind uplift test at 60 seconds showed 105 pounds of pressure per square foot.
B) Standard Metal Stress Plate
Wind uplift tests were conducted using the same materials, conditions and processes described in (A) above, except instead of the composite stress plate of the present invention a standard stainless steel stress plate was used. The stainless steel stress plates spaced every 6″ from each other showed a wind uplift at 60 seconds 150 pounds of plates pressure per square foot, and when the stainless steel stress plates were spaced 12″ from each other, the wind uplift test at 60 seconds was found to be 75 pounds of pressure per square foot.
PARTS LIST
First and Second Embodiments
Circular and ellipsoidal stress plates, generally designated
10, 10′
Fastener, generally designated
12, 12′
Opening in center portion of stress plate
14, 14′
First flat surface
16, 16′
Head portion of fastener
18, 18′
Second flat surface
20, 20′
Third flat surface
22, 22′,
First circumferential portion
24, 24′
Second circumferential portion
26, 26′
Circumferential edge of stress plate
28, 28′
Plastic coating on stress plate
29, 29′
Third and Fourth Embodiments
Square and rectangular stress plate, generally designated
30, 30′
Fastener, generally designated
32, 32′
Opening in center portion of stress plate
34, 34′
First flat surface
36, 36′
Head portion of fastener
38, 38′
Second flat surface
40, 40′
Third flat surface
42, 42′
First parametrical portion
44, 44′
Second parametrical portion
46, 46′
Parametrical edge of stress plate
48, 48′
Plastic coating on stress plate
49, 49′
Using the Stress Plate
Lower thermoplastic membrane
50
Insulation
52
Roof deck
54
Fastener (screw)
56
Stress plate
58
Upper thermoplastic membrane
60
Welded seam
62
Having described the invention with reference to its preferred embodiments, it is to be understood that modifications within the scope of the invention will be apparent to those skilled in the art.
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A two-piece fastener assembly for securing thermoplastic roof membranes to an underlying roof deck having: a stress plate and a fastener. The stress plate consists of a pre-fabricated metal layer and a thermoplastic layer which are integral with each other. The stress plate has top having three flat surfaces and two circumferential portions, forming ridges or protuberances connecting the flat surfaces. In a method aspect the steps of securing thermoplastic roof membranes to an underlying roof deck, includes: placing a first thermoplastic roof membrane on the roof deck; placing a line of stress plates on the marginal portion of the first thermoplastic roof membrane and securing the stress plates along with the first thermoplastic roof membrane to the roof deck by use of the fastener; placing a second thermoplastic roof membrane to overlap the line of stress plates and the marginal portion of the first thermoplastic roof membrane; and applying heat and pressure to the line of stress plates and the overlapped portion of the first and second thermoplastic roof membranes to fuse them together and provide a waterproof covering over the roof deck.
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CROSS-REFERENCE TO RELATED APPLICATIONS
U.S. Provisional Application No. 61/442,149 for this invention was filed on Feb. 11, 2011 for which application this inventor claims domestic priority.
BACKGROUND OF THE INVENTION
This invention generally relates to vacuum excavation methods, and more particularly to devices which may be utilized for clearing rocks and other objects from the generally vertical excavation formed in the vacuum excavation process.
Air vacuum excavation, which is also known as potholing, is an excavation methodology which is utilized to expose utilities to ascertain the exact depth and location of the utilities, typically in preparation for more extensive excavation done in the process of construction activities. Because it is intended to cause a relatively small amount of disruption, air vacuum excavation generally utilizes a small diameter excavation to accomplish this purpose. The larger pieces of equipment utilized for the excavation, such as the vacuum truck, air compressor, etc., may be generally located to the side of the excavation, thereby allowing the survey to take place without major disruptions in surface operations occurring at the site, which is most commonly vehicle traffic along a roadway. Precisely locating underground utilities help the designers to plan construction projects to eliminate potential damage to the utilities and avoiding unnecessary relocations. Air vacuum excavation uses a combination of high-pressure air and a powerful vacuum to safely remove the soil above and around the utility eliminating the risk of damaging the utility which might otherwise occur utilizing traditional methods of mechanical excavation. After the pothole is completed and the utility data is collected then the excavation is backfilled.
So long as the material removed from the excavation during the potholing process is soil, the vacuum excavation process works very well. Because the material being removed is usually backfill, it would be expected that the material being removed would be compacted soil. However, it is not unknown for excavations to be filled with other materials, such as rocks, asphalt and concrete chunks, and other objects and materials.
If larger objects are encountered during the potholing process, major problems can arise. For example, if a large rock is encountered during the excavation, it is necessary to either remove the rock, or to change the location of the pothole. Under the known methods, the rock is typically eliminated by enlarging the excavation with a backhoe or other mechanical excavation machinery and either breaking up the rock with a jack hammer or chisel, or removing the rock. However, utilizing these methods eliminates the primary advantages of potholing, including that it is generally non-destructive and relatively inexpensive.
It is to be appreciated that the present invention may have utility in excavations created by methods other than vacuum excavation and used for purposes other than ascertaining the location of utilities. For example, drilled shafts (also called caissons, drilled piers or pile borings) may be used for bridges and structures where large loads and lateral resistance are major factors. There are a variety of tools utilized by construction contractors when constructing these types of excavations. However, regardless of the type of equipment used, hard rock and individual rock bodies and fragments are often encountered and often the excavation tool cannot advance until the rock is removed. Removal of the rock bodies and fragments can be a laborious and time consuming task to accomplish, particularly if specialized and/or expensive equipment is required to be brought on site for removal. In addition, the utilization of this equipment may require shutting down normal activities for mobilization and operation of the equipment, such as limiting or closing down traffic on a roadway. Accordingly, a need exists for a device which is capable of removing objects from a generally vertical excavation where the device is readily available, relatively compact, and relatively inexpensive.
SUMMARY OF THE INVENTION
The present invention, a grasping device for retrieving objects from generally vertical excavations, satisfies the need described above by providing a device that is convenient and easy to use, manually deployable, durable yet lightweight in design, versatile in its applications and allows anyone drilling or digging a hole to move rocks and rock fragments from a vertical excavation or potholing operation.
One embodiment of the device has a handle member comprising a length of tubing having a grasping surface which is manually grasped by the user as the grasping apparatus is lowered into the excavation. Depending from the handle member is a frame member. Attached to the lower end of the frame member is a pivot plate. A pair of opposite facing jaw members depend from the pivot plate. Each of the jaw members is pivotably attached to the pivot plate. A ram member, which may be pneumatically actuated, is operationally linked between at least one of the jaw members and the frame member. Operation of the ram by, for example, providing an air supply to cause the ram piston to retract into the cylinder, causes the opposite facing jaw members to open for receiving the rock or other object disposed within the vertical excavation. The ram may also be operated by releasing the air pressure such that air exhausts from the ram, which allows the jaw members to close around the object, allowing for its retrieval from the vertical excavation. Biasing means, such as helical torsion springs, may be utilized to maintain the jaw members in a closed position until opened by operation of the ram.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is side perspective view of an embodiment of the disclosed apparatus with the opposite facing jaws in a closed position.
FIG. 2 is a second perspective view of an embodiment of the disclosed apparatus.
FIG. 3 shows a front view of an embodiment of the disclosed apparatus with the opposite facing jaws in an open position.
FIG. 4 is side perspective view of an embodiment of the disclosed apparatus.
FIG. 5 is a front view of an embodiment of the disclosed apparatus.
FIG. 6 is a perspective view of an embodiment of the opposite facing jaws of the disclosed apparatus.
FIG. 7 is an exploded view of an embodiment of the opposite facing jaws of the disclosed apparatus.
FIG. 8 shows an embodiment of the apparatus being manually lowered to retrieve an object in a generally vertical excavation
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the figures, embodiments of the present invention will now be described more fully hereinafter. The invention may be embodied in different forms and should not be construed as limited to the embodiments set forth herein.
The present invention is a grasping apparatus which is utilized for retrieving objects from generally vertical excavations such as potholes, boreholes, drilled shafts, etc. Rather than requiring attachment to machinery, such as the articulating arm of a backhoe, the present invention is manually lowered into the excavation by the user. Manual deployment is often effective for potholes because the objects routinely encountered in excavations made in backfilled utility installations are relatively small in size, allowing a single person to manually lift an object out of the excavation. The manual deployment of the invention is one of the most attractive features of the invention, because it simplifies mobilization and utilization of the apparatus, and minimizes disruption of other activities at the worksite.
An embodiment of the grasping apparatus is depicted in FIGS. 1 through 8 . As shown in the figures, an embodiment of the apparatus 10 has a first jaw member 12 and a second jaw member 14 , each depending from and pivotably attached to a pivot plate 16 . The first jaw member 12 and the second jaw member 14 are placed in opposite facing relation. A frame member 18 and pivot plate 16 are connected together. In the embodiment of the apparatus 10 depicted in the figures, the frame member 18 generally has a tee configuration, where a pair of pivot plates 16 are attached to the cross-member of the tee.
The figures show the first jaw member 12 and second jaw member 14 as each made up from parallel blade members 20 , 22 , with each blade member having a plurality of teeth members 24 . The teeth members of the jaw members 12 , 14 are in general facing relationship with the teeth members of the opposite facing jaw member. The teeth members 24 may either be integral components of the blade members 20 , 22 , or the teeth members may be separately attached to the blade members with fastening means known in the art. The blade members 20 , 22 are attached together with cross-members 26 . However, it is to be appreciated that the first jaw member 12 and second jaw member 14 may also be fabricated as solid units as opposed to the blade/cross-member construction utilized in the embodiments shown in the figures.
The top of the frame member 18 comprises a connector 28 for attaching a handle member 30 to the tool body, which comprises the jaw members 12 , 14 , frame member 18 , and other functional components. The handle member 30 is generally one or more lengths of tubing which are manually grasped by a user as the apparatus 10 is lowered into and raised out of a vertical excavation 100 . The handle member 30 comprises a grasping surface 32 along its length which passes through the user's hands. This grasping surface 32 may be knurled, textured, or have other means for improving the user's ability to maintain a grip on the handle member 30 . The handle member 30 may have a length which may be adjusted by either connecting extensions to the handle member with conventional couplings, or utilizing a telescoping handle member 30 . Thus the operational depth of the apparatus is not limited by the handle length.
The apparatus 10 will typically use one or more rams 34 for manipulating the jaw members 12 , 14 . The rams 34 comprise a piston 36 and a cylinder 38 . The rams 34 are operationally linked between at least one of the jaw members 12 , 14 and the frame member 18 . One end of the ram may be attached to either one or both of the jaw members 12 , 14 , by connecting to an appropriate structure, such as attaching the piston 36 to cross-member 26 as shown, for example, in FIG. 2 . The opposite end of the ram 34 is attached to the frame member 18 or to structures appurtenant to the frame member, such as extension members 48 as shown in the figures. It is to be appreciated that utilization of linkage systems not depicted in the figures may accomplish the same result of manipulating the jaw members 12 , 14 to open and closed positions by utilizing two rams 34 as depicted in the figures, a single ram, or more than two rams.
The inventor herein has found that pneumatic rams function particularly well as rams 34 for the apparatus 10 . The pneumatic rams 34 receive air (or other suitable operational gas, all collectively referred to herein as “air”) when an air valve 40 is opened by the user. Air is exhausted from the rams 34 when the air valve 40 is closed. The air is exhausted from the rams 34 through integral exhaust ports and air is exhausted from the frame member 18 and handle member 30 through exhaust port 42 . The handle member 30 may comprise an air conduit for operation of the rams 34 . The air conduit may be an independent line running in parallel with the handle member 30 or, as shown in FIG. 8 , be integral to the handle member, where the handle itself is the conduit. As further shown in FIG. 8 , an air supply means, such as compressor 44 is connected to the air conduit, in this case handle member 30 , where the air valve 40 is disposed between the air supply means and the air conduit. Air from the handle member 30 may be delivered to each of the rams 34 through lines 50 . The rams 34 may be configured such that pressurization of the rams 34 by opening air valve 40 causes retraction of the piston 36 into cylinder 38 , which manipulates jaw members 12 , 14 into an open position as depicted in FIG. 3 . Release of pressure by closing air valve 40 causes piston 36 to extend from cylinder 38 , allowing jaw members 12 , 14 to move into a closed position. It is to be appreciated that, alternatively, the rams 34 may be configured to manipulate the jaw members 12 , 14 into the closed position by pressurization of the rams, and into the open position by release of the pressure. In this configuration, the rams 34 would be of the type where the piston 36 would extend from the cylinder 38 upon pressurization of the ram.
FIG. 3 depicts the apparatus 10 in an open position, while the other figures depict the apparatus in a closed position. In one embodiment, the apparatus 10 is biased in the closed position by biasing means, such as helical torsion springs 46 , with the springs retained by spring pins 52 , where the spring pins prevent the springs from rotating thus allowing the springs to be placed in torsion by the opening of the jaw members 12 , 14 . Alternatively, the springs may be placed in torsion by the closing of the jaw members 12 , 14 . In an embodiment of the device which is sized for application in commonly sized vacuum excavations, the jaw members 12 , 14 may open as widely apart at 22 inches and close to within approximately 7½ inches apart.
Use of the apparatus 10 is depicted in FIG. 8 . The apparatus 10 is manually lowered into a generally vertical excavation 100 . Once the apparatus is adjacent to the object to be retrieved, in this case a rock 102 , the apparatus is placed into the open position (as depicted in FIG. 3 ) by pressurizing the rams 34 with a fluid, such as air in the case of pneumatic rams. Pressuring the rams 34 , causes the opposite facing jaw members 12 , 14 to move into the open position, allowing the apparatus 10 to be placed over and receive the rock 102 . Once the rock 102 has been received by the opposite facing jaw members 12 , 14 , pressure is released from the rams 34 by closing the air valve 40 , usually by releasing an activation lever, and allowing the air to vent through the ram exhausts and through exhaust port 42 . When the pressure is released from the rams 34 , the object is captured between the opposite facing jaw members 12 , 14 . The closing of the jaw members 12 , 14 may be facilitated by the use of a biasing means, such as helical torsion springs 46 . Once the rock 102 has been captured inside the jaw members, the apparatus 10 may be raised through the vertical excavation and the rock removed by moving the opposite facing jaw members 12 , 14 into the open position.
The jaw members 12 , 14 may be configured in such a shape and tooth configuration such that the weight of the object being retrieved acts to reinforce the closed position of the jaw members. That is, the gravitational force of the object, such as rock 102 , has a resultant force which acts to force the jaw members 12 , 14 together rather than apart.
While the above is a description of various embodiments of the present invention, further modifications may be employed without departing from the spirit and scope of the present invention. Thus the scope of the invention should not be limited according to these factors, but according to the following appended claims.
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A manually deployed grasping apparatus may be utilized for retrieving objects, such as rocks, concrete chunks and other debris, from vertical excavations such as potholes, boreholes, drilled shafts, etc. Unlike backhoes and other articulated arm machinery, the disclosed grasping apparatus is manually lowered into the excavation by the user. Once the apparatus is adjacent to the object to be retrieved, the opposite facing jaw members of the apparatus are placed into an open position to receive the object. Once the object has been received by the opposite facing jaw members, the jaw members are closed to capture the object. The jaw members are then manually withdrawn from the vertical excavation to retrieve the object.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is a foldable frame, and cradle seat couplable to same, for baby carriages.
2. Related Art
The applicant is title holder of the Invention Patent ES P9002663, refering to a baby carriage frame made up of an inverted U handlebar slide mounted on the front feet by a guide flange, and to which the upper end of the corresponding rear foot is hinged. To the upper ends of the front feet, which are joined together by a cross member, are hinged the section ends of the transversal U element, which at the lower end vertical sections is hinged to the intermediate zone of the rear feet, being hinged in the rear to the upper zone of the sections of the mentioned U element, stringers for supporting the seat and/or cradle type carrier. Securing elements have been placed at the upper end of the front feet.
SUMMARY OF THE INVENTION
The purpose of this invention is to improve the frame of the baby carriage indicated in the Spanish Patent to allow it to be folded not only from top to bottom, but also transversely, that is, moving the sides together to notably reduce its volume, with the added advantage of providing the baby carriage with another securing element which prevents accidental folding should the securing elements on the front feet fail, or be positioned defectively.
It is a characteristic feature of this new frame that all the transverse elements are hinged to allow the described folding operation of the frame.
Thus, the U section transverse element has been deprived of the transverse section, which has been replaced by two cross-hinged arms, which join the lower ends of the remaining vertical parts of the U section to the lower end of the handlebar sections, hinging the rear sections of said arms by means of tie-bars to the middle sections of the mentioned vertical elements.
Also, the middle section of the handlebar and the cross element joining the front feet together are split into hinged parts, the middle section of the handlebar being made up of two L-shaped elements, which are joined together by inserting and partially turning coaxially the corresponding sections of the handlebar, while the other sections are hinged together by a central transverse rod parallel to the handlebar sections, the hinge of which includes a securing pin which locks it in the unfolded position.
The hinged parts that make up the cross element between the front feet will, advantageously, be elastically impelled to its extended position.
Another characteristic is the presence of an eccentric locating pin which by partially turning its circular control device determines the linear displacement of the locking element, which ensures the coupling of the seat or cradle carrier to the stringers provided for this purpose on the frame, and which are hinged at the back to the above mentioned vertical elements.
Different models of cradle seats are already known which are made up of a seat frame with lateral arm rests and front railing, with backrest and footrest hinged to the frame. It is also known that these types of cradle seats are coupled removably to the frame of different models of baby carriages, being able to be positioned facing the front or rear.
In most of these carriages, above all in those in which the frame is folded transversely, the seat must be removed in order to fold the carriage as the framework of the former is transversely rigid, with the person pushing the baby in the carriage, usually mothers or baby sitters, have to perform various operations, usually cumbersome, when they have to fold the carriage, and they find themselves on one side of the folded carriage with the seat on the other, and, with the baby in it, cannot alone, for example, carry all the equipment onto public transport.
Another purpose of this invention is to obtain a cradle seat that folds together with the carriage, that is, a seat that does not require removal to fold the carriage. This eliminates the above mentioned problem, and also allows storing the carriage in a very small space, whether in the boot of a car or at home.
Another very important feature of this cradle seat is an automatic locking device which, when the seat is removed from the frame of the carriage, locks the transverse folding apparatus of the seat to prevent accidental folding and ensure the safety of the baby.
To obtain transverse folding of the cradle seat, the seat itself, backrest and footrest are flexible and mounted on frames, which include lateral supports, joined together by hinged elements.
These hinged elements, in the case of the seat are made up of two cross-hinged arms, which also include a locking caliper which, subject to elastic pressures, ensures the locking of the arms in their open position, and the use of the seat out of the carriage.
When the seat is coupled to the corresponding side stringers of the carriage frame, the operation of the above mentioned automatic locking device is cancelled as a crosswise hinged and divided rod hinged transversely to one of the longitudinal supports of the seat frame, and which protrudes at one end through the corresponding side armrest, makes contact with said end with the frame stringer and turns in such a way that the other end of the rod unlocks the above mentioned caliper, thereby allowing the crossed arms to fold when the cradle seat receives the transverse folding pressure exerted when the frame is folded.
When this type of baby carriage has to be folded, it presents some difficulties for the person who is looking after the baby, as the three locking pins must be manipulated, the handlebar locking pin and those on each side of the frame, and usually only one hand is available to do this as the other must be used to hold the baby.
To simplify this baby carriage pin unlocking operation a device has been conceived by which a single operation on the handlebar locking pin unlocks this pin as well as the two lateral locking pins.
In order that the baby carriage does not become insecure in its open position when the direct unlocking controls of the lateral locking pins are suppressed, as per the invention, a safety device has been envisaged on the handlebar hinge that can be manually unlocked in the same unlocking operation of said locking pin.
The handlebar in this case is made up of two "L" sections, whose shorter arms are hinged together to form the middle section of the handlebar, while the longer arms make up the branch sections of the handlebar, with the particularity that said branch sections are made up of two sections which may be turned coaxially to each other, one of whose sections, joined to the shorter arm, has the projection on which the baby carriage folding locking pin is hooked on, which locking pin is mounted on the front feet of the baby carriage.
Another characteristic is that the hinge, envisaged on the handlebar, in the position corresponding to the extended handlebar position is retained by an elastically sprung safety device, and has a manual control which can release the indicated hinge.
With this system, on turning one of the two shorter arms of the middle section of the handlebar with reference to the other, the coaxial rotation of the branch sections of the handlebar joined to said shorter arms is achieved, and with this the release of the projections of said branches with respect to the locking pins mounted on the front feet, thereby allowing the sliding of the handlebar branch sections over these, to achieve complete folding of the baby carriage.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features will be understood more clearly from the detailed description which follows, together with eight sheets of drawings, which serve as a practical representation of the carriage, and are shown only as a non limiting example of the scope of the invention.
In the drawings:
FIG. 1 shows a perspective of the frame assembly in the open position.
FIG. 2 is a schematic top view of the cross-hinged arms and the tie rods which allow the frame to be folded transversely.
FIGS. 3 and 4 show a top view and sectional elevation, respectively, of the hinge and locking device of the two elements which make up the middle section of the handlebar.
FIG. 5 shows a top view of the folded frame.
FIG. 6 shows a perspective of the eccentric locking pin which locks the seat and/or cradle carrier coupling.
FIGS. 7 and 8 show, schematically, an elevation of the position of this locking device and the locking element in the locked and unlocked position, respectively.
FIG. 9 shows a perspective of the cradle seat coupled to the frame of the baby carriage.
FIG. 10 shows a top view of this assembly, cradle seat and frame, in the folded position.
FIG. 11 shows a side elevation of the cradle seat.
FIG. 12 shows a top plan view of a cradle seat section.
FIG. 13 shows a bottom plan view of the cradle seat.
FIG. 14 shows an elevation of the middle section of the handlebar in the extended position of the baby carriage.
FIG. 15 shows in detail a sectional elevation of the construction of the handlebar safety device.
FIG. 16 shows a rear elevation of the above mentioned safety device.
FIG. 17 shows a side elevation of the construction details, with coaxial rotation, of the handlebar branch sections, with the locking pin envisaged on the front feet.
FIG. 18 is a detail plan view of the locking pin mounted on the front feet.
FIG. 19 is an elevation of the initiation of folding of the handlebar with unlocking of the locking pins mounted on the front feet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in the drawings, the frame is made up of a handlebar 1, of general U shape, whose middle section, which forms the pushing handle, consists of two L-shaped sections 2 and 3, of which one section, shorter and tubular, is inserted, with capacity for partial coaxial turning, on the corresponding 4 and 5 sections of the handlebar, while the other sections of the L-shaped elements are hinged together by a transversal rod 6 parallel to the handlebar sections. Partial coaxial turning of the 2 and 3 L-shaped elements is achieved by the use of crosswise arranged slots 7 on same which are adjusted onto a fixed pivot on the 4 and 5 sections of the handlebar, and which are not shown in the drawings.
The handlebar 1 is slide mounted on the front feet 8 and 9 and is guided in movement by brackets 10 and 11 which are hinged with a pin 12 to the upper end of the vertical elements 13 and 14, which at their lower parts hinge the arm ends 15 and 16, which are cross-hinged at their centre 17 (FIG. 2), which at the other end are hinged with the lower ends of the 4 and 5 sections of the handlebar.
The rear sections of said arms 15 and 16 are hinged by tie rods 18 and 19 to the middle sections of the vertical elements 13 and 14.
The end hinges 20 and 21 of the arms 15 and 16, as well as 22 and 23 of the tie rods 18 and 19 are double and are parallel to two axis arranged perpendicularly to each other.
The sections 4 and 5 of the handlebar, below the flanges 10 and 11, are joined to other guide brackets 24 and 25 through which slide the front feet 8 and 9, on whose guide flanges is hinged with a pin 26 the upper end of the rear feet 27 and 28, at the lower end of which are hinged by pins 29 the lower section of the vertical elements 13 and 14.
At the upper section of said vertical elements are hinged by a pin 30 the rear ends of the side stringers 31 and 32 which at their front end are hinge supported by their respective angular struts 33 and 34, which at their bottom end are hinged to the upper section of their respective rear feet 27 and 28.
These stringers are provided with devices 35 and 36 which allow a seat to be moveably coupled on them. The front devices 35 are provided with a pin to ensure said coupling and consists of a circular control knob 37, which by partial rotation G and the intervention of an eccentric internal protrusion 38 determines the rectilinear displacement R of the locking device 35 and of which entails an internal location 39 with a radial branch 40 upon which acts said eccentric projection (FIGS. 7 and 8).
The transverse folding of the chassis, bringing together the side elements, is assisted by the hinged arms 15 and 16, the tie rods 18 and 19, the hinges of the handlebar middle section 2-3 and the hinges of the cross-element 41 which joins the front feet 8 and 9 together.
This cross-element consists of two sections 42 and 43 hinged together by a pin 44 and hinged at their ends to their matching squares 45 and 46 fixed to the front feet, with a spiral spring 47 mounted on the central hinge 44 which pushes said sections to their extended position in which they locate in prolongation to each other.
The hinge of the central shaft 6 of the handlebar has a pin 48, which locks it in the extended position, the locating pin consisting of a stopping dog 49 (FIG. 4) seated in the recess 50 of the disc-shaped extension 51 at the end of the L-section 2 of the handlebar, and which protrudes from said recess by the force of a spring 52 and is inserted into a notch 53 at the outer edge of the other disc-shaped extension 54 at the end of the other L-section 3 of the handlebar, on whose stopping dog there is an external push button 55 which locates the mentioned notch and when pressed seats the stopping dog 49 inside the seat 50, allowing free rotation between the two superposed expansions 51 and 54 around the shaft 6 which passes through their centre.
In addition to this locating pin the frame also has a locating pin 56 on each side to ensure locking of the extended in use position, whose pin, for example, is of the same specifications as those for the frame of the previously mentioned ES-P9002663 patent.
This frame may be complemented with a tray which is coupled to the lower part with suitable devices.
As shown in FIGS. 9 and 10 the cradle seat is coupled to the foldable baby carriage for which this cradle seat has been mainly designed, and is made up of flexible seat frame 60, consisting of two lateral longitudinal support elements 61 and is provided with lateral arm rests 62. To the lower part of this frame is hinged the flexible back rest frame 63 consisting of two lateral longitudinal support elements 64 on whose lateral part of the frame there are devices 65 for locking the back rest at different angles.
To the front part of the seat frame is hinged a footrest 66, and on the lateral arm rests 62 is hinged a sliding type front railing 67, whose lower lateral sections on the exterior face are provided with chanelled extensions 68 which are fitted to their respective lateral stringers 31 of the baby carriage frame.
The two longitudinal supports 61 of the seat frame are joined together at the lower end by two cross-hinged arms 69 and 70 (FIG. 13) of which one section is hinged through an intermediate point 71. The other sections of said two arms are joined together by a locking caliper 72 which locks the cradle seat in the open, useful position. At the point where the caliper is hinged to the arm 69, a spring 73 is mounted which ensures the open position of the locking caliper to maintain the locked position.
At their free ends said cross-hinged arms 69 and 70 are bent upward to form vertical sections 74 which are coupled together and may be rotated coaxially in their seats 75 set in the lateral arm rests 62.
Means have been envisaged on the cradle seat which, when coupled to the frame of the baby carriage, release the locking caliper 72 to allow crosswise folding of the cradle seat together with the folding of the frame, as shown in FIG. 10. The indicated devices are made up of a bent rod 76, which at one end 77, directed downward, is hinged by means of a bracket 78 (FIG. 12) to one of the longitudinal supports 61 of the seat frame, while at the other end 79 (FIG. 13) the rod protrudes from the channeled extension 68 of the corresponding lateral arm rest 62.
On coupling the cradle seat onto the frame of the baby carriage, the end 79 of the rod 76 makes contact with the corresponding lateral stringer 31 of the frame, by which said rod is rotated through the hinge on the bracket 78, whose rotation acts upon the other end 77 of the rod, which pushes the extended arm 80 of the locking caliper, overcoming the resistance of the spring 73 and releasing said caliper, by which the cradle seat can be folded crosswise together with the frame.
When the cradle seat is removed with respect to the frame, the locking caliper 72 is locked again and the bent rod 76 is maintained in its inactive position, as its ends 77 is subjected to the traction of a spring 81 fixed to the corresponding longitudinal support element 61.
The inclined position locking devices 65 of the back rest are released by means of a common central control 82, which is hinged with two diverging tie rods 83 to said devices, whose control is coupled slidewise on a support 84 coupled on the hinge point of two cross-hinged arms 85 and 86 which are joined together at the two longitudinal supports 64 of the back rest frame, of which one of its sections is hinged in turn through an intermediate point 87.
The leg rest is made up of a flexible sheet 88, and consists of a frame with two lateral support elements 89 provided with locking devices 90 for the different inclined positions of the leg rest, and to which are coupled, with optional coaxial rotation capacity, the angular elements 91 located at the side and the front half of the leg rest, and which are joined together hingewise through its front section by a tie rod 92.
The lateral support elements 89 of the frame of the leg rest are at the lower end made up of their respective blocks 93 with lower inclined face, through which the leg rest is pushed upward by the cross-hinged arms 69 and 70 of the seat during transverse folding of the cradle seat if the leg rest is in the lowered position.
The front railing 67 is made up of two lateral arms 94 which are inserted telescopically into the upper tubular sections 95 of the lateral arm supports 62, and which are retained in different protruding positions by means of a locking device 96 so as to adapt its length should the seat be used as such or as a cradle. The front section of the railing consists of three sections, one central-section 97 and the other two 98 and 99 which are longer lateral sections, hinged together, and are held in alignment by means of stopping dogs and the pressure of a spring 100, which is extended when the front railing is folded toward the interior of the seat when the cradle seat is folded (FIG. 10).
The back rest of the cradle seat is provided with a hinged head 101, which is coupled laterally with tie rods 102 to the lateral arm rests 62 to achieve rotation and lock the end of the back rest in its folded position (FIG. 11)
The cradle seat is finished with its corresponding seating pad, and can be generally fitted to foldable frames that are folded in a way similar to the one described.
As shown in FIG. 14, the handlebar is made up of two "L" sections, 2 and 3, which are hinged together through their lower arms by a transversal shaft 6, and make up the middle section of the handlebar which forms the pushing handle of same, while the upper arms of the "L" sections make up the branches 4 and 5 of the handlebar.
The lower arms of the 2 and 3 "L" sections are made up of plastic tubular parts in whose elbow ends the upper ends of the upper steel arms 4 and 5 are inserted, to stiffen these two "L" sections, and are secured with a rivet 7, (FIG. 16)
The handlebar, by means of its branch sections is slide-mounted on the front feet 8 and 9, and its branches 4 and 5 have divided lower zones to make up the end sections 4 (FIG. 17) joined to the guide-flanges 24 along which the front feet slide.
The branches 4 and 5 of the handlebar can rotate coaxially with respect to the end sections 4 of same. To this purpose, coupling between each other can be performed, for example, by a threaded rod 103, joined to the branches 4 and 5, which is threaded into a threaded socket 104 joined to said sections 4.
Said handlebar sections 4 and 5 have a projection 105 (FIG. 17) on their lower face on which the locking pin 56 is hooked when the baby carriage is in the extended position, whose locking pin is mounted on the front feet 8 and 9. This locking pin is made up of a hook 106 made of a single "U" section and hinged by means of the pin 107 to the upper part of the front feet, whose hook holds the projection 105 against which it is pushed by a helical spring 108 threaded on the pin 107, and whose ends rest, respectively, on the front foot and the "U" section which makes up the hook 106.
The extended position of the handlebar (FIG. 14) is locked, besides locking pin 48 action, by means of a safety device made up of a latch 110 (FIG. 15) pressed on one end by a spring 111, and which on the other end is inserted in a bolt eye 112 envisaged in the discoidal expansion 51, preventing its rotation with respect to discoidal expansion 54 of part 3 of the handlebar where said latch 110 is mounted in a recess 113 of said part.
This latch is joined to an exterior control 114 of half-round section which slides on the rear part of the short end of part 3 of the handlebar.
On turning the safety device in the direction of the arrow F (FIG. 15) it is released to the expansion 51 with respect to the latch 110, and on pressing the button 55 as well, the safety pin 48 is unlocked, and it is now possible to turn the shorter arms of the "L" shaped sections, 2 and 3, which form the pushing handle of the handlebar with reference to each other, and by whose angular rotation (FIG. 6) determines the coaxial rotation of the branches, 4 and 5, of the handlebar joined to said shorter arms, and thereby release the projections 105 of said branches with respect to the locking pins 56 mounted on the front feet, thereby allowing complete folding of the baby carriage.
The safety device which locks the hinge of the handlebar can also be mounted on the locking pin itself 48 to lock it against involuntary pressing of its pushbutton.
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A collapsible baby carriage includes a foldable frame including a cradle seat defined by a pair of seat support arms each having one end pivotally connected to a lower end of a guide bracket with a guide bracket having an upper end connected to a pivot member allowing the front legs of the carriage to be folded intermediate their ends; a pair of vertical arms are provided each having one end connected to a respective leg of a second pair of legs and an opposite end connected to a leg of the first pair between said pivot member and a second end of a leg of the first pair; the frame includes a pair of rods each having one end rotatably connected to one of the vertical arms intermediate the ends thereof on one side of the frame and a second end pivotally connected to a respective one of the seat support arms intermediate the ends thereof.
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The invention described herein may be manufactured, used, and licensed by or for the Government for governmental purposes without the payment to me of any royalties thereon.
BACKGROUND OF THE INVENTION
The present invention relates generally to operational amplifiers (hereinafter op amps) and more particularly, to such amplifiers which are utilized in circuitry where low level signals are common, for example, digital circuitry.
As is well known in the electronic arts, most op amps generate an offset voltage output when null output conditions exist at the inverting and non-inverting inputs thereof. In fact, op amp manufacturers list this null offset voltage most prominently on their specifications sheets. Although this null offset voltage output presents few problems in circuitry where high level signals are common, such as in servo controllers, it is always a design consideration in other circuitry, for example where an op amp is connected as a comparator in an analog-to-digital converter. As recommended by op amp manufacturers, when this null offset voltage output presents a problem, active compensation therefor is commonly provided by applying a supplemental DC bias equal in magnitude and of opposite polarity to the offset voltage, at the appropriate power input terminal of the op amp. Of course, the energizing power supply or battery arrangement can be modified or a separate battery may be added to provide this active compensation. However, the cost and design complexity is increased significantly as the result of such compensation. Furthermore, such compensation does nothing to preclude the continuous power drain which is inherent to the null offset condition and is very undesirable for battery operated equipment.
SUMMARY OF THE INVENTION
It is the general object of the present invention to provide passive compensation for the null offset voltage output of op amps.
It is a specific object of the present invention to accomplish the above-stated general object by blocking current flow from the output of each op amp until the voltage output level thereof exceeds its null offset voltage level.
These and other objects are accomplished in accordance with the present invention by connecting at least one diode directly to each op amp output. The number of diodes required for each op amp will depend on whether the diodes are forward biased or backbiased and the magnitude of the null offset voltage to be compensated.
The scope of the present invention is only limited by the appended claims for which support is predicated on the preferred embodiments hereinafter set forth in the following description and the attached drawings wherein like reference characters relate to like parts throughout the several figures.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram for a signal comparator circuit that includes an op amp;
FIG. 2 is a schematic diagram for a signal comparator circuit of similar type to that of FIG. 1 and wherein a battery is connected to energize the op amp while also applying conventional null offset compensation thereto;
FIG. 3 is a schematic diagram for the signal comparator circuit of FIG. 1, having diodes connected therein to block current flow from the op amp in accordance with preferred embodiments of the invention;
FIG. 4 is a schematic diagram for an integrator circuit that includes an op amp from which output current is blocked in accordance with preferred embodiments of the invention; and
FIG. 5 is a schematic diagram for an adder circuit that includes an op amp from which output current is blocked in accordance with preferred embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The meaning of "offset" in regard to op amps can be explained using FIG. 1, wherein an op amp 10 is arranged as a signal comparator which is commonly utilized in the computer arts to convert or translate between analog and digital signal levels. As is well known in the art of electronics, op amp 10 is always energized with a DC bias applied across positive and negative power input terminals, 12 and 14 respectively. This is accomplished in FIG. 1 by connecting a positive DC bias V to terminal 12 and connecting terminal 14 to ground. Otherwise, op amp 10 also includes an output terminal 16, as well as inverting and non-inverting signal input terminals, 18 and 20 respectively. For purposes of explanation, v 1 is designated as the signal applied to the non-inverting terminal 20 and v 2 is designated as the signal applied to the inverting terminal 18, while v out is designated as the signal at the output terminal 16. Ideally, when v 1 is equal to or greater than v 2 , v out is the DC bias across terminals 12 and 14 (V in FIG. 1) and when v 1 is less than v 2 , v pout is 0. If "offset" conditions exist for the op amp however, when v 1 is equal to or greater than v 2 , v out is the DC bias across terminals 12 and 14 less the voltage offset and when v 1 is less than v 2 , v out is the voltage offset. Except for the power drain which results therefrom, the null voltage offset is often inconsequential in those op amp applications where high level signals are utilized. However, where low level signals are utilized, such as in the digital computer arts, the null voltage offset presents major problems unless compensation is provided therefor.
One very common means for providing such offset compensation is shown in FIG. 2 where a battery 22 is connected to apply both the DC bias and the offset compensation across terminals 12 and 14. Battery 22 is connected across the power input terminals 12 and 14 of the op amp 10 in the FIG. 2 arrangement and ground is connected to apply one cell thereof as the offset compensation to the negative power input terminal 14. Of course, the offset compensation must be precise and it can be applied through a variable voltage means (not shown), such as a potentiometer. Furthermore, offset compensation can be applied in other ways, such as with an auxiliary battery or power supply.
As shown in FIG. 3, the present invention resolves the null offset problem for the signal comparator of FIG. 1 by incorporating means 24 for blocking current flow from the op amp output terminal 16 until the voltage level thereat exceeds the offset voltage level. Furthermore, the voltage level at which the blocking means 24 permits current flow, can be precisely predetermined to establish a digital threshold level beyond the offset voltage level. The signal comparator of FIG. 3 has many applications, such as to detect a single transition level in an analog-to-digital converter. As is well known to those skilled in the computer arts, the analog threshold level relating to a desired digital level transition is applied at one op amp input and the analog signal is applied at the other op amp input, while the digital level transition occurs at the op amp output. Of course, at which op amp input the analog threshold level is applied depends on whether the digital level transition is to be from low to high or from high to low.
In one preferred embodiment of the invention, the blocking means 24 includes at least one forward biased diode 26 connected at the op amp output terminal 16. Each forward biased diode 26 presents a voltage drop which must be overcome if current is to flow therethrough. Consequently, the output voltage level of the op amp 10 must exceed the accumulative voltage drop of all the forward biased diodes 26, if current is to flow from the output terminal 16 thereof. Depending on the magnitude of the offset voltage level therefore, the number of a particular diode required in the blocking means 24 can readily be calculated by simple division, using the offset voltage level or a digital threshold level beyond the offset voltage level as the numerator and the voltage drop characteristic of the selected diode as the denominator.
Of course, the voltage drop characteristic of any semiconductor diode depends upon the junction materials utilized in its fabrication. For the most common commercially available semiconductor diodes, the voltage drop characteristic can vary from approximately 0.1 volt to over 1.0 volt. Consequently, it is possible to select a combination of commercially available semiconductor diodes for nearly any desired accumulative voltage drop. Furthermore, backbiased or zener diodes could also be included in any such diode combination to facilitate the attainment of the accumulative voltage drop.
The concept of this invention may also be applied in the analog computer arts where signal levels are higher than in the digital computer arts and where op amps are commonly utilized to perform mathematical processes such as integration, addition and etc. Those skilled in the analog computer arts will certainly understand the functional aspects of the op amp circuitry that performs any mathematical process, without further explanation thereof being provided herein. Furthermore, such artisans will also have a full appreciation for the computational errors that result in those mathematical processes when the op amp circuitry is not compensated for the null offset voltage output and therefore no explanation thereof will be provided herein.
In op amp circuitry of the type for performing mathematical processes, the current blocking means 24 of the present invention may be incorporated to compensate for the null offset voltage output of each op amp and thereby preclude the computational errors that would otherwise result therefrom. An integrator with the current blocking means 24 of the invention incorporated into the circuitry thereof is illustrated in FIG. 4. The op amp 10 is conventionally connected in the integrator with its output v out supplying negative feedback to its inverting input terminal 18 through a capacitor 28. However, the current blocking means 24 is connected between the op amp output terminal 16 and the capacitor 28. As is also conventional, the op amp non-inverting input terminal 20 is grounded through a resistor 30 and the signal v 1 to be integrated is applied to the inverting input terminal 18 through a resistor 32. Although forward biased diodes could be included therein, the current blocking means 24 of FIG. 4 includes at least one backbiased (zener) diode 26' connected at the op amp output terminal 16.
An adder with the current blocking means 24 of the invention incorporated into the circuitry thereof is illustrated in FIG. 5. The op amp 10 is conventionally connected in the adder with its output v out supplying negative feedback to its inverting input terminal 18 through a resistor 34. However, the current blocking means 24 is connected between the op amp output terminal 16 and the resistor 34. As is also conventional, the op amp non-inverting input terminal 20 is grounded through a resistor 36 and the signals v i1 , V i2 , v i3 to be added are applied to the inverting input terminal 18 through individual resistors 38, 40, and 42 respectively. Although either forward biased or backbiased diodes alone could be included therein, the current blocking means 24 of FIG. 5 includes at least one forward biased diode 26 and at least one back biased diode 26' connected at the op amp output terminal 16.
Those skilled in the art will appreciate without any further explanation that many modifications and variations are possible to the above disclosed embodiments of the null offset compensation, within the concept of this invention. Consequently, it should be understood that all such modifications and variations fall within the scope of the following claims.
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The null offset voltage of an operational amplifier is compensated with des connected at the output terminal thereof. These diodes are either forward biased and/or backbiased to block current flow from the operational amplifier until the output voltage thereof exceeds the offset voltage level.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a device for producing a neat edge for lawns, borders, garden paths and the like. More particularly, but not exclusively, it relates to a device to demarcate and support an edge of a lawn, and to a method for using such a device.
[0003] 2. Background Art
[0004] Creating a lawn with a neat edge where it meets flower beds, borders, paths, ponds and the like can be difficult. There is a risk that the edge of the lawn may crumble, especially if the turf is not very well knitted together. If a damaged edge is trimmed back to shape, for example with a spade or an edging tool, the lawn inevitably shrinks and the bed, path, etc. widens. Damaged sections may even need to be removed and re-turfed.
[0005] A particular problem may arise in the case of garden ponds, where the surrounding turf can easily be damaged or even undermined. Clods of soil falling into a pond can make the water unacceptably muddy, necessitating frequent cleaning. It is not always a satisfactory solution to pave the immediate surrounds of a pond.
[0006] It would be helpful to provide a barrier to discourage the spread of grass from the lawn into beds, borders and paths, particularly when regular weeding would be inconvenient or impracticable.
[0007] Simple lawn edging materials, such as vertically inserted ceramic tiles or metal strips, are well known. However, if the lawn is lower than the bed or vertical edge, mowing becomes difficult, and if only one side of the edging material is supported, such as where the lawn is higher than adjacent portions of a flower bed, or where the lawn borders on a pond, the edging material can easily fall over. It may be attached to posts, stakes and the like, extending deep into the ground, but these can be unsightly and are not compatible with waterproof membranes such as are used to line garden ponds.
[0008] Substantial graveled areas are becoming increasingly popular as an alternative to traditional grassed lawns. However, for graveled areas as well as grassed ones, a neat edge can be difficult to produce and maintain, particularly when the graveled area is higher than a neighboring area, and there is a risk of gravel falling or being kicked, say, into the neighboring area. There are hence problems with edging graveled areas akin to those with edging traditional grassed lawns, particularly when it is desired that a graveled area extends up to a pond. The term “lawn” as used herein should therefore be understood to refer to both traditional grassed lawns and to graveled garden areas, except where clearly restricted to one or the other by context.
BRIEF SUMMARY OF THE INVENTION
[0009] It is therefore an object of the present invention to provide a means to support and protect a periphery of a lawn, particularly adjacent a pond, bed or border, which obviates the above problems and permits the creation of a neat and durable edge to the lawn. It is a further object of the present invention to provide a method for protecting an edge of a lawn using such means.
[0010] According to a first aspect of the invention, there is provided an edge support means for a margin of a lawn as defined herein, comprising an elongate generally L-shaped support member having a base part adapted to be fixable to ground beneath the lawn, and an upstanding wall part adapted to retain an edge of the lawn.
[0011] The base part may be apertured, to allow grass root growth therethrough.
[0012] Preferably, the base part comprises a lattice of strut means joining the wall part to an elongate member, optionally extending parallel to the wall part.
[0013] The lattice may define a plurality of elongate apertures extending substantially between the wall part and the elongate member.
[0014] Said elongate apertures may comprise at least one third of a total area of the base part.
[0015] The elongate apertures may each extend transversely to the wall part.
[0016] Each elongate aperture may have a smooth rounded periphery.
[0017] The base part, preferably the elongate member, may be provided with anchoring means.
[0018] The anchoring means may comprise peg means adapted to cooperate with apertures in or adjacent to the elongate member.
[0019] The wall part may optionally extend downwardly from the plane of the base part so that the edge support has a T-shaped profile.
[0020] The elongate member may be provided with a plurality of severable zones, anyone of which may be cut or broken as required to permit alteration, at any desired point, of the alignment of the wall part.
[0021] The wall part may thus be deformable, either convexly or concavely.
[0022] The wall part may comprise zones of weakness, better to allow its bending.
[0023] The edge support means may be provided with connection means to connect it to further edge support means.
[0024] The wall part may be provided along its upper margin with strengthening means, such as a zone of increased thickness or a flange means, optionally a flange means extending towards the base part.
[0025] The base part may be provided along its margin remote from the wall means with strengthening means, such as a zone of increased thickness or a flange means, optionally a flange means extending towards the wall part.
[0026] The connection means may conveniently connect via flange means of adjoining edge support means.
[0027] The edge support means may be provided adjacent a junction of the wall part and the base part with reinforcing means adapted to resist flexion of said junction, particularly bending of the wall part away from the base part.
[0028] The reinforcing means may comprise a simple reinforcing bead extending along the junction or more complex shapes, such as a C-shaped bead, disposed with a convex side towards said junction.
[0029] The edge support means may comprise a plastics material, such as polyethylene, polypropylene or poly (vinyl chloride).
[0030] The edge support means may be provided with illumination means.
[0031] The illumination means may comprise fiber-optic cable means operatively linked to a light source locatable remotely from the edge support means.
[0032] The edge support means may comprise a fiber-optic cable element provided with means to connect it operatively to a fiber-optic cable element of adjoining edge support means.
[0033] The edge support means may thus illuminate a margin of a lawn, path, pond or the like, for safety or for decorative purposes.
[0034] According to a second aspect of the present invention, there is provided a method of protecting an edge of a lawn which comprises the steps of providing an edge support means as described above, locating the base part thereof to a ground surface, and laying lawn material on top of the base part with an end of the lawn material abutting the wall part.
[0035] When the lawn is a grassed lawn, the lawn material may comprise turf, which may be a freshly laid turf or alternatively may be a peripheral zone of an existing lawn.
[0036] Alternatively, where the lawn is a graveled area, the lawn material may be gravel.
[0037] The method may comprise the step of removing existing turf or other lawn material from the lawn over at least an area corresponding to an extent of the base part.
[0038] Alternatively, the method may comprise the step of peeling back existing turf from said area.
[0039] The method may comprise the step of anchoring the edge support means to the ground using a peg means or other anchoring means.
[0040] The method may further comprise the steps of providing a plurality of edge support means, and linking them in series, either before or after disposing them in position on the ground.
[0041] To protect an edge of a lawn adjacent a pond, the method may further comprise the steps of digging the pond and laying a waterproof lining means over a base of the pond and a surface of the ground surrounding the pond, and the base part of the or each edge support means is then disposed on top of said waterproof lining means, and the turf or other lawn material is laid on top of both the base part and the waterproof lining means.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Embodiments of the invention will now be more particularly described by way of example and with reference to the accompanying drawings, in which:
[0043] [0043]FIG. 1 is a plan view of part of an edge support embodying the invention;
[0044] [0044]FIG. 2 is a cross-sectional view of the support of FIG. 1 in use;
[0045] [0045]FIG. 3 is a cross-sectional view of the support of FIG. 1 in use adjacent a pond;
[0046] [0046]FIG. 4 is a cross-sectional view of an alternative form of edge support in use adjacent a pond;
[0047] [0047]FIG. 5 is a plan view of part of another edge support embodying the invention;
[0048] [0048]FIG. 6 is a cross-sectional view of a further edge support with strengthening elements;
[0049] [0049]FIG. 7 is a cross-sectional view of a variant form of the support of FIG. 6;
[0050] [0050]FIG. 8 is a cross-sectional view of the support of FIG. 1 in use with a graveled “lawn”;
[0051] [0051]FIG. 9 is a plan view of a further embodiment of the invention;
[0052] [0052]FIG. 10 is a plan view of the edge support of FIG. 9 with all the removable panels knocked out to allow flexure in either direction of the support;
[0053] [0053]FIG. 11 is a cross-sectional view of the support of FIG. 9 taken along the line XI-XI thereof,
[0054] [0054]FIG. 12 is a cross-sectional view of a connecting member; and
[0055] [0055]FIG. 13 is a scrap cross-sectional view showing a zone of weakness and taken along the line XIII of FIG. 9.
DETAILED DESCRIPTION
[0056] Referring now to the drawings, and to FIG. 1 in particular, an edge support 1 for a lawn comprises a generally vertical, in use, wall 2 and a generally horizontal, in use, base member 3 . In the embodiment shown, the wall 2 and the base member 3 comprise a single L-shaped molding of thermoplastics material, although in an alternative embodiment, the wall 2 and the base member 3 are formed separately and fastened together. In other embodiments, the support may comprise other materials such as wood or metal, especially aluminum.
[0057] The base member 3 comprises an elongate strip 4 and a plurality of diagonal strips 5 connecting it to the wall 2 . The diagonal strips 5 slant in alternately opposing directions to form a series of triangular apertures 6 . This configuration imparts excellent rigidity to the base member 3 , while saving raw materials and allowing grass roots to grow down through the base member 3 , helping to anchor it in place. The strip 4 is provided with a plurality of holes 7 , spaced one from another, each configured to receive a peg (not shown in this view) to help to anchor the edge support 1 .
[0058] The edge support 1 may be used in the configuration shown in FIG. 1 to support a straight lawn edge. To support a concave or convex lawn edge, the frame strip 4 is severed along any or each of dotted lines 8 . The wall 2 may then be folded concavely or convexly. In the wall 2 , at the apex of each triangular space, a fold zone 9 may optionally be provided to allow bending of the wall 2 . However, this may not be necessary, especially with lighter gauge material. The severed ends of the strip 4 may be overlapped where necessary.
[0059] The strip 4 may be grooved, notched or otherwise weakened along the dotted lines 8 , to ease cutting. Similarly, each fold zone 9 may be grooved, notched or otherwise prepared for easy folding. However, in a preferred embodiment, both the wall 2 and the base member 3 are composed of thermoplastics material of thickness two to three millimeters, which may be folded manually without especial preparation. Similarly, the strip 4 may then be cut at any convenient point along its length with readily available tools, such as a knife, scissors, garden shears, secateurs or the like.
[0060] In use, the edge support 1 is disposed as shown in FIG. 2. When a grassed lawn is being laid from scratch, the edge support 1 is placed, with the base member 3 on a generally level surface, at a boundary between, for example, a flower bed 10 and an area 11 which is or will be lawn. A peg 12 is inserted through each hole 7 of the base member 3 . A turf 13 is then laid on top of the base member 3 , such that an end of the turf 13 is in contact with the wall 2 . The remainder of the area 11 may be turfed conventionally.
[0061] If a lawn is being grown from seed, soil is placed on top of the base member 3 and in contact with the wall 2 , and the area 11 may then be seeded conventionally.
[0062] If the edge support 1 is to be used to edge an existing grassed lawn, a turf 13 is either cut out of the existing area 11 , or a corresponding zone is undercut and peeled back. In either case, sufficient space is created to emplace the edge support as above, and the turf 13 is then replaced or folded back into position, as appropriate. Any gaps remaining between the turf 13 and the wall 2 , due, for example, to previous damage to the edge of the lawn area 11 , can be filled with soil and reseeded, or plugged with small pieces of turf, as desired.
[0063] The wall 2 of the edge support 1 thus creates a neat edge to the lawn, resistant to crumbling and other damage. The weight of the turf 13 on the base member 3 , and the presence of the pegs 12 , keep the edge support 1 securely in position. In a preferred embodiment, the wall 2 is dimensioned to be almost as high as a typical turf thickness (normally from twenty to twenty-five millimeters). The wall 2 may thus conveniently be about 20 millimeters high. The lawn area 11 can then be mown right up to its edge, which is supported by the wall 2 , without the wall 2 being damaged by lawnmower blades, or vice versa. Edge trimming, with shears or a string trimmer, for example, may be unnecessary. Roots 14 of grass plants 15 growing on the turf 13 (only some of which are shown, for clarity) may in time grow through the apertures 6 in the base member 3 , anchoring the edge support even more securely. In this connection, the apertures are shown as triangles. However, other shapes may be used, as described below.
[0064] In normal use, it is envisaged that the base member 3 should extend perhaps 70 to 80 millimeters from the wall 2 , to provide sufficient stability. In an alternative embodiment, larger edge supports 1 may be provided, with a turf 13 already in situ thereon, for convenience.
[0065] Clearly, edge supports 1 may be provided with walls of a convenient length, and a number of walls may be connected, end-to-end, to provide a desired continuous length of wall 2 . Standard male-female engagement devices may be provided at each end of each length, and one embodiment of such a connector is shown in FIG. 12, described in more detail below.
[0066] For the edge support 1 to be used adjacent a pond 16 , there is a slight variation in the installation method. A pit is dug for the pond 16 , and the pond 16 is lined with a water impermeable membrane 17 , which is extended to underlie the area 11 . The base member 3 is then placed on top of the membrane 17 as shown in FIG. 3. The pegs 12 are set far enough from the edge of the pond to be able to penetrate the membrane 17 without possibility of leakage. Such a perforation in a periphery of the membrane 17 would not cause the leakage problems that could result from the use of retaining stakes at a margin of the pond 16 itself. For a grassed lawn, the turf 13 may then be placed on top of the base member 3 and in contact with the wall 2 , as described above.
[0067] A neat and secure edge can thus be provided for a pond in a lawn area, without recourse to concrete rims, paving slabs and the like. There will be very little tendency for soil to crumble into the pond, and the lawn can be mown up to its edge without its giving way.
[0068] In this application of the edge support 1 , a short downward extension 18 of the wall 2 , below the general level of the base member 3 , may form a sideways ‘T’ -shaped support. This is useful for cosmetic and other purposes, as shown in FIG. 4.
[0069] The edge support 1 may be made of appropriately colored materials, such as green plastics material, and may have appropriate surface textures molded or embossed into a face of the wall 2 exposed in use, to blend in with its surroundings.
[0070] [0070]FIG. 5 shows a plan of an edge support 21 with an alternative configuration of base member 3 to that shown in FIG. 1. The wall 2 and the base member 3 comprise a single L shaped extrusion of thermoplastics material. The base member 3 is provided with a plurality of elongate apertures 22 , which may be formed by stamping out portions of the base member 3 (which is typically only two or three millimeters thick). Each end 23 of the elongate apertures 22 is rounded, conveniently being substantially semicircular. This shape reduces stresses in the material of the base member 3 around the elongate apertures 22 , compared to shapes with distinct corners, reducing accidental breakages. The elongate apertures 22 extend generally perpendicularly away from the wall 2 towards an elongate strip 4 defining an edge of the base member 3 remote from the wall 2 . The strip 4 is provided with a plurality of holes 7 , each configured to receive a peg, as for the edge support 1 of FIG. 1.
[0071] To support a concave or convex lawn edge, the elongate strip 4 is severed along a line between its edge remote from the wall 2 and an elongate aperture 22 . The wall 2 may then be folded concavely or convexly, as for the edge support 1 of FIG. 1, overlapping severed ends of the strip 4 where necessary.
[0072] A plurality of narrow slots 24 are also provided in the base member 3 , also with rounded ends 25 . The narrow slots 24 supplement the elongate apertures 22 , lightening the edge support 21 further, and providing additional routes through which grass roots may grow and engage with the base member 3 , anchoring the edge support 21 .
[0073] In an alternative embodiment of the invention, the base member 3 is an unapertured sheet. Alternatively, the base 3 may be provided with slits or notches, extending from the wall 2 towards an opposite margin of the base member 3 , to facilitate bending of the wall 2 .
[0074] [0074]FIGS. 6 and 7 show, in cross-section, edge supports 31 , 32 with strengthening elements. The wall 2 of each edge support 31 , 32 has its upper rim 33 folded over. This strengthens the upper rim 33 without making the wall 2 much more difficult to bend convexly or concavely, as described above.
[0075] The base member 3 of each edge support 31 , 32 is provided adjacent its edge remote from the wall 2 with a flange 34 extending therefrom upwardly and slightly towards the wall 2 . This strengthens the base member 3 and may engage with a turf 13 (not shown) placed thereon, helping to anchor the edge support 31 , 32 . It does not make the base member 3 significantly more difficult to sever, where required.
[0076] The folded upper rim 33 and the flange 34 are simple shapes to be formed in a continuous plastics extrusion (which may be cut into individual edge supports as required). The recesses 35 , 36 formed between the upper rim 33 and the wall 2 , and between the flange 34 and the base member 3 , respectively, providing convenient points of attachment for connecting elements 39 to join adjacent edge supports.
[0077] The edge support 31 of FIG. 6 is provided with a reinforcing element 37 with a C-shaped profile adjacent a junction of the wall 2 and the base member 3 . The edge support 32 of FIG. 7 is instead provided with a reinforcing bead 38 of generally quarter-circular profile along the junction. The reinforcing element 37 and the reinforcing bead 38 each strengthen the respective edge support 31 , 32 against any tendency for the wall 2 to be bent away from the base member 3 , for example by someone treading on an edge of a lawn supported by the edge support.
[0078] A preferred embodiment of the invention is shown in FIGS. 9 and 10. The base member 3 is apertured similarly to that of the preceding embodiment, but is additionally provided with zones of weakness 50 , two of which lead from an edge of the base 3 at a converging angle across the frame strip 4 to connect to the rounded end 23 of each aperture 22 , defining a removable panel 51 of generally trapezoidal shape.
[0079] A cross section of such a zone of weakness 50 is shown in FIG. 13. It may easily be fractured by manual pressure to remove the panel 51 , allowing the support to be bent in either direction. FIG. 10 shows a support where all the panels 51 have been removed. Of course, it is not always necessary to remove every panel. Where the degree of curvature required is shallow, alternate panels 51 may be left in place, and where no curvature is required, all the panels 51 in that section may remain unbroken. Essentially, any panel may be removed to allow curvature at that section of the edge support.
[0080] [0080]FIG. 8 shows an edge support 1 supporting an edge of a graveled “lawn” 41 adjacent a flowerbed 10 . The base member 3 is placed on a generally level surface, as for a grassed lawn, and a peg 12 is inserted through each hole 7 of the base member 3 . Gravel 42 is then poured on top of the base member 3 , and is retained by the wall 2 , restraining it from spilling on to the flowerbed 10 . In this use, an apertured base member 3 is not required, as plant growth through the graveled “lawn” 41 is not desired.
[0081] A graveled “lawn” 41 is frequently laid over a sheet 43 of “geotextile”, which is permeable to moisture, but too finely apertured to allow shoots and roots therethrough. Geotextile may lift up at its edges, which is unsightly and allows weeds to grow. If an edge support 1 is placed on top of the geotextile sheet 43 and is pegged into place with the pegs 12 extending through the sheet 43 , the sheet 43 can be neatly maintained in position.
[0082] An edge support means as described above thus provides a convenient and reliable means of providing a neat and durable edge for a lawn, where it meets a flowering bed, a border or a pond. It can be used for straight, convex or concave edges with minimal adjustment. The lawn can be mown up to the edge with little risk of damage, and the lawn edge does not require frequent trimming, tidying and repair. The edge support can equally well be used to edge graveled garden areas as to edge traditional grassed lawns.
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An edge support for a margin of a lawn comprises an elongate generally L-shaped support member having a base part fixable to ground beneath the lawn, and an upstanding wall part to retain an edge of the lawn. The base part has elongate apertures to allow grass roots to grow therethrough. The base part may have several zones at which it may be cut or broken to permit bending of the wall part. The edge support may be provided with connectors to connect it to further edge supports via flanges on the wall part and the base part.
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TECHNICAL FIELD
[0001] The present disclosure relates to a stretchable coated fabric and a process for producing the same.
BACKGROUND ART
[0002] A need exists for a process for imparting water-oil-repellency to a surface of a garment that is a textile product. In particular, a process for using a C8 fluorinated water repellent to treat the surface has been used. As used herein, the term “C8 fluorinated water repellent” refers to a fluorinated water repellent that containing an emulsion of a copolymer comprises a perfluoroalkyl group with eight or more carbon atoms dispersed in a medium. However, the EPA (US Environmental Protection Agency) has discovered that the C8 fluorinated water repellents contain perfluorooctanoic acid, perfluorooctane sulfonate, and the like. These compounds degrade in the environment and in organisms. As their degradation products accumulate in the environment and in organisms, the compounds place a heavy burden on the environment. Thus, there is a need for a fluorinated water repellent that does not contain these compounds.
[0003] Then, a replacement to a C6 fluorinated water repellent is pushed forward rapidly. As used herein, the term “C6 fluorinated water repellent” refers to a fluorinated water repellent that comprises a copolymer comprises a perfluoroalkyl group with six or less carbon atoms. For example, Patent Literature 1 discloses a water-oil-repellent fabric using a C6 fluorinated water repellent and a process for producing the same. Moreover, in order to obtain a moisture permeable, waterproof, and windproof fabric, a synthetic resin solution that contains an organic solvent has been applied, for example by a dry process, to a fabric given a water-oil-repellency using a C6 fluorinated water repellent.
CITATION LIST
Patent Literature
[0000]
Patent Literature 1: Unexamined Japanese Patent Application Kokai Publication No. 2007-270374
SUMMARY OF INVENTION
Technical Problem
[0005] However, the C6 fluorinated water repellent has a relatively lower water-oil-repellency, compared with the conventional C8 fluorinated water repellent. If the C6 fluorinated water repellent is used to treat a fiber fabric only for water-oil-repellency, the fabric obtains, as initial performance, similar water-oil-repellency to a fabric using the C8 fluorinated water repellent. However, when the fiber fabric is subsequently coated with a synthetic resin solution, the synthetic resin solution penetrates the fiber fabric. It is presumed that this phenomenon occurs because a fabric treated with a C6 fluorinated water repellent has a lower dynamic oil-repellency offered by coating, compared with a fabric treated with a C8 fluorinated water repellent. Consequently, it is difficult to form a continuous resin film on a surface of the fiber fabric, which causes the problem that the necessary performance (hydraulic resistance, moisture permeability, wind proof property, and the like) is not provided.
[0006] The present disclosure has been developed in view of these problems, and directed to provide a stretchable coated fabric that exerts no influence on the environment and that is highly moisture permeable, waterproof, and windproof and a process for producing the same.
Solution to Problem
[0007] In order to achieve the objective described above, a stretchable coated fabric according to a first aspect of the present disclosure is
a stretchable coated fabric produced by treating a stretchable fiber fabric for water repellency with a fluorinated water repellent that comprises a copolymer comprises a perfluoroalkyl group with six or less carbon atoms and applying a synthetic resin solution to at least one side of the stretchable fiber fabric to form a resin coating film that comprises a synthetic resin, wherein the stretchable fiber fabric treated for water repellency with the fluorinated water repellent has a toluene repellency of 100 seconds or longer, and the synthetic resin solution has a thixotropic index at 23° C. in a range from 1.4 to 2.0, and wherein the synthetic resin has a 100% modulus of 5 kgf/cm 2 or greater.
[0011] Preferably, the synthetic resin is at least one selected from acrylic resins, urethane resins, and silicone resins.
[0012] Preferably, the stretchable coated fabric has an initial water-repellency (JIS L1092) of a fourth grade or higher, and a water repellency after 20 washings of a third grade or higher.
[0013] Preferably, the stretchable coated fabric has a hydraulic resistance (JIS L1092 A Method) in a range from 100 to 3000 mmH 2 O and a moisture permeability of 3000 g/m 2 /24 hr or greater (JIS L1092 A-1 Method).
[0014] Preferably, the stretchable coated fabric has an air permeability of 6 cc/cm 2 /sec or less (JIS L1018 Frazier Method).
[0015] Preferably, the stretchable fiber fabric is a fabric knitted by a fine gauge knitting machine with 28 gauge or higher.
[0016] Preferably, the stretchable fiber fabric is a fabric that primarily comprises polyamide fibers and/or polyester fibers having a total fineness of 84 dtex or less, and that has a basis weight of 200 g/m 2 or less, a warp elongation (JIS L1096 A Method) at a load of 0.5 kgf of 45% or less, and a warp elongation at a load of 2.0 kgf of 75% or less.
[0017] In order to achieve the objective described above, a process for producing a stretchable coated fabric according to a second aspect of the present disclosure comprises
a step of preparing a stretchable fiber fabric treated for water repellency with a fluorinated water repellent that comprises a copolymer comprises a perfluoroalkyl group with six or less carbon atoms, and a step of applying a solution of a synthetic resin in a solvent to at least one side of the stretchable fiber fabric, wherein the fluorinated water repellent is used to impart a toluene repellency of 100 seconds or longer to the stretchable fabric, and the synthetic resin solution has a thixotropic index at 23° C. in a range from 1.4 to 2.0, and wherein the synthetic resin has a 100% modulus of 5 kgf/cm 2 or greater.
[0022] Preferably, the synthetic resin is at least one selected from acrylic resins, urethane resins, and silicone resins.
[0023] Preferably, the stretchable fiber fabric is a fabric knitted by a fine gauge knitting machine with 28 gauge or higher.
[0024] Preferably, the stretchable fiber fabric is a fabric that primarily comprises polyamide fibers and/or polyester fibers having a total fineness of 84 dtex or less and that has a basis weight of 200 g/m 2 or less, a warp elongation (JIS L1096 A Method) at a load of 0.5 kgf of 45% or less, and a warp elongation at a load of 2.0 kgf of 75% or less.
Advantageous Effects of Invention
[0025] The stretchable coated fabric according to the present disclosure is treated for water repellency with a fluorinated water repellent that comprises a copolymer comprises-a perfluoroalkyl group with six or less carbon atoms (C6 fluorinated water repellent). The use of no C8 fluorinated water repellents that contain perfluorooctanoic acid, perfluorooctane sulfonate, and the like makes the fabric environmentally friendly. And the stretchable fiber fabric treated for water repellency with a C6 fluorinated water repellent has a toluene repellency of 100 seconds or longer; the synthetic resin solution applied to at least one side of the stretchable fiber fabric has a thixotropic index at 23° C. in a range from 1.4 to 2.0; and the synthetic resin has a 100% modulus of 5 kgf/cm 2 or greater. This prevents the synthetic resin from leaking to the back side, and allows formation of a resin coating film that has good film forming properties. Consequently, a stretchable coated fabric that has excellent moisture permeability, excellent waterproofness, and excellent windproof property can be provided.
DESCRIPTION OF EMBODIMENTS
[0026] The stretchable coated fabric according to an embodiment of the present disclosure will be described in detail below. The stretchable coated fabric according to the embodiment is produced by treating a stretchable fiber fabric for water repellency with a C6 fluorinated water repellent and then applying a synthetic resin to at least one side of the stretchable fiber fabric.
[0027] (1) Stretchable Fiber Fabric
[0028] The stretchable fiber fabric used in the embodiment includes, for example, woven fabrics, knitted fabrics, nonwoven fabrics, and the like. Among them, knitted fabrics are preferred in terms of stretchability. Fiber materials include, for example, natural fibers such as cotton, hemp, wool, and silk, regenerated fibers such as rayon and cupra, semisynthetic fibers such as acetate and triacetate, and synthetic fibers such as polyamides (nylon 6, nylon 66, and the like), polyesters (polyethylene terephthalate, polytrimethylene terephthalate, and the like), polyurethanes, and polyacrylics. Two or more of these materials may be used in combination. Among them, synthetic fibers are preferred in terms of fiber physical properties, and especially, a fabric that comprises polyamide fibers and/or polyester fibers is preferred. It is preferred to combine these fibers with stretchable fibers such as polyurethane fibers to produce, for example, a woven fabric, because it allows for control of stretchability. Moreover, among the polyester fibers, cationic-dyeable polyester fibers are preferred to prevent migration and sublimation of dispersed dye.
[0029] Preferably, the yarns that constitute the stretchable fiber fabric have a total fineness of 84 dtex (decitex) or less. If the yarns used in the embodiment have a total fineness of greater than 84 dtex, the yarns produce a hard hand feeling. In addition, if the stretchable fiber fabric is, for example, a knitted fabric, such yarns produce large irregularities in the surface of the stretchable fiber fabric. Thus, the film-forming properties are reduced. As a result, the fabric may not provide physical properties such as hydraulic resistance and air permeability that are required after coating.
[0030] Preferably, the stretchable fiber fabric has a basis weight of 200 g/m 2 or less. If the stretchable fiber fabric has a basis weight of greater than 200 g/m 2 , such fabric provides a heavy garment. And the resulting garment tends to have a hard hand feeling.
[0031] Preferably, the stretchable fiber fabric has a warp elongation (JIS L1096 A Method) at a load of 0.5 kgf of 45% or less. Moreover, the stretchable fiber fabric preferably has a warp elongation at a load of 2.0 kgf of 75% or less. If the fabric has a warp elongation at a load of 0.5 kgf of more than 45% and a warp elongation at a load of 2.0 kgf of more than 75%, the fabric is excessively stretched in the warp direction. This results in a larger reduction in width in the weft direction, and thus the fabric may not provide physical properties such as hydraulic resistance and air permeability that are required after coating.
[0032] Preferably, the stretchable fiber fabric used in the embodiment is a fabric knitted by a fine gauge knitting machine with 28 gauge or higher. If the knitting machine has less than 28-gauge needles, the stretchable fiber fabric has a lower knit density, thereby reducing the film forming properties in coating the fabric. Thus, the fabric may not provide the necessary physical properties such as moisture permeability, hydraulic resistance and air permeability.
[0033] The stretchable fiber fabric may be dyed, where necessary. The stretchable fiber fabric may be, for example, treated for antistatic protection, treated for flame retardancy, and calendered.
[0034] (2) C6 Fluorinated Water Repellent
[0035] In the embodiment, the fabric is treated for water repellency before application of the synthetic resin. The water-repellent treatment not only improves waterproofness, but also inhibits the synthetic resin solution from deeply penetrating the fiber fabric. This allows prevention of a hard hand feeling of the stretchable fiber fabric and improvement in physical properties such as hydraulic resistance and air permeability.
[0036] A water repellent used in the embodiment is a fluorinated water repellent that comprises a copolymer comprises a perfluoroalkyl group with six or less carbon atoms (C6 fluorinated water repellent), because such repellent can impart high water repellency and is environmentally and biologically friendly. In the embodiment, the C6 fluorinated water repellent is preferably contained in an amount of 80-100% based on the overall water repellents used, and a paraffin-based water repellent and/or a silicone-based water repellent as another water-repellent may be contained in an amount of less than 20%.
[0037] Preferably, the water repellent used in the embodiment impart a toluene repellency of 100 seconds or longer to a fabric treated for water repellency when the repellent is combined with the stretchable fiber fabric used, as determined by a measurement method described below. If the fabric has a toluene repellency of less than 100 seconds, the resin more easily penetrates the stretchable fiber fabric. Thus, the resin leaks through the coated surface to the other side, and thus the fabric may not provide the necessary physical properties such as hydraulic resistance and air permeability.
[0038] The C6 fluorinated water repellent used in the present disclosure may be individually used, or two or more thereof may be used in combination, as long as performance requirements such as water repellency and oil-repellency are met depending on usage.
[0039] (3) Coating Resin
[0040] The synthetic resin solution used in the embodiment should have a thixotropic index at 23° C. in a range from 1.4 to 2.0. More preferably, the thixotropic index is in a range from 1.45 to 1.7. The term thixotropic index refers to a viscosity at a low rotation speed divided by a viscosity at a high rotation speed, as determined with a rotary viscometer at constant temperature. If the thixotropic index is less than 1.4, the synthetic resin that has been coated onto the fiber fabric to a desired thickness is flowable until the resin cures, and thus the fabric is unable to retain the coating film. If the thixotropic index is more than 2.0, the viscosity significantly changes relative to shear stress during coating, and thus there is difficulty in controlling the coating form.
[0041] During coating, the synthetic resin solution preferably has a viscosity at 23° C. in a range from 8000 to 25000 mPa·s, and more preferably in a range from 10000 to 20000 mPa·s. If the viscosity at 23° C. is less than 8000 mPa·s, the synthetic resin may deeply penetrate the fiber fabric and produce a hard hand feeling. And the synthetic resin solution may leak through the fiber fabric to the other side. On the other hand, if the viscosity at 23° C. is more than 25000 mPa·s, streaks and air bubbles are prone to be formed during coating. As a result, it becomes difficult to form a resin film, and thus sufficient hydraulic resistance and sufficient windproof property may not be provided.
[0042] Preferably, the synthetic resin used in the present disclosure has a 100% modulus of 5 kgf/cm 2 or greater. If the synthetic resin used has a 100% modulus of less than 5 kgf/cm 2 , it becomes difficult to form a continuous film during coating. The film may also have a reduced strength, and the necessary physical properties such as hydraulic resistance and air permeability may not be achieved. When considering use in a garment, the upper limit for the 100% modulus is preferably less than 60 kgf/cm 2 in order not to impair the hand feeling.
[0043] The synthetic resin used in the present disclosure can be at least one selected from acrylic resins, urethane resins, and silicone resins. Particularly, the acrylic resins and the urethane resins can be preferably used, because these resins can provide the necessary film strength.
[0044] These synthetic resins alone may not be able to provide the necessary moisture permeability and the necessary air permeability. In this case, a pigment for coloration can be added into these synthetic resins, to the extent that the pigment does not impair the physical properties. To improve the moisture permeability and the hand feeling of the surface, inorganic/organic particulates can be added. A crosslinking agent, an antibacterial agent, and/or the like can be added to improve the film strength.
[0045] For example, to improve the moisture permeability and the air permeability, the synthetic resin is used in an amount of 70% by weight or more, and 30% by weight or less of inorganic particulates having an average particle size from 0.2 to 20 μm and an appropriate amount of water are admixed into the synthetic resin. This allows achievement of the necessary moisture permeability and the necessary air permeability. If a coating resin contains the synthetic resin in an amount of less than 70% by weight and inorganic particulates having an average particle size from 0.2 μm to 20 μm in an amount of more than 30% by weight, the resulting synthetic resin film has a reduced strength, which is not preferred. If the inorganic particulates added have an average particle size from 0.2 μm to 20 μm, the necessary hydraulic resistance, the necessary moisture permeability, and the necessary air permeability can be controlled, and the synthetic resin film does not have a significantly reduced strength. If the inorganic particulates added have an average particle size of more than 20 μm, the film strength is reduced, which is not preferred. If the inorganic particulates added have an average particle size of less than 0.2 μm, the necessary hydraulic resistance, the necessary moisture permeability, and the necessary air permeability may not be able to be controlled.
[0046] (4) Coating Pretreatment (Water-Repellent Treatment)
[0047] The stretchable fiber fabric used in the embodiment is previously scoured and dyed according to routine procedures, and then treated, as normally, for water repellency with a C6 fluorinated water repellent as a pretreatment prior to coating. As the treatment process, a padding process, a coating process, a gravure coating process, a spraying process, or the like can be employed.
[0048] The C6 fluorinated water repellent alone may not impart wash resistance to the water repellency, and thus it is preferred to add a melamine or isocyanate crosslinking agent, a crosslinking catalyst, and/or the like, when the fabric is treated for water repellency. Moreover, an antistatic agent, a sewability enhancer, and/or the like also may be added, where necessary. Before or after the treatment for water repellency, the fabric may also be calendered, where necessary.
[0049] If it is additionally desired to improve the tear strength, the hand feeling, the smoothness, and/or the like of the coated fabric, a mixed aqueous dispersion of an emulsion of a fluorinated water repellent and an emulsion of polyethylen may be used as a water repellent. In addition to the dispersion, use of a silicone resin, a lubricant, and/or the like, for example, can further improve the hand feeling, the smoothness, and the like.
[0050] (5) Coating Process
[0051] Preferably, a process for coating at least one side of the stretchable fiber fabric with the synthetic resin in the embodiment is a common knife coating process. A known coating device such as a floating knife coater or a knife over roll coater can be used to coat at least one side of the stretchable fiber fabric with the synthetic resin. After coating, the fabric is preferably dried in a common hot air dryer at a temperature from 100 to 120° C. for 1 to 5 minutes.
[0052] In the embodiment, the coating resin is preferably applied in an amount so that the resin solids present in an amount from 12 to 25 g/m 2 . If the resin solids present in an amount of less than 12 g/m 2 , the fabric is less likely to provide the necessary physical properties such as hydraulic resistance and air permeability. On the other hand, if the resin solids present in an amount of more than 25 g/m 2 , the fabric tends to have a hard hand feeling.
[0053] (6) Stretchable Coated Fabric
[0054] Preferably, the stretchable coated fabric in the embodiment has an initial water-repellency (JIS L1092) of a fourth grade or higher and a water repellency after 20 washings of a third grade or higher. And the stretchable coated fabric preferably has a hydraulic resistance (JIS L1092 A Method) in a range from 100 to 3000 mmH 2 O. Particularly, the stretchable coated fabric for outdoor and sports applications preferably has a hydraulic resistance of 300 mmH 2 O or higher.
[0055] Preferably, the stretchable coated fabric in the embodiment has a moisture permeability (JIS L1092 A-1 Method) of 3000 g/m 2 /24 hr or greater. If the stretchable coated fabric has a moisture permeability of less than 3000 g/m 2 /24 hr, the fabric becomes stuffy when worn as a garment, which may bring about a discomfort.
[0056] Preferably, the stretchable coated fabric in the embodiment has an air permeability of 6 cc/cm 2 /sec or less (JIS L1018 Frazier Method). Typically, if the air permeability is 20 cc/cm 2 /sec or less, the fabric can be used as a common windproof material. However, when a stretchable coated fabric is stretched in the warp or weft direction, the fabric tends to exhibit a rapid increase in air permeability. Thus, a stretchable coated fabric is required to have a smaller air permeability. And recently, some applications have required a smaller air permeability. For example, knitted materials are increasingly used for down garments, and a stretchable coated fabric in such application preferably has an air permeability from 1 to 3 cc/cm 2 /sec or less. When a stretchable coated fabric is used for sport applications and/or the like, the stretchable coated fabric having an air permeability of more than 6 cc/cm 2 /sec cannot provide sufficient windproofness, when worn as a sports garment.
[0057] When the stretchable coated fabric with only one side coated in the embodiment is used as a garment, the uncoated side or the coated side may be used as the outer surface. Typically, the uncoated side is used as the outer surface for water repellency, although the coated side may be used as the outer surface. In the latter case, however, the water repellency is reduced due to the coating resin film, which is not preferred.
EXAMPLES
[0058] Now, the present disclosure will be described more specifically with reference to Examples, although the present disclosure is not limited in any way to Examples described below.
[0059] As described below, stretchable coated fabrics according to Examples 1-5 of the present disclosure were produced to evaluate their performance. And for comparison, stretchable coated fabrics of Comparative Examples 1-4 were produced to evaluate their performance.
[0060] In Examples and Comparative Examples, measurement of various physical property values and evaluation of the performance of the stretchable coated fabrics were done as follows.
[0061] (1) Thixotropic Index
[0062] The thixotropic index of the synthetic resin solutions is a ratio of a viscosity at a rotation speed of 6 rpm to a viscosity at a rotation speed of 30 rpm, as determined at 23° C. with a Brookfield-type (BM-type) viscometer from Toki Sangyo Co., Ltd. with a No. 4 spindle (without guard), and is represented by a general formula (A):
[0000] Thixotropic Index=Viscosity(6 rpm)/Viscosity(30 rpm) (A)
[0063] (2) Viscosity of Synthetic Resin Solution
[0064] The viscosity of the synthetic resin solutions is a viscosity at a rotation speed 12 rpm at 23° C., as determined with a Brookfield-type (BM-type) viscometer from Toki Sangyo Co., Ltd. with a No. 4 spindle (without guard).
[0065] (3) 100% Modulus of Synthetic Resin
[0066] The term modulus refers to the stress required to stretch a test specimen to a given elongation, and was measured as described below. A crosslinking agent for the coating resin composition was added to a synthetic resin to be measured, and then a diluting solvent for the coating resin composition was added to dilute the synthetic resin solution so that the resin solution had a viscosity from 3000 to 5000 mPa·s at room temperature. The synthetic resin solution was injected into a mold to form a resin film having a thickness of about 0.2 mm, and then dried at ambient temperature. After drying, the film was treated with heat at 150° C. for 3 minutes to cure the film. In this way, a sheet of the synthetic resin was prepared and cut with a dumbbell-shaped die to produce a No. 2 tensile test specimen according to JIS. Then, the sheet thickness of the synthetic resin was measured. A 1 cm bench mark was drawn on the section having a dumbbell width of 1 cm. At a temperature of 23° C., the specimen was stretched at a rate of 200 mm/min until the longitudinal length of the mark was 2 cm to measure the 100% modulus.
[0067] (4) Method for Evaluating Toluene Repellency
[0068] Toluene as an organic solvent was added dropwise via syringe onto a stretchable fiber fabric treated for water repellency to form a droplet having a diameter of 5 mm, and then the time for the toluene to completely penetrate the fabric was measured.
[0069] (5) Warp Elongation of Fiber Fabric (JIS L1096 A Method)
[0070] Measurement was made with a specimen having a width of 5 cm, a grip distance of 20 cm, a tensile speed of 200 mm/min, and a load of 0.5 kgf and 2.0 kgf.
[0071] (6) Water Repellency
[0072] Measurement was made according to the spraying method of JIS L1092.
[0073] (7) Hydraulic Resistance
[0074] Measurement was made according to the low water-pressure method of JIS L1092 A.
[0075] (8) Moisture Permeability
[0076] Measurement was made according to JIS L1092 A-1 Method (calcium chloride method).
[0077] (9) Air Permeability
[0078] Measurement was made according to the Frazier method of JIS L1018.
[0079] (10) Hand Feeling
[0080] The hand feeling of a specimen was evaluated according to the following criteria.
Very good: Very soft Good: Soft Slightly bad: Slightly hard Bad: Hard
[0085] (11) Quality of Coated Surface
[0086] The quality of the coated surface was evaluated by observing the resin film covering the coated surface according to the following criteria.
[0087] Good: The coating resin does not significantly penetrate the fabric, and the resin film covers the coated surface of the fabric.
[0088] Not bad: The coating resin slightly penetrates the fabric, although the resin film almost covers the coated surface of the fabric.
[0089] Bad: The coating resin mostly penetrates the fabric, and little resin film is formed on the coated surface.
Example 1
[0090] A 33 dtex/36 filament polyester yarn was used to knit an interlock knitted fabric by a 40 gauge flat knitting machine. Then, the fabric was scoured and dyed according to routine procedures. The knitted fabric dyed had a basis weight of 74 g/m 2 . The knitted fabric had a warp elongation at a load of 0.5 kgf of 8.6% and a warp elongation at a load of 2.0 kgf of 24.9%.
[0091] Next, the knitted fabric produced above was immersed in an aqueous solution containing two types of C6 fluorinated water repellents as described in Composition 1. The fabric was wrung out by a mangle (to a wet pick-up of 55% by weight), dried at 120° C. for 60 seconds, and then treated with heat at 160° C. for 60 seconds for water repellency. After the water-repellent treatment, the toluene repellency of the water-repellent fabric was measured to be 153 seconds.
[0092] <Composition 1>
[0000]
1) NUVA 2114 LIQ
3.0%
by weight
(C6 fluorinated water repellent
from Clariant (Japan) Co., Ltd.)
2) ARKOPHOB NANO 2605 LIQ
3.0%
by weight
(C6 fluorinated water repellent from
Clariant (Japan) Co., Ltd.)
3) NICEPOLE FE-26
0.5%
by weight
(Antistatic agent from Nicca
Chemical Co., Ltd.)
4) MEIKANATE TP 10
0.5%
by weight
(Isocyanate crosslinking agent from
Meisei Chemical Works, Ltd.)
5) Isopropyl alcohol
3.0%
by weight
(Penetration enhancer)
6) Water
90.0%
by weight
[0093] Next, a synthetic resin solution as described in Composition 2 was applied by a floating knife coating process using a knife coater. The solution was applied to the knitted fabric in an amount so that the resin solids present in an amount of 16 g/m 2 , and then treated with heat at 120° C. for a minute. Then, the fabric was heat-set at 150° C. to give a stretchable coated fabric of Example 1. The stretchable coated fabric had a basis weight of 90 g/m 2 .
[0094] <Composition 2>
[0000]
1) XE-5573
100.0
parts by weight
(Acrylic resin solution (having a 100% modulus
of 9 kgf/cm 2 ) from Tohpe Corp.)
2) RESAMINE UD crosslinking agent
2.0
parts by weight
(Urethane crosslinking agent from Dainichiseika
Color & Chemicals Mfg. Co., Ltd.)
3) Toluene
17.0
parts by weight
(Diluting solvent)
[0095] The synthetic resin solution had a viscosity of 15900 mPa·s (as determined with a Brookfield-type (BM-type) viscometer) and a thixotropic index at 23° C. of 1.44.
[0096] When the resulting stretchable coated fabric was measured for physical properties and the like, the fabric had an air permeability of 1 cc/cm 2 /sec, a hydraulic resistance of 300 mmH 2 O, a moisture permeability of 6568 g/m 2 /24 hr, an initial water repellency of a fourth grade, and a water repellency after 20 washings of a third grade. And the stretchable coated fabric had a soft hand feel. When the quality of the coated surface was observed, the coating resin did not significantly penetrate the fabric, and the resin film covered the coated surface of the fabric.
Example 2
[0097] A 22 dtex/24 filament polyester yarn was used to knit an interlock knitted fabric by a 40 gauge flat knitting machine. Then, the fabric was scoured and dyed according to routine procedures. The knitted fabric dyed had a basis weight of 55 g/m 2 . The knitted fabric had a warp elongation at a load of 0.5 kgf of 9.6% and a warp elongation at a load of 2.0 kgf of 23.0%.
[0098] Next, the knitted fabric produced above was immersed in an aqueous solution containing two types of C6 fluorinated water repellents as described above in Composition 1. The fabric was wrung out by a mangle (to a wet pick-up of 53% by weight), dried at 120° C. for 60 seconds, and then treated with heat at 160° C. for 60 seconds for water repellency. After the water-repellent treatment, the toluene repellency of the water-repellent fabric was measured to be 144 seconds.
[0099] Next, the synthetic resin solution as described above in Composition 2 was applied by a floating knife coating process using a knife coater. The solution was applied to the knitted fabric in an amount so that the resin solids present in an amount of 16 g/m 2 , and then treated with heat at 120° C. for a minute. Then, the fabric was heat-set at 150° C. to give a stretchable coated fabric of Example 2. The stretchable coated fabric had a basis weight of 71 g/m 2 .
[0100] When the resulting stretchable coated fabric was measured for physical properties and the like, the fabric had an air permeability of 1 cc/cm 2 /sec, a hydraulic resistance of 220 mmH 2 O, a water-vapor permeability of 8384 g/m 2 /24 hr, an initial water repellency of a fourth grade, and a water repellency after 20 washings of a third grade. And the stretchable coated fabric had a soft hand feel. When the quality of the coated surface was observed, the coating resin did not significantly penetrate the fabric, and the resin film covered the coated surface of the fabric.
Example 3
[0101] A 56 dtex/48 filament 6 nylon yarn was used to knit a 32 gauge tricot knitted fabric. Then, the fabric was scoured and dyed according to routine procedures. The knitted fabric dyed had a basis weight of 178 g/m 2 . The knitted fabric had a warp elongation at a load of 0.5 kgf of 8.2% and a warp elongation at a load of 2.0 kgf of 19.3%.
[0102] Next, the knitted fabric produced above was immersed in an aqueous solution containing two types of C6 fluorinated water repellents having different performance characteristics as described above in Composition 1. The fabric was wrung out by a mangle (to a wet pick-up of 56% by weight), dried at 120° C. for 60 seconds, and then treated with heat at 160° C. for 60 seconds for water repellency. After the water-repellent treatment, the toluene repellency of the water-repellent fabric was measured to be 174 seconds.
[0103] Next, the synthetic resin solution as described above in Composition 2 was applied by a floating knife coating process using a knife coater. The solution was applied to the knitted fabric in an amount so that the resin solids present in an amount of 16 g/m 2 , and then treated with heat at 120° C. for a minute. Then, the fabric was heat-set at 150° C. to give a stretchable coated fabric of Example 3. The stretchable coated fabric had a basis weight of 194 g/m 2 .
[0104] When the resulting stretchable coated fabric was measured for physical properties and the like, the fabric had an air permeability of 3 cc/cm 2 /sec, a hydraulic resistance of 180 mmH 2 O, a moisture permeability of 7240 g/m 2 /24 hr, an initial water repellency of a fourth grade, and a water repellency after 20 washings of a third grade. And the stretchable coated fabric had a soft hand feel. When the quality of the coated surface was observed, the coating resin did not significantly penetrate the fabric, and the resin film covered the coated surface of the fabric.
Example 4
[0105] An 84 dtex/72 filament polyester yarn was used to knit an interlock knitted fabric by a 28 gauge flat knitting machine. Then, the fabric was scoured and dyed according to routine procedures. The knitted fabric dyed had a basis weight of 188 g/m 2 . The knitted fabric had a warp elongation at a load of 0.5 kgf of 5.3% and a warp elongation at a load of 2.0 kgf of 10.5%.
[0106] Next, the knitted fabric produced above was immersed in an aqueous solution containing two types of C6 fluorinated water repellents having different performance characteristics as described above in Composition 1. The fabric was wrung out by a mangle (to a wet pick-up of 54% by weight), dried at 120° C. for 60 seconds, and then treated with heat at 160° C. for 60 seconds for water repellency. After the water-repellent treatment, the toluene repellency of the water-repellent fabric was measured to be 163 seconds.
[0107] Next, the synthetic resin solution as described above in Composition 2 was applied by a floating knife coating process using a knife coater. The solution was applied to the knitted fabric in an amount so that the resin solids present in an amount of 16 g/m 2 , and then treated with heat at 120° C. for a minute. Then, the fabric was heat-set at 150° C. to give a stretchable coated fabric of Example 4. The stretchable coated fabric had a basis weight of 204 g/m 2 .
[0108] When the resulting stretchable coated fabric was measured for physical properties and the like, the fabric had an air permeability of 1 cc/cm 2 /sec, a hydraulic resistance of 220 mmH 2 O, a moisture permeability of 8453 g/m 2 /24 hr, an initial water repellency of a fourth grade, and a water repellency after 20 washings of a third grade. And the stretchable coated fabric had a soft hand feel. When the quality of the coated surface was observed, the coating resin did not significantly penetrate the fabric, and the resin film covered the coated surface of the fabric.
Example 5
[0109] To a water-repellent knitted fabric as used in Example 1, a synthetic resin solution as described in Composition 3 was applied by a floating knife coating process using a knife coater. The solution was applied to the knitted fabric in an amount so that the resin solids present in an amount of 19 g/m 2 , and then treated with heat at 120° C. for a minute. Then, the fabric was heat-set at 150° C. to give a stretchable coated fabric of Example 5. The stretchable coated fabric had a basis weight of 93 g/m 2 .
[0110] <Composition 3>
[0000]
1) XE-5573
100.0
parts by weight
(Acrylic resin solution (having a 100% modulus
of 9 kgf/cm 2 ) from Tohpe Corp.)
2) RESAMINE UD crosslinking agent
2.0
parts by weight
(Urethane crosslinking agent from Dainichiseika
Color & Chemicals Mfg. Co., Ltd.)
3) Toluene
6.0
parts by weight
(Diluting solvent)
[0111] The synthetic resin solution had a viscosity of 24800 mPa·s (as determined with a Brookfield-type (BM-type) viscometer) and a thixotropic index at 23° C. of 1.69.
[0112] When the resulting stretchable coated fabric was measured for physical properties and the like, the fabric had an air permeability of 0.5 cc/cm 2 /sec, a hydraulic resistance of 360 mmH 2 O, a moisture permeability of 6165 g/m 2 /24 hr, an initial water repellency of a fourth grade, and a water repellency after 20 washings of a third grade. The stretchable coated fabric had a soft hand feel. When the quality of the coated surface was observed, the coating resin did not significantly penetrate the fabric, and the resin film covered the coated surface of the fabric.
Comparative Example 1
[0113] To a water-repellent knitted fabric as used in Example 1, a synthetic resin solution as described in Composition 4 was applied by a floating knife coating process using a knife coater. The solution was applied to the knitted fabric in an amount so that the resin solids present in an amount of 18 g/m 2 , and then treated with heat at 120° C. for a minute. Then, the fabric was heat-set at 150° C. to give a stretchable coated fabric of Comparative Example 1. The stretchable coated fabric had a basis weight of 92 g/m 2 .
[0114] <Composition 4>
[0000]
1) SA-6218
100.0
parts by weight
(Acrylic resin solution (having a 100% modulus
of 4 kgf/cm 2 ) from Tohpe Corp.)
2) RESAMINE UD crosslinking agent
2.0
parts by weight
(Urethane crosslinking agent from Dainichiseika
Color & Chemicals Mfg. Co., Ltd.)
3) Toluene
8.0
parts by weight
(Diluting solvent)
[0115] The synthetic resin solution had a viscosity of 15500 mPa·s (as determined with a Brookfield-type (BM-type) viscometer) and a thixotropic index at 23° C. of 1.32.
[0116] When the resulting stretchable coated fabric was measured for physical properties and the like, the fabric had an air permeability of 12 cc/cm 2 /sec, a hydraulic resistance of 90 mmH 2 O, a moisture permeability of 8965 g/m 2 /24 hr, an initial water repellency of a fourth grade, and a water repellency after 20 washings of a third grade. And the stretchable coated fabric had a slightly hard hand feel. When the quality of the coated surface was observed, the coating resin slightly penetrated the fabric, although the resin film almost covered the coated surface of the fabric.
Comparative Example 2
[0117] A water-repellent fabric as used in Comparative Example 1 was treated for water repellency with a C8 fluorinated water repellent as described below in Composition 5. Then, the synthetic resin solution as described in Composition 4 was applied by a floating knife coating process using a knife coater. The solution was applied to the knitted fabric in an amount so that the resin solids present in an amount of 16 g/m 2 , and then treated with heat at 120° C. for a minute. Then, the fabric was heat-set at 150° C. to give a stretchable coated fabric of Comparative Example 2. When the toluene repellency of the water-repellent fabric was measured prior to the coating, the toluene did not penetrate the fabric for 600 seconds or longer. The stretchable coated fabric had a basis weight of 90 g/m 2 .
[0118] <Composition 5>
[0000]
1) AG-7000
6.0%
by weight
(C8 fluorinated water repellent
from Asahi Glass Co., Ltd.)
2) NICEPOLE FE-26
0.5%
by weight
(Antistatic agent from Nicca Chemical Co., Ltd.)
3) MEIKANATE TP 10
0.5%
by weight
(Isocyanate crosslinking agent from Meisei
Chemical Works, Ltd.)
4) Isopropyl alcohol
3.0%
by weight
(Penetration enhancer)
5) Water
90.0%
by weight
[0119] When the resulting stretchable coated fabric was measured for physical properties and the like, the fabric had an air permeability of 0.5 cc/cm 2 /sec, a hydraulic resistance of 300 mmH 2 O, a moisture permeability of 6350 g/m 2 /24 hr, an initial water repellency of a fourth-to-fifth grade, and a water repellency after 20 washings of a fourth grade. And the stretchable coated fabric had a soft hand feel. When the quality of the coated surface was observed, the coating resin did not significantly penetrate the fabric, and the resin film covered the coated surface of the fabric. According to the above, the fabric treated with the C8 fluorinated water repellent had good physical properties.
Comparative Example 3
[0120] To a water-repellent knitted fabric as used in Example 1, a synthetic resin solution as described in Composition 6 was applied by a floating knife coating process using a knife coater. The solution was applied to the knitted fabric in an amount so that the resin solids present in an amount of 16 g/m 2 , and then treated with heat at 120° C. for a minute. Then, the fabric was heat-set at 150° C. to give a stretchable coated fabric of Comparative Example 3. The stretchable coated fabric had a basis weight of 90 g/m 2 .
[0121] <Composition 6>
[0000]
1) SA-6218
100.0
parts by weight
(Acrylic resin solution (having a 100% modulus
of 4 kgf/cm 2 ) from Tohpe Corp.)
2) RESAMINE UD crosslinking agent
2.0
parts by weight
(Urethane crosslinking agent from Dainichiseika
Color & Chemicals Mfg. Co., Ltd.)
3) Toluene
2.0
parts by weight
(Diluting solvent)
[0122] The synthetic resin solution had a viscosity of 19400 mPa·s (as determined with a Brookfield-type (BM-type) viscometer) and a thixotropic index at 23° C. of 1.42.
[0123] When the resulting stretchable coated fabric was measured for physical properties and the like, the fabric had an air permeability of 8 cc/cm 2 /sec, a hydraulic resistance of 140 mmH 2 O, a moisture permeability of 7920 g/m 2 /24 hr, an initial water repellency of a fourth grade, and a water repellency after 20 washings of a third grade. And the stretchable coated fabric had a slightly hard hand feel. When the quality of the coated surface was observed, the coating resin slightly penetrated the fabric, although the resin film almost covered the coated surface of the fabric.
Comparative Example 4
[0124] A knitted fabric as used in Example 2 was immersed in an aqueous solution containing a single type of a C6 fluorinated water repellent as described in Composition 7. The fabric was wrung out by a mangle (to a wet pick-up of 53% by weight), dried at 120° C. for 60 seconds, and then treated with heat at 160° C. for 60 seconds for water repellency. After the water-repellent treatment, the toluene repellency of the water-repellent fabric was measured to be 36 seconds.
[0125] <Composition 7>
[0000]
1) NUVA 2114 LIQ
6.0%
by weight
(C6 fluorinated water repellent from
Clariant (Japan) K.K.)
2) NICEPOLE FE-26
0.5%
by weight
(Antistatic agent from Nicca Chemical Co., Ltd.)
3) MEIKANATE TP 10
0.5%
by weight
(Isocyanate crosslinking agent from Meisei
Chemical Works, Ltd.)
4) Isopropyl alcohol
3.0%
by weight
(Penetration enhancer)
5) Water
90.0%
by weight
[0126] Next, the synthetic resin solution as described above in Composition 2 was applied by a floating knife coating process using a knife coater. The solution was applied to the knitted fabric in an amount so that the resin solids present in an amount of 17 g/m 2 , and then treated with heat at 120° C. for a minute. Then, the fabric was heat-set at 150° C. to give a stretchable coated fabric of Comparative Example 4. The stretchable coated fabric had a basis weight of 72 g/m 2 .
[0127] When the resulting stretchable coated fabric was measured for physical properties and the like, the fabric had an air permeability of 10 cc/cm 2 /sec, a hydraulic resistance of 80 mmH 2 O, a moisture permeability of 7453 g/m 2 /24 hr, an initial water repellency of a fourth grade, and a water repellency after 20 washings of a third grade. The stretchable coated fabric had a hard hand feel. When the quality of the coated surface was observed, the coating resin slightly penetrated the fabric, although the resin film almost covered the coated surface of the fabric.
[0128] The results of Examples 1-5 described above are summarized in Table 1. The results of Comparative Examples 1-4 are summarized in Table 2.
[0000]
TABLE 1
Example 1
Example 2
Example 3
Example 4
Example 5
Fabric Fiber
33 dtex
22 dtex
56 dtex
84 dtex
33 dtex
polyester
polyester
nylon
polyester
polyester
Knit Gauge
40
40
32
28
40
Fabric Basis Weight
74
55
178
188
74
Water Repellent
C6 Water
C6 Water
C6 Water
C6 Water
C6 Water
Repellent
Repellent
Repellent
Repellent
Repellent
Toluene Repellency (Sec)
153
144
174
163
153
Warp
0.5 kg
8.6
9.6
8.2
5.3
8.6
Elongation
2.0 kg
24.9
23.0
19.3
10.5
24.9
(%)
Resin Type
Acrylic
Acrylic
Acrylic
Acrylic
Acrylic
100% Modulus
9
9
9
9
9
Thixotropic Index of
1.44
1.44
1.44
1.44
1.69
Coating Resin
Air Permeability
1
1
3
1
0.5
Hydraulic Resistance
300
220
180
220
360
Moisture Permeability
6568
8384
7240
8453
6165
Water
Initial
4th grade
4th grade
4th grade
4th grade
4th grade
Repellency
After 20
3rd grade
3rd grade
3rd grade
3rd grade
3rd grade
Washings
Hand Feeling
Good
Good
Good
Good
Good
Quality of Coated Surface
Good
Good
Good
Good
Good
[0000]
TABLE 2
Comparative
Comparative
Comparative
Comparative
Example 1
Example 2
Example 3
Example 4
Fabric Fiber
33 dtex
33 dtex
33 dtex
22 dtex
polyester
polyester
polyester
polyester
Knit Gauge
40
40
40
40
Fabric Basis Weight
74
74
74
55
Water Repellent
C6 Water
C8 Water
C6 Water
C6 Water
Repellent
Repellent
Repellent
Repellent
Toluene Repellency (Sec)
153
600 or longer
153
36
Warp Elongation (%)
8.6
8.6
8.6
8.6
9.6
24.9
24.9
24.9
24.9
23.0
Resin Type
Acrylic
Acrylic
Acrylic
Acrylic
100% Modulus
4
4
4
9
Thixotropic Index of Coating Resin
1.32
1.32
1.42
1.44
Air Permeability
12
0.5
8
10
Hydraulic Resistance
90
300
140
80
Moisture Permeability
8965
6350
7920
7453
Water
Initial
4th grade
4th-5th grade
4th grade
4th grade
Repellency
After 20
3rd grade
4th grade
3rd grade
3rd grade
Washings
Hand Feeling
Slightly bad
Good
Slightly bad
Slightly bad
Quality of Coated Surface
Not bad
Good
Not bad
Not bad
[0129] As shown in Table 1, all of the stretchable coated fabrics according to Examples 1-5 met the requirements that a fluorinated water repellent should have a toluene repellency of 100 seconds or longer and that a synthetic resin (coating resin) should have an thixotropic index at 23° C. in a range from 1.4 to 2.0 and a 100% modulus of 5 kgr/cm 2 or greater. Consequently, the fabrics had a small air permeability of 3 cc/cm 2 /sec or less and thus had sufficient windproof property. The fabrics also had a high hydraulic resistance of 180 mmH 2 O or higher and a high — moisture permeability of 6165 g/m 2 /24 hr or greater, and thus had sufficient moisture permeability and waterproofness.
[0130] And the fabrics had an initial water repellency of a fourth grade and a water repellency after 20 washings of a third grade, which were sufficient. The fabrics also had a soft hand feeling and a good quality of the coated surface, as their resin film almost covered the coated surface of the fabric.
[0131] In contrast, as shown in Table 2, the synthetic resin (coating resin) of the stretchable coated fabric of Comparative Example 1 had a thixotropic index at 23° C. of 1.32, which did not meet the requirement in a range from 1.4 to 2.0, a 100% modulus of 4 kgf/cm 2 , which did not meet the requirement of 5 kgf/cm 2 or greater. Consequently, the fabric had a large air permeability of 12 cc/cm 2 /sec and thus had insufficient windproof property. The fabric also had a low hydraulic resistance of 90 mmH 2 O, and thus the waterproofness was problematic. And the fabric had a hard hand feeling, and the quality of the coated surface was problematic.
[0132] As shown in Table 2, the stretchable coated fabric of Comparative Example 2 had no problem with the air permeability, the hydraulic resistance, the moisture permeability, the hand feeling, and the quality of the coated surface, although the fabric did not solve the environmentally sensitive problem, as the fabric uses a C8 fluorinated water repellent instead of a C6 fluorinated water repellent.
[0133] As shown in Table 2, the synthetic resin (coating resin) of the stretchable coated fabric of Comparative Example 3 had a thixotropic index at 23° C. of 1.42, which met the requirement in a range from 1.4 to 2.0, and a 100% modulus of 4 kgf/cm 2 , which did not meet the requirement of 5 kgf/cm 2 or greater. Consequently, the fabric had a high air permeability of 8 cc/cm 2 /sec and thus had insufficient windproof property. The fabric also had a slightly insufficient hydraulic resistance of 140 mmH 2 O or higher. And the fabric also had a problem with the hand feel and the quality of the coated surface.
[0134] As shown in Table 2, the synthetic resin (coating resin) of the stretchable coated fabric of Comparative Example 4 had a thixotropic index at 23° C. of 1.44, which met the requirement in a range from 1.4 to 2.0, and a 100% modulus of 9 kgf/cm 2 , which met the requirement of 5 kgf/cm 2 or greater. However, the fluorinated water repellent had a small toluene repellency of 36 seconds, which did not meet the requirement of 100 seconds or longer. Consequently, the fabric had a large air permeability of 10 cc/cm 2 /sec and thus had insufficient windproof property. The fabric also had an insufficient hydraulic resistance of 80 mmH 2 O or higher. And the fabric had a problem with the hand feel and the quality of the coated surface.
[0135] As shown in Table 1, the synthetic resin (coating resin) of the stretchable coated fabric of Example 5 had a thixotropic index at 23° C. of 1.69, which was larger than the thixotropic index of 1.44 of the stretchable coated fabrics of Examples 1-4. Thus, the fabric had a smaller air permeability of 0.5 cc/cm 2 /sec and thus had particularly good_windproof property. The fabric also had a larger hydraulic resistance of 360 mmH 2 O and thus had good waterproofness.
[0136] As described above, the stretchable coated fabrics according to the embodiment and Examples have good water-vapor permeability, good waterproofness, and good windproofness. Thus, the fabrics are favorably used for outdoor and sports applications in the garment field.
[0137] Various embodiments and modifications can be made without departing from the broad spirit and scope of the present disclosure. The embodiment and Examples described above are presented for illustration of the present disclosure and do not limit the scope of the present disclosure.
[0138] The present application is based on Japanese Patent Application No. 2012-132309 filed on Jun. 11, 2012. This application claims the benefit of Japanese Patent Application No. 2012-132309, filed on Jun. 11, 2012, the entire disclosure of which is incorporated by reference herein.
INDUSTRIAL APPLICABILITY
[0139] The stretchable coated fabric according to the present disclosure is suitable for a garment fabric used for outdoor and sports applications.
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A stretchable coated fabric is treated for water repellency with a fluorinated water repellent that comprises a copolymer containing a perfluoroalkyl group with six or less carbon atoms (C6 fluorinated water repellent). The use of no C8 fluorinated water repellents that contain perfluorooctanoic acid, perfluorooctane sulfonate, and the like makes the fabric exerts no influence on the environment. And the fluorinated water repellent has a toluene repellency of 100 seconds or longer; a synthetic resin solution applied to at least one side of the stretchable fiber fabric has a thixotropic index at 23° C. in a range from 1.4 to 2.0; and the synthetic resin has a 100% modulus of 5 kgf/cm 2 or greater. This prevents the synthetic resin from leaking to the back side and allows formation of a resin coating film that has good film forming properties.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. §119(e) from U.S. Provisional Patent application No.60/331,684 filed on Nov. 19, 2001, and which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a lipstick composition, and more particularly to a lipstick composition that imparts a beneficial moisturizing effect, is easily applied on the lips, spreads smoothly and imparts increased cushion and improved lip comfort.
BACKGROUND OF INVENTION
[0003] Lip appearance has been enhanced by the use of colorants since antiquity. Artifacts from early Egyptian, Babylonian and Sumerian civilizations disclose that women in these societies painted their lips with mixtures of hematite and red ochre in animal fat or vegetable oil. Lip cosmetics were used by Syrians, Persians, Greeks and Romans for aesthetic, medical or ritualistic purposes.
[0004] Lipsticks have been used for many years to accentuate the positive aspects of the wearer's lips. Lipsticks are capable of altering the apparent facial characteristics of the wearer; narrow lips may be widened and broad lips narrowed. Besides altering the shape of the lips, lipsticks can be made in a great number of colors and shades to promote a desired effect or express the mood of the wearer.
[0005] Color imparted to the lips helps to define the mouth area while imparting cosmetic shades that are suitable with fashion trends. The color is ordinarily provided by insoluble pigments such as lakes of dye finely dispersed in the oily vehicle and one or more fluorescein dye derivatives that serve to stain the lips. When dyes are used, a solvent for the dye is also included for increasing the effectiveness of this staining on the lips.
[0006] Lipsticks, in general, are made of an oily vehicle comprising fat or oil stiffened to a desired consistency with waxes of various types, which serve to raise the melting point and improve the physical stability. Modem lipsticks comprise a base of oil and wax and one or several dissolved or suspended colorants. These lipstick formulations first appeared in the early years of the twentieth century. Carmine was the original lip colorant of choice replaced in the late 1920s by eosin. Later fluorescein-based stains followed, until today a plethora of colors and finishes are available, ranging from opaque full-coverage lipsticks to sheer or colorless lip glosses, all available in a choice of stick or paint vehicles.
[0007] Contemporary lipsticks may be classified by primary colorant (stain or pigment), appearance (cream or pearl) or finish on lips (matte or glossy). Lipstick wax bases may also be categorized by chemical class (organic, silicone), source (natural, synthetic), function (moisturizing, contouring) and so on.
[0008] Molded lipsticks comprise a solid fatty base containing dissolved and suspended dyes, preservatives and fragrance in admixture with cosmetically acceptable waxes, oils, solids and semisolids. Waxy and oily materials are included in lipsticks to give the lips a moist and alluring look. Several of the most important materials used in lipstick compositions are cosmetic waxes such as beeswax, Candelilla wax, Carnauba wax and ozokerite and cosmetic oils such as castor oil and lanolin. Beeswax adds binding and molding properties to lipstick, Candellila wax gives lipstick hardness, rigidity and high gloss and Carnauba wax and ozokerite give molded lipstick toughness; castor oil is a solvent for the dyes and functions as an emollient and lanolin aids in maintaining homogeneity during manufacturing as well as serving as an emollient. Emollients provide a supple and pleasant feeling to the lips of the wearer. Dyes, preservative and fragrance are typically also present.
[0009] Lipsticks that contain water in addition to waxes and oils purportedly are more effective in moisturizing the lips. Despite the purported benefits of water-containing lipsticks, consumers still favor anhydrous lipsticks since these usually last much longer. Among the other numerous materials useful for incorporation into a lipstick composition, fatty alcohols and fatty acid esters have been found to be useful in cosmetic products because of the ability of such compounds to maintain a porous fatty film on the lips.
[0010] Lips typically have a rough surface comprising tiny ridges and cracks. Such cracks detract from the smooth elegant appearance desired by most wearers. It is desirable to provide a lipstick composition that fills these the tiny crevices on the surface of the lip and gives the wearer's lips a smoother more even surface. In addition, the small cracks, ridges and fissures typical are the initiation point of lip cracking and damage during dry and cold conditions.
[0011] Thus, in addition to the cosmetic benefits of filling these tiny ridges and cracks to provide a smoother more elegant appearing look and feel, there exists the need to provide a lipstick ridge and crack filling composition which provides a method of forestalling the presence of these ridges and cracks from acting as the nucleus of cracks and breakages of the skin during cold or dry weather.
SUMMARY OF INVENTION
[0012] The present invention is a lipstick formulation which imparts a beneficial moisturizing effect, is easily applied on the lips, spreads smoothly and imparts increased cushion providing a unique feel to the wearers lips while at the same time providing added protection against adverse environmental conditions.
[0013] This lipstick imparts these properties by utilizing a gel/cream base incorporating a mixture of canola oil, glycine soja (soybean) germ extract, zea mays (corn) starch and silica and two botanicals as a synergistic complex to aide in moisturization. A significant part of the composition is the use of a base system comprising the mixture of canola oil, glycine soja (soybean) germ extract, zea mays (corn) starch and silica to provide “extra cushion” and soft rich feel to the lipstick.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a table of the ingredients of compositions within the scope of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Lips typically have a rough surface comprising tiny ridges and cracks. It is desirable to provide a lipstick composition that fills these the tiny crevices on the surface of the lip and gives the wearer's lips a smoother more even surface. A lipstick base having high cushion gels incorporated into the product allows the product to fill in the rough areas. The high cushion gels in the disclosed composition, in combination with the other ingredients, deposit a thicker film on the lips and provide a smoother, more harmonious surface to the wearer's lips.
[0016] The disclosed lipstick composition provides a unique feel and ease in application. It imparts cushion, creaminess, moisturization and substantivity (thicker film on lip) to the wearer thereby providing increased comfort and ease in application to the consumer. This lipstick imparts these properties by utilizing a gel/cream base incorporating a mixture of canola oil, glycine soja (soybean) germ extract, zea mays (corn) starch and silica and by utilizing two botanicals as a synergistic complex to aide in moisturization. A significant part of the composition is the use of a base system comprising the mixture of canola oil, glycine soja (soybean) germ extract, zea mays (corn) starch and silica to provide “extra cushion” and soft rich feel to the lipstick.
[0017] The composition utilizes a gel/cream base with incorporates canola gel, a proprietary mixture of canola oil, glycine soja (soybean) germ extract, zea mays (corn) starch and silica sold by Natunola Health (Nepean, Ontario, Canada) under its trademark Vegelatum® Equiline.
[0018] Canola Oil is a vegetable oil from the canola seed that is very stable, high in oleic acid, rich in Vitamin E that is an excellent emollient and moisturizer and helps reduce skin irritation. Vegelatum® Equiline is a botanical emollient produced from a non-transgenically modified canola oil.
[0019] Canola gel is superior to petroleum based emollients, such as petrolatum, as it has exceptional thermostability, a gel-like structure and is also less greasy. In combination with the other ingredients of the gel/cream base, it softens and smoothes the skin, forming a light film which prevents evaporation of moisture from the skin and protects the skin from irritation.
[0020] In appearance canola gel is an off-white, opaque gel, with a very light odour. It is soluble in all vegetable oils, glycerol triisostearate, isostearyl isosterate, oleic acid, isostearic acid, coco-caprylate/caprate and mixed glycerides and insoluble in water, absolute ethanol and 1,2-propanadiol, dimethicone and cyclomethicone.
[0021] The base also incorporates Euphorbia cerifera wax (Candelilla wax), a natural vegetable wax used as a film former and for skin conditioning.
[0022] The composition also includes one or more oils or oil-like emollients. Any cosmetically or pharmaceutically acceptable oil may be used in the wax base, the selection only being limited by the necessity for successfully wetting out pigments, a technique well known in the art. Examples of suitable oils or oil-like emollients can be found in the International Cosmetic Ingredient Handbook, CTFA, 1996, the contents of which are incorporated herein by reference.
[0023] Useful materials include, but are not limited to, castor oil, coconut oil, corn oil, jojoba oil, cottonseed oil, soybean oil, walnut oil, wheat germ oil, sunflower seed oil, palm kernel oil, calendula oil, C8-18 triglycerides, lanolin and lanolin derivatives, illipe butter, shea butter; esters, such as isodecyl neopentanoate, tridecyl octanoate, diisostearyl malate, cetyl palmitate, cetyl octanoate, cetyl stearate, cetyl myristate, isopropyl palmitate, isopropyl myristate, dipentaerythrityl hexahydroxy stearate/stearate/rosinate, polyglyceryl-2-isostearate, neopentyl glycol distearate, isodecyl oleate, decyl isostearate, diisopropyl sebacate, PEG-4 diheptanoate, dioctyl malate, and isohexyl neopentanoate; fatty alcohols, such as lanolin alcohol or oleyl alcohol; and silicone oils, such as cyclomethicone, dimethicone, cetyl dimethicone, lauryl trimethicone, and dimethiconol.
[0024] Compositions of the present invention contain sufficient pigments to provide the look sought by the user. The amount of pigment present in the composition is in the range of 0 to approximately 25% by weight of the total composition, preferably from about 0 present to approximately 18% by weight of the total composition.
[0025] Pigments which may be used herein are all inorganic and organic colors/pigments suitable for use in lip composition compositions. These are usually aluminum, barium or calcium salts or lakes. Lakes are either a pigment that is extended or reduced with a solid diluent or an organic pigment that is prepared by the precipitation of a water-soluble dye on an adsorptive surface, which usually is aluminum hydrate. A lake also forms from precipitation of an insoluble salt from an acid or basic dye. Calcium and barium lakes are also used herein.
[0026] Preferred lakes of the present invention are Red 3 Aluminum Lake, Red 21 Aluminum Lake, Red 27 Aluminum Lake, Red 28 Aluminum Lake, Red 33 Aluminum Lake, Yellow 5 Aluminum Lake, Yellow 6 Aluminum Lake, Yellow 10 Aluminum Lake, Orange 5 Aluminum Lake and Blue 1 Aluminum Lake, Red 6 Barium Lake, Red 7 Calcium Lake. Other colors and pigments can also be included in the lip compositions, such as pearls, titanium oxides, Red 6, Red 21, Blue 1, Orange 5, and Green 5 dyes, chalk, talc, iron oxides and titanated micas.
[0027] There are a number of other ingredients approved for use in the cosmetic art that may be used in compositions of the present invention. Such ingredients are those approved for use in cosmetics and can be found listed in reference books such as the CTFA Cosmetic Ingredient Handbook, Second Edition, The Cosmetic, Toiletries, and Fragrance Association, Inc. 1988, 1992. Said materials may be used provided their inclusion does not significantly disrupt the composition once it has been applied to the skin wherein a film has been formed. Said ingredients include waxes, fragrances, flavor oils, skin care ingredients such as sunscreen, emulsifiers and the like. Hypoallergenic compositions can be made into the present invention where said compositions do not contain fragrances, flavor oils, lanolin, sunscreens, particularly PABA, or other sensitizers and irritants.
[0028] Waxes used in the present invention are used at levels that do not interfere with film formation process. Generally waxes are not used in the present invention higher than about 12.5% of the composition, preferably not higher than about 8% of the composition. Waxes are defined as lower-melting organic mixtures or compounds of high molecular weight, solid at room temperature and generally similar in composition to fats and oils except that they contain no glycerides. Some are hydrocarbons, others are esters of fatty acids and alcohols. Waxes useful in the present invention are selected from the group consisting of animal waxes, vegetable waxes, mineral waxes, various fractions of natural waxes, synthetic waxes, petroleum waxes, ethylenic polymers, hydrocarbon types such as Fischer-Tropsch waxes, silicone waxes, and mixtures thereof. Waxes preferred for use in the present invention are selected from the group consisting of Euphorbia cerifera (Candelilla) wax; microcrystalline wax; Ozokerite and paraffin. The waxes most useful herein are the Ozokerite waxes.
[0029] Flavor oils such as peppermint oil, orange oil, citrus oil, or wintergreen oil can be used along with an alcohol or glycerine. Flavor oils are usually mixed in a solvent such as ethanol to dilute the flavor. The flavor oils useful herein can be derived from natural sources or be synthetically prepared. Generally, flavor oils are mixtures of ketones, alcohols, fatty acids, esters and terpenes. The term “flavor oil” is generally recognized in the art to be a liquid which is derived from botanical sources, i.e. leaves, bark, or skin of fruits or vegetables, and which are usually insoluble in water. The level of flavor oil used can range from 0% to about 0.5%, preferably from 0% to about 0.3% of the lip composition.
[0030] Emulsifiers may be used as coupling agents that have an affinity for the hydrophilic and hydrophobic phases of lip compositions of this invention. Such emulsifiers include those routinely used in cosmetics and are found in the CTFA.
[0031] Skin care active ingredients in both water-soluble and water insoluble forms can be added to the lip composition. Said ingredients may include fat-soluble vitamins, sunscreens and pharmaceutically active ingredients. Skin care active ingredients include glycerine, zinc oxide; chamomile oil; ginko biloba extract; pyroglutamic acid, salts or esters; sodium hyaluronate; 2-hydroxyoctanoic acid; sulfur; salicylic acid; carboxymethyl cysteine, water, propylene glycol and mixtures thereof.
[0032] The most important parts of the composition and those which provide the superior qualities are the gels in the base, the lauroyl lysine and talc, and the synergistic combination of Tamanol and Prunus oil. Tamanol and Prunus oil both aid in hydration and dryness prevention. Prunus oil is further recognized scientifically as a free-radical scavenger. Tamanol's beneficial effects of tissue regeneration and healing are associated with a polyunsaturated fatty acid, calophyllic acid.
[0033] It is the use of these ingredients, in the specified proportions and alone or in combination with the other listed ingredients, all as set forth in the table of FIG. 1, that yields the superior results obtained. Table 1 describes the ingredients most useful in compositions of this invention along with preferred embodiments of the inventive composition.
[0034] In a most preferred embodiment, the disclosed lipstick compositions imparting increased cushion, creaminess, moisturization and substantivity comprise propylparaben; PEG-8 (and) tocopherol (and) ascorbyl palmitate (and) ascorbic acid (and) citric acid; Ricinus communis (castor) oil; caprylic/capric triglyceride; Euphorbia cerifera (candelilla) wax; octyldodecyl stearoyl stearate; Polybutene; canola oil (and) glycine soja (soybean) germ extract (and) Zea mays (corn) starch (and) silica; microcrystalline wax; hydroxylated lanolin; ozokerite; paraffin; Carthamus tinctorius (safflower) oil (and) aleurites moluccana seed extract; Vaccinium macrocarpon (cranberry) fruit extract; Persea gratissima (avocado) fruit extract; talc; lauroyl lysine; Calophyllum inophyllum seed oil; Prunus domestica seed extract; flavor/fragrance; mica, iron oxides, titanium dioxide, organic pigments and their lakes.
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A lipstick composition that overcomes the dry and waxy feel of lipstick, that applies softly, does not drag upon application, and leaves the wearers lips feeling comfortable and protected against cracking and dryness.
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BACKGROUND
[0001] This disclosure relates to electro-hydraulic servovalves (EHSVs) and an apparatus and method for controlling and/or monitoring such valves.
[0002] Electro-hydraulic servovalves (EHSVs) are used with many position control systems. An EHSV converts a low energy signal level command from a controller into a high energy hydraulic command. This hydraulic command is used to position mechanical components.
[0003] The use of high temperature fuels in gas turbine engines has created potential issues with valves and/or actuators being subjected to fuel lacquering and coking of their fine screens. Additionally, long term exposure to contamination and higher flow rates can potentially result in servovalve erosion which can cause problems in control loop design as well.
[0004] Accordingly, it is desirable to provide an apparatus and method for predicting trends or potential problems in the valve or actuator.
BRIEF DESCRIPTION
[0005] In one embodiment, a method for actively calculating a capability of an electronically controlled valve is provided. The method including the steps of: a) operating the electronically controlled valve in accordance with a task; b) testing the electronically controlled valve in order to determine a range of movement of the electronically controlled valve in accordance with an initial gain, wherein the testing of the electronically controlled valve occurs after the valve has been operated in accordance with the task; c) determining a new gain required for providing a predetermined range of movement of the electronically controlled valve; and d) repeating steps a-c at least once, wherein the new gain is used to operate the valve in accordance with the task.
[0006] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the task may be controlling an amount of fuel provided to a gas turbine engine.
[0007] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the electronically controlled valve may be a fuel valve of a gas turbine engine.
[0008] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the new gain may be an average of a plurality of gains each being a result of one of a plurality of tests of the electronically controlled valve, wherein each one of the plurality of tests determines a range of movement of the electronically controlled valve in accordance with the initial gain, wherein each one of the plurality of tests occurs after the valve has been operated in accordance with the task.
[0009] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the method further comprising: recording an initial gain required for providing the predetermined range of movement of the electronically controlled valve.
[0010] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the electronically controlled valve may be a fuel valve of a gas turbine engine.
[0011] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, each new gain may be compared to a predetermined value in order to determine whether the valve is trending towards a threshold value.
[0012] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the threshold value may be a speed of the valve that is indicative of a repair.
[0013] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the initial gain may be in mA/inch and is applied to a control loop of the electronically controlled valve.
[0014] In another embodiment, a system for actively calculating a capability of an electronically controlled valve, the system having: an engine electronic control; an initial gain that provides a range of movement of the electronically controlled valve when the initial gain is provided to the electronically controlled valve by the engine electronic control; and wherein the engine electronic control is configured to: i) operate the electronically controlled valve in accordance with a task; ii) test the electronically controlled valve in order to determine a range of movement of the electronically controlled valve in accordance with the initial gain, wherein the testing of the electronically controlled valve occurs after the valve has been operated in accordance with the task; iii) determine a new gain required for providing the predetermined range of movement of the electronically controlled valve; and iv) repeat steps i-iii at least once, wherein the new gain is used to operate the valve in accordance with the task.
[0015] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the task may be controlling an amount of fuel provided to a gas turbine engine.
[0016] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the electronically controlled valve may be a fuel valve of a gas turbine engine.
[0017] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the new gain may be an average of a plurality of gains each being a result of one of a plurality of tests of the electronically controlled valve, wherein each one of the plurality of tests determines a range of movement of the electronically controlled valve in accordance with the initial gain, wherein each one of the plurality of tests occurs after the valve has been operated in accordance with the task.
[0018] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the task may be controlling an amount of fuel provided to a gas turbine engine.
[0019] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the electronically controlled valve may be a fuel valve of a gas turbine engine.
[0020] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the new gain may be compared to a predetermined value in order to determine whether the valve is trending towards a threshold value.
[0021] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the threshold value is a speed of the valve that is indicative of a repair.
[0022] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the initial gain may be in mA/inch and is applied to a control loop of the electronically controlled valve.
[0023] In yet another embodiment, a method for predicting a trend of an electronically controlled valve is provided. The method including the steps of: a) recording an initial gain required for providing a predetermined range of movement of the electronically controlled valve; b) operating the electronically controlled valve in accordance with a task; c) testing the electronically controlled valve in order to determine a range of movement of the electronically controlled valve in accordance with the initial gain, wherein the testing of the electronically controlled valve occurs after the valve has been operated in accordance with the task; d) determining a new gain required for providing the predetermined range of movement of the electronically controlled valve; e) comparing the new gain to a threshold value to determine whether the new gain is greater than the threshold value; and f) repeating steps b-e at least once, wherein the new gain is used to operate the valve in accordance with the task.
[0024] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the initial gain may be in mA/inch and is applied to a control loop of the electronically controlled valve and wherein the task is controlling an amount of fuel provided to a gas turbine engine and wherein the electronically controlled valve is a fuel valve of the gas turbine engine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The subject matter which is regarded as the present disclosure is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the present disclosure are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0026] FIG. 1 is a schematic illustration of a system for controlling the operation of an electro-hydraulic servovalve(s) in accordance with an embodiment of the disclosure;
[0027] FIG. 2 is a schematic illustration of a minorloop control of an actuator or valve in accordance with an embodiment of the disclosure;
[0028] FIG. 3 is a graph illustrating potential trends of K amp of a valve or actuator in accordance with an embodiment of the disclosure; and
[0029] FIG. 4 is a flow chart illustrating a method for varying a gain of a valve in accordance with an embodiment of the disclosure.
[0030] While the above-identified drawing figures set forth one or more embodiments of the invention, other embodiments are also contemplated. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the invention. The figures may not be drawn to scale, and applications and embodiments of the present disclosure may include features and components not specifically shown in the drawings. Like reference numerals identify similar structural elements.
DETAILED DESCRIPTION
[0031] Various embodiments of the present disclosure are related to an apparatus and method for adaptively changing an EEC gain of a minorloop (measured in mA/in) in an electronically actuated valve or actuator in order to correct for any flow gain issues as well as providing a means to trend the output of the valve or actuator for lacquering or coking issues as well as servovalve erosion issues.
[0032] Due to increased fuel temperatures on certain engine platforms, fuel lacquering and coking of fine screens presents challenges to actuator and valve components. Each actuator or valve typically employs a series of screens across the supply and return flow ports in order to protect the small passageways of the EHSVs from being clogged by debris. When the actuator or valve (EHSV) lacquers or cokes up, the flow gain is reduced and the actuator or valve will start to respond sluggishly. Conversely, window areas of the valve may erode over time due to contamination and/or time of usage. If this occurs, the valve or actuator may respond quicker. Currently, a constant gain for the valve or actuator is used, which is based upon a non-clogged or non-coked up state of the valve or actuator and/or the screens of the valve or actuator as well as a non-eroded valve or actuator. Various embodiments of the disclosure are directed to a method and apparatus to adaptively change the EEC gain of the minorloop (mA/in), in order to correct any flow gain issues experienced during the life of the valve as well as provide a means to trend the output for fuel lacquering or coking issues as well as erosion issues.
[0033] Referring now to FIG. 1 , a schematic illustration of a gas turbine engine 10 and a system 12 for detecting and controlling an operational state of the gas turbine engine 10 is provided.
[0034] The gas turbine engine 10 has among other components a fan through which ambient air is propelled into the engine housing, a compressor for pressurizing the air received from the fan and a combustor wherein the compressed air is mixed with fuel and ignited for generating combustion gases. The gas turbine engine 10 further comprises a turbine section for extracting energy from the combustion gases. Fuel is injected into the combustor of the gas turbine engine 10 for mixing with the compressed air from the compressor and ignition of the resultant mixture.
[0035] As illustrated in FIG. 1 , the system 12 comprises a Full Authority Digital Engine Control (FADEC) or EEC, or other processor configured to control aspects of an aircraft engine and its performance. The FADEC or EEC is illustrated schematically as item 14 . The FADEC or EEC 14 receives multiple input variables including but not limited to air density, throttle lever position, engine temperatures, engine pressures, and many other parameters. These inputs are illustrated schematically as boxes 16 , 17 .
[0036] These inputs are received by the FADEC or EEC and may be analyzed numerous times per second. Engine operating parameters such as fuel flow, stator vane position, bleed valve position, and others are computed from this data and applied as appropriate. The FADEC or EEC also controls engine starting, running, shutdown and restarting. During any of the aforementioned controls the FADEC or EEC may provide commands to one or more fuel valves or actuators 18 that control a supply of fuel 20 to the engine 10 . As mentioned above, the valves may be electro-hydraulic servovalves (EHSV) and it is desirable to predict trends or potential problems in a valve or actuator, which may be used to supply fuel to the engine.
[0037] Referring now to FIG. 2 , a schematic illustration of a minorloop control or control loop or proportional control loop of an actuator and plant or valve is provided. As is known in the related arts, an electro-hydraulic servovalve (EHSV) is driven by an input position command typically in the form of mA of current. During operation an EHSV accepts a position command in the form of mA of current, which in the illustrated embodiment is provided by the EEC.
[0038] As is known in the related arts and referring to at least FIG. 2 , at least the following: the request; the engineering units conversion; the error, which is the request minus the feedback; the product of K amp and the error; and any other required step is performed by a processor or equivalent device of the EEC.
[0039] For a given example of K bandwidth or K bw that =30 rad/sec we can use the following formula:
[0000] K bw =K amp *K act =30 rad/sec.
[0040] K amp =the proportional gain that the control or EEC provides in milliamps/inch. As shown in at least FIG. 2 , (K amp )(error signal) will provide a product in milliamps that is used to provide a desired movement of the valve. K amp may also be referred to as K eec , in either scenario this refers to the gain provided to the valve in order to effectuate movement of the valve. For example and in one non-limiting embodiment, a given error signal with K amp will provide a current from the control loop to the actuator or valve.
[0041] K act or K actuator the plant or valve dynamics itself or velocity of the actuator or valve for a given current received from the control loop. An actuator (or hydraulic cylinder with EHSV) can be roughly modeled as an integrator with a gain. K act represents the velocity that can be expected, given a certain current. In various embodiments disclosed herein, the valve has linear variable transformer (LVDT) feedback to the EEC as shown in at least FIG. 2 (the feedback to the EEC is also shown at least by box 16 in FIG. 1 ) and tests or calculations are run on the EEC to determine what the K act or velocity of the valve or actuator is in (in/sec/mA) by noting the speed and how much current it takes to get that speed (e.g., Actuator Gain (in/sec/mA)). These calculations are performed by a microprocessor or equivalent device of the EEC or in operable communication with the EEC or FADEC as well as the actuator or valve. As shown in at least FIG. 2 , the LVDT converts mechanical displacement to an electrical signal, typically a voltage ratio, which is received by the EEC and the EEC performs an Engineering Units Conversion or converts the received electrical signal to inches, which is then provided as a feedback and the EEC can determine if there is an error or difference between the Request in inches for a given K amp and the actual movement of the valve K act in accordance with the request so that K amp can be modified, if necessary, to provide a request movement of the valve or actuator.
[0042] Accordingly and in one embodiment, the gain of K amp is a quantity that, coupled with the error, will result in an adaptive current being applied to the electronically controlled valve.
[0043] K bw =Loop Gain or Bandwidth (rad/sec) of the system. K bw is the product of K act *K amp .
[0044] In accordance with one non-limiting embodiment, K amp and K act for a given K bw are known. If we know from an initial factory setting that K amp =1000 mA/in and K act =0.03 in/sec/mA for a K bw of 30 rad/sec, we can determine K act as the valve is used and its performance is recorded/calculated. Recordation and/or calculation of K act , of the valve as it is used will allow the EEC to vary K amp in order to maintain the desired valve operation or movement while also predicting trends in the operation of the valve. In this example, K act of 0.03 in/sec/mA would be attributable to a new valve or actuator that does not have coking or servovalve erosion issues that are attributable to operational usage of the valve or actuator. In other words, K act =0.03 in/sec/mA is used as the normal or beginning value of a new valve or actuator placed into service and various embodiments of the disclosure adjust K amp such that it maintains a design K bw given the relation: K bw ,=K amp *K act .
[0045] If K amp remains constant at 1000 mA/in the bandwidth of the valve 18 will change as K act changes. An example of this is illustrated in the below table in the column identified as without adaptive gain. As used herein K act is attributable to the physical characteristics of the valve 18 or how fast it will go for a given current, which may be attributable to fuel lacquering or coking and/or erosion of the valve or actuator.
[0000]
Without Adaptive Gain
Bandwidth
With Adaptive Gain
EHSV
K amp
Bandwidth
Degrade
K amp
remains at
K amp
Mechanism
Velocity
K act
Adjusted
1000
Stability
Adjusted
Stability
valve
Slower
0.01
3,000
10
Ok
30
Ok
screens
coke or
clog
valve
Slower
0.02
1,500
20
Ok
30
Ok
screens
coke or
clog
Nominal
0.03
1,000
30
Ok
30
Ok
Valve
Faster
0.04
750
40
Low
30
Ok
windows
erode
Valve
Faster
0.05
600
50
Lower
30
Ok
window
erode
[0046] Various embodiments of the present disclosure are directed to actively calculating the actual capability of the valve or actuator 18 (K act ) as shown in at least FIG. 2 , such that K amp can be adjusted to maintain the bandwidth of the valve or actuator (K bw ) within a desired range as well as predict a trend of the valve or actuator.
[0047] This provides at least two benefits, by actively calculating the actual capability of the valve or actuator, a means is provided to adaptively adjust the valve EEC gain in order to maintain a constant loop gain or system bandwidth (Kbw=Kact*Kamp). Without adaptive adjustment, a slower valve would exhibit lower bandwidths which could be destabilizing to the outer loop. Also and without adaptive adjustment, a faster valve could produce limit cycles on the minorloop because of a gain mismatch. Accordingly and by adaptively adjusting the valve EEC gain, a constant and consistent minorloop gain is ensured. Another benefit is achieved by calculating a moving-average of the EEC gain, this allows the system to trend the actuator or valve for potential fuel lacquering or coking effects of screens or other devices that could cause sluggish performance in actuator or valve as well as deleterious effects that may cause the valve or actuator to operate faster. See for example, the graph 30 illustrated in FIG. 3 . Line 32 illustrates a valve or actuator that is trending to become slower while line 34 illustrates a valve or actuator that is trending to become faster.
[0048] Also shown are thresholds 36 and 38 , which may represent an indication that the valve or actuator 18 should be serviced or replaced. As shown in FIG. 3 , the thresholds are illustrated as changing (e.g., increasing in value) with respect to the number of missions, flights or engine cycles as newer valves are expected to have lower tolerances and those tolerances may be expected to have acceptable increases over usage. It is, of course, understood that the thresholds may be alternatively fixed or static with respect to the number of missions, flights or engine cycles such that the lines 36 , 38 would not have a slope.
[0049] One way to actively calculate the actual capability of the valve or actuator 18 is to leverage built in tests of the metering valve 18 , for example, the EEC can be programmed to test the actuator to determine the maximum rate of the valve via an engine shutdown or a specific ground idle test. As such, these tests are performed after the engine has been shut down and/or its associated aircraft has landed. Another method for actively calculating the actual capability of the valve or actuator may involve monitoring of velocity and current to continuously determine the maximum rate of the valve 18 . Accordingly and once the max rate of the actuator 18 is determined, it is then used to calculate an effective EEC gain (mA/in) or minorloop gain using a target bandwidth or loop gain (Kbw=Kact*Kamp). By keeping a moving average of the last 20 (for example) tests, this prevents a sudden change of the control gain. The new EEC gain would be then stored in memory such that it could be used in the next power up of the EEC. Of course, the moving average can be more or less than 20 tests.
[0050] For example and referring now to FIG. 4 a flow chart 100 illustrating a method for actively calculating the actual capability of the valve or actuator 18 of the engine 10 is illustrated. At box or step 102 , an initial actuator or valve gain K amp is provided. This may be provided by a manufacturer of valve 18 or some other analysis that provides K amp when the valve or actuator 18 is put into service. For example, this may occur when the valve is replaced. Again, one non-limiting example uses K am as 0.03 in/sec/mA. At step 104 , the engine is started. In one non-limiting embodiment, the engine may be a gas turbine engine 10 that is used in an aircraft. Still further and in accordance with various embodiments of the present disclosure the method described herein may be a series of executable code resident upon a microprocessor of the FADEC or EEC 14. Once the engine 10 and/or the associated aircraft has completed its flight or mission (box 106 ) the engine 10 is shut down and a computer program resident upon the FADEC or EEC 14 will perform a rate test to see if the valve or actuator is increasing or decreasing in speed, which may be indicative of the health or operational state of the valve or actuator.
[0051] This rate test is illustrated by box or step 108 wherein the rates and fuel temperatures are recorded. At box 110 the plurality of recorded rates are added together and averaged. These recorded rates are normalized for variations in fuel density (e.g., fuel density effects on the recorded rate). Then and at step or box 112 , K act (new) is calculated. This calculated rate gain of the actuator K act (new) is then used to calculate a K amp (new) based upon the calculated K act (new) in order to achieve a desired K bw . In other words, K bw /K act (new) =K amp (new) . This calculated K amp (new) is then added to a predetermined amount of previously calculated K amps (new ) that were calculated via the same formula K bw /K act (new ) =K amp (new) and wherein the sum of the previously calculated K amps (new) is divided by the number of K amps (new) calculated in order to provide a weighted K amp or K amp new weighted which is then stored as K amp . In one non-limiting embodiment, the last calculated or oldest K amp (new) is removed and replaced with the newly calculated K amp (new) and the sum of all of the remaining calculated K amps (new) is divided by the predetermined number in order to provide the new updated K amp (box or step 114 ) which is then stored in the non-volatile memory of the FADEC or EEC 14 (box or step 116 ). The newly stored K amp is now used to control the valve or actuator 18 , which has been dynamically updated to reflect changes in the operational aspects of the valve or actuator 18 , which may be attributable to lacquering or coking issues. In the given example, 20 calculations are performed to determine K amp new weighted by using a moving average of the last 20 (for example) tests, this prevents a sudden change of the control gain. The new EEC gain would be then stored in memory such that it could be used in the next power up of the EEC. Of course, 20 calculations are provided as one non-limiting example of course, greater or less than 20 calculations may be used.
[0052] Still further, the recordation or trending of the valve variation may be used to predict or set a threshold for valve replacement. This is illustrated by box, step or decision node 118 . If at decision node 118 , K amp from box or step 116 is not within a range of the threshold values, the engine electronic control and/or FADEC can indicate that it is time to service or replace the valve 18 at step or box 120 . Accordingly, once the percentage of the variation of the valve performance exceeds a threshold, the engine electronic control and/or FADEC may indicate that it is time to service or replace the valve 18 via an indication on a visual display. In one embodiment, the threshold may be a predetermined threshold that is set at the start of the valve's service.
[0053] In an exemplary embodiment, the engine electronic control and/or FADEC 14 comprises a microprocessor, microcontroller or other equivalent processing device capable of executing commands of computer readable data or program for executing a control algorithm and/or algorithms that control the start sequence of the gas turbine engine. In order to perform the prescribed functions and desired processing, as well as the computations therefore (e.g., the execution of fourier analysis algorithm(s), the control processes prescribed herein, and the like), the controller may include, but not be limited to, a processor(s), computer(s), memory, storage, register(s), timing, interrupt(s), communication interfaces, and input/output signal interfaces, as well as combinations comprising at least one of the foregoing. For example, the controller may include input signal filtering to enable accurate sampling and conversion or acquisitions of such signals from communications interfaces. As described above, exemplary embodiments of the disclosure can be implemented through computer-implemented processes and apparatuses for practicing those processes. The system 12 may include memory to store instructions that are executed by a processor. The executable instructions may be stored or organized in any manner and at any level of abstraction, such as in connection with a controlling and/or monitoring operation of the engine 10 of FIG. 1 . The processor can be any type of central processing unit (CPU), including a general purpose processor, a digital signal processor, a microcontroller, an application specific integrated circuit (ASIC), a field programmable gate array, or the like. Also, in embodiments, the memory may include random access memory (RAM), read only memory (ROM), or other electronic, optical, magnetic, or any other computer readable medium onto which is stored data and control algorithms in a non-transitory form. The system 12 can be embodied in an individual line-replaceable unit, within a control system (e.g., in an electronic engine control), and/or distributed between multiple electronic systems.
[0054] A technical effect of the apparatus, systems and methods described herein is achieved by actively calculating a capability of an electronically controlled valve.
[0055] While the present disclosure has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the present disclosure is not limited to such disclosed embodiments. Rather, the present disclosure can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the present disclosure. Additionally, while various embodiments of the present disclosure have been described, it is to be understood that aspects of the present disclosure may include only some of the described embodiments. Accordingly, the present disclosure is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
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A method for actively calculating a capability of an electronically controlled valve is provided. The method including the steps of: a) operating the electronically controlled valve in accordance with a task; b) testing the electronically controlled valve in order to determine a range of movement of the electronically controlled valve in accordance with an initial gain, wherein the testing of the electronically controlled valve occurs after the valve has been operated in accordance with the task; c) determining a new gain required for providing a predetermined range of movement of the electronically controlled valve; and d) repeating steps a-c at least once, wherein the new gain is used to operate the valve in accordance with the task.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to metered-dose dispensing valves and in particular to valves for dispensing medicament from pressurized aerosol containers.
2. Description of the Related Art
Metering valves for use with pressurized metered dose inhalers (MDIs) need to meet certain performance criteria with regard to the sampling of the medicinal formulation, which is generally in the form of suspension of micronized drug particles in an aerosol propellant system. Specifically, the valve must sample the formulation homogeneously in order that the correct dose of medicament is delivered to the patient on each actuation of the valve. Most commercially available valves fulfill this requirement when the formulation is well dispersed.
It has been found that valve types vary considerably in their ability to dose high potency low concentration formulations. This problem is particularly significant when the formulations are not well dispersed as may occur in various conditions in the field, for instance when a formulation has been allowed to stand for a while such that creaming has taken place and the valve is actuated without shaking the product.
In such circumstances, depending on the valve design, it may be possible to deliver either a dose within intended specification or a dose of up to about twenty times the target value. This problem is of concern since it cannot be assumed that a patient will always shake an MDI product before use.
In addition, a second effect has been identified where valve design may influence the consistency of drug delivery. This effect concerns a tendency for drug particles to migrate to the metering tank of the valve during storage or transit, with a consequent elevation in the amount of drug delivered in the first shot. It has been found that elevated drug doses may be obtained due to this effect, particularly with high potency drugs for which there is a very small total quantity of active substance in the aerosol container.
A third effect has been identified which may cause erratic dosing and this concerns the ability of drug to cream out of the metering tank of valves stored in the stem down position when the valve is of a type having an axial point of product entry.
SUMMARY OF THE INVENTION
According to one embodiment of the invention there is provided a metered dose valve for dispensing a medicinal aerosol formulation from a pressurized container, comprising:
a valve ferrule having an aperture therethrough; a metering tank having walls defining an exterior, an internal metering chamber, an inlet orifice, an inlet end, and an outlet end; an elongate valve stem having a filling channel, a filling end, a discharge end, and a discharge orifice; and a tank retaining cup having a proximal end and a distal end,
wherein the outlet end of the metering tank is in sealing engagement with the valve ferrule, the discharge end of the valve stem passes through the valve ferrule aperture and the outlet end of the metering tank and is in slidable sealing engagement with the valve ferrule aperture,
the filling end of the valve stem passes through and is in slidable engagement with the inlet orifice of the metering tank,
wherein the valve stem is movable between an inoperative position in which the filling channel of the valve stem allows open communication, via the inlet orifice, between the interior and the exterior of the metering chamber and the outlet end of the metering tank is closed, and an open position in which the inlet orifice of the metering tank is in sealing engagement with the filling end of the valve stem and the discharge orifice of the valve stem allows open communication between the interior and exterior of the metering chamber,
and wherein the tank retaining cup has walls defining an aperture, is attached at its proximal end to the valve ferrule, and surrounds the metering tank forming a capillary pathway from the proximal end of the tank retaining cup to the inlet end of the metering tank, which pathway is defined by the tank retaining cup and the exterior of the metering tank, in which the aperture in the tank retaining cup has a diameter of no more than 0.70 mm, preferably about 0.5 mm.
According to a further embodiment of the invention there is provided a metered dose valve for dispensing a medicinal aerosol formulation from a pressurized container, comprising:
a valve ferrule having an aperture therethrough; a metering tank having walls defining an exterior, an internal metering chamber, an inlet orifice, an inlet end, and an outlet end; an elongate valve stem having a filling channel, a filling end, a discharge end, and a discharge orifice; and a tank retaining cup having a proximal end and a distal end,
wherein the outlet end of the metering tank is in sealing engagement with the valve ferrule, the discharge end of the valve stem passes through the valve ferrule aperture and the outlet end of the metering tank and is in slidable sealing engagement with the valve ferrule aperture,
the filling end of the valve stem passes through and is in slidable engagement with the inlet orifice of the metering tank,
wherein the valve stem is movable between an inoperative position in which the filling channel of the valve stem allows open communication, via the inlet orifice, between the interior and the exterior of the metering chamber and the outlet end of the metering tank is closed, and an open position in which the inlet orifice of the metering tank is in sealing engagement with the filling end of the valve stem and the discharge orifice of the valve stem allows open communication between the interior and exterior of the metering chamber,
and wherein the tank retaining cup has walls defining an aperture, is attached at its proximal end to the valve ferrule, and surrounds the metering tank forming a capillary pathway from the proximal end of the tank retaining cup to the inlet end of the metering tank, which pathway is defined by the tank retaining cup and the exterior of the metering tank, and the tank retaining cup is shaped to closely follow the configuration of the end of the valve stem within the tank retaining cup.
According to a further embodiment of the present invention there is provided a metered dose valve for dispensing a medicinal aerosol formulation from a pressurized container, comprising:
a valve ferrule having an aperture therethrough; a metering tank having walls defining an exterior, an internal metering chamber, an inlet orifice, an inlet end, and an outlet end; an elongate valve stem having a filling channel, a filling end, a discharge end, and a discharge orifice; and a bottle emptier having a proximal end and a distal end,
wherein the outlet end of the metering tank is in sealing engagement with the valve ferrule, the discharge end of the valve stem passes through the valve ferrule aperture and the outlet end of the metering tank and is in slidable sealing engagement with the valve ferrule aperture,
the filling end of the valve stem passes through and is in slidable engagement with the inlet orifice of the metering tank,
wherein the valve stem is movable between (a) an inoperative position in which the filling channel of the valve stem does not allow open communication via the inlet orifice between the interior and the exterior of the metering chamber, (b) a filling position in which the filling channel of the valve stem allows open communication, via the inlet orifice, between the interior and the exterior of the metering chamber and the outlet end of the metering tank is closed, and (c) an open position in which the inlet orifice of the metering tank is in sealing engagement with the filling end of the valve stem and the discharge orifice of the valve stem allows open communication between the interior and exterior of the metering chamber,
and wherein the bottle emptier is attached at its distal end to the filling end of the valve stem and surrounds at least the inlet end of the metering tank forming a capillary pathway from the proximal end of the bottle emptier to the inlet end of the metering tank, which pathway is defined by the bottle emptier and the exterior of the metering tank.
In another embodiment of the invention, in the inoperative position there is open communication between the interior and exterior of the metering chamber via a cross-sectional area effective to reduce or prevent axial cream out of the contents of the metering chamber.
Optionally the bottle emptier may have one of the following constructions:
1. the bottle emptier extends substantially the entire length of the metering chamber but has no flange at the open end of the capillary pathway,
2. the bottle emptier extends no more than 90% of the length of the metering chamber,
3. the bottle emptier extends the entire length of the metering chamber to prevent free flow of contents from the dispensing container to the capillary pathway when the valve stem is in its inoperative position.
It has been found that valves incorporating one or more of the above configurations provide improved dosing uniformity characteristics compared with the standard valves.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the accompanying drawings in which:
FIG. 1 represents a longitudinal section through a known dispensing valve,
FIGS. 2 and 3 represent longitudinal sections through a dispensing valve of the type shown in FIG. 1 incorporating modifications in accordance with the invention,
FIG. 4 represents a longitudinal section through a second known dispensing valve, and
FIG. 5 represents a longitudinal section through a valve of the type shown in FIG. 4 incorporating a modification in accordance with the invention.
Throughout the drawings like reference numerals designate like parts.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 represents a known valve in which the bottle emptier (24) is in the form of a tank retaining cup which is fixed relative to the metering chamber (8) and completely envelopes the metering chamber (8) and end of the valve stem (14). Communication between the capillary pathway (26) and interior of the dispensing container is afforded by aperture (34). It has been found that this valve may provide non-uniform dosing characteristics when used with low concentration dispersion aerosol formulations, for example, formulations comprising an active ingredient suspended in an aerosol propellant where the concentration of the active ingredient is not more than 1 mg/g (1 milligram of active ingredient per gram of formulation).
As seen in FIG. 1, bottle emptier (24) has a first vertical wall (50) which is more proximate to the discharge end (16) of the valve stem (14) than the filling end (21) of the valve stem (14), and a second vertical wall (52) which is more proximate to the filing end (21) of the valve stem (14) than the discharge end (16) of the valve stem (14). An inclined wall (54) joins the first vertical wall (50) to the second vertical wall (52) at a first bend (56) and second bend (58), respectively. As shown in FIG. 1, aperture (34) is located approximately the same distance from first bend (56) as from second bend (58).
The dosing uniformity of a valve of the type shown in FIG. 1 may be improved by a modification as shown in FIG. 2. The aperture (34) through which formulation passes to gain entry into the metering chamber has been reduced in diameter from 1 mm to 0.5 mm. In addition the aperture has been repositioned further away from the valve crimp. In this regard, as seen in FIG. 2, aperture (34) is located in inclined wall (54) at a position closer to second bend (58) than first bend (56). Both factors allow for more consistent dosing of product following a resting period when creaming of the formulation may have taken place.
FIG. 3 shows a further modification in which the volume of the bottle emptier (24) is reduced by the end region (36) conforming closely to the valve stem (14). This design reduces the tendency for formulations to move in and out of the metering chamber (8) due to liquid expanding and contracting inside the bottle emptier (24) with changes in temperature.
Referring to FIG. 4, the known valve comprises a housing (2) having a flange (4) and annular seal (6). The neck of a dispensing container (not shown) is placed within the flange (4) against the seal (6) and the flange crimped around the neck to secure the valve to the dispensing container.
The valve comprises a metering chamber (8) having valve seals (10, 12) closing each end. A valve stem (14) extends through the seals (10, 12) and comprises a discharge end (16) in communication with a discharge orifice (18) which is positioned outside the metering chamber (8) when the valve stem is in its inoperative position but is moved within the metering chamber (8) when the valve stem (14) is depressed to its operative position to allow discharge of the contents of the metering chamber (8). The valve stem (14) is biased to its inoperative position by spring (20).
The valve stem defines a filling channel in the form of a groove (22.) which, when the valve stem is in its inoperative position, extends through the seal (12) to allow passage of contents into the metering chamber (8). As the valve stem (14) is moved to its operative position the groove (22) is moved out of the metering chamber (8) preventing passage of contents thereto.
The valve further comprises a bottle emptier (24) which is attached to the valve stem (14) and moves therewith. The bottle emptier (24) envelopes the end of the valve stem and metering chamber (8) and extends substantially the length of the metering chamber terminating in a circumferential flange (26). A capillary pathway in the form of an annular channel (28) is formed between the metering chamber (8) and bottle emptier (24) which allows passage of contents from the dispensing chamber to the metering chamber. As seen in FIG. 4, at the base of the bottle emptier (24), a closed void (40) is formed between the bottle emptier (24) and the bottom end of valve stem (14). As also seen in FIG. 4, in the rest position, groove (22) provides communication between metering chamber (8) and closed void (40). The bottle emptier allows substantially the entire contents of the dispensing container to be dispensed since it collects the contents from the bottom of the valve (the valve being inverted in use).
It has been found that the valve of FIG. 4 is prone to dosing inconsistencies when used with low concentration dispersion formulations having a propensity to cream, for example, formulations comprising an active ingredient suspended in an aerosol propellant where the concentration of the active ingredient is not more than 1 mg/g (1 milligram of active ingredient per gram of formulation).
The valve shown in FIG. 5 is similar to that of FIG. 4 with the exception that the length of the stem groove (22) is reduced to the extent that when the valve is at rest, only the edge (32) of the stem groove protrudes from the metering tank, i.e., groove (22) does not extend to the very end of the bottom end of valve stem (14), thus providing for communication between annular channel (28) and groove (22) while preventing communication between groove (22) and the closed void (40) at the base of the tank. This arrangement substantially reduces axial cream out of contents of the metering chamber (8). The stem groove (22) can be further reduced in length such that the metering chamber is a closed volume when the valve is at rest. This design prevents material leaving or entering the metering tank during storage.
The flange (26) present in FIG. 5 may be removed. Removal of the flange eliminates the possibility of creaming of the contents between the flange and the metering tank. Also, a shorter bottle emptier (24) which extends no more than 90%, preferably less than 80%, more preferably about 70%, along the length of the metering chamber (8) may be employed. This arrangement further reduces the possibility of creaming of product between the bottle emptier (24) and metering chamber (8).
In a further embodiment, by elongating the bottle emptier the effect of creaming can be virtually reduced as can the possibility of excessive migration of active substance into the metering chamber. In such a design the bottle emptier flange and the metering tank flange may be in contact when the valve is in its inoperative position. In addition to flange-to-flange contact the bottle emptier (24) can also be profiled so that the shoulder (30) of the bottle emptier forms a contact with the inlet end of the metering tank when the valve stem is in its inoperative position thereby providing an additional barrier to migration of drug during storage.
A pathway for the contents can be provided by a radial channel formed by a debossing in the bottle emptier flange (26).
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Metered dose dispensing valves providing good dosage reproducibility with formulations having a propensity to cream and with low concentration formulations. Valves having a tank retaining cup have a small inlet aperture of no more than 0.7 mm and preferably the tank retaining cup follows the configuration of the end of the valve stem. Valves having a bottle emptier attached to the valve stem have a filling channel in the valve stem which protrudes only slightly from the metering chamber when the valve is in its inoperative position.
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INCORPORATION BY REFERENCE
[0001] The following publications are incorporated herein by reference in their entireties (where <dot> indicates a period or dot character “.”):
(a) “IBM Redbook: Working with the Sametime Community Server Toolkit”, published by International Business Machines, ISBN 0738423912, January, 2003, at ibm<dot>com/redbooks. (b) “Introducing the Sametime Community: A Lotus Software White Paper”, published by Lotus Software, June 2003. (c) “Use the Event Catalog in the IBM Common Event Infrastructure: Integrating event management across business and IT systems”, published by International Business Machines on Apr. 7, 2005, at http://www-128<dot>ibm<dot>com/developerworks/library/ac-catalog. (d) “Chapter 23 Developing an Instant Messaging Architecture”, published by Sun Microsystems on http://docs<dot>sun<dot>com/source/819-0063/im-architecture.html.
BACKGROUND OF THE INVENTION
[0006] 1. Field of the Invention
[0007] This invention relates to technologies for providing and managing real-time or “instant” messaging services, and for providing online “chat” groups or rooms.
[0008] 2. Background of the Invention
[0009] Chat rooms, chat groups, and Instant Message buddy lists are widely used in business and private lives today.
[0010] Generally, the organization of systems shown in FIG. 4 is implemented, where a plurality of client devices ( 41 , 42 , 43 , 44 ) are interfaced by one or more computer or communication networks ( 45 , 45 ′, 45 ″, 45 ′″) to one or more real-time or chat messaging servers ( 46 ), such as an International Business Machines™ (“IBM”) SameTime™ server, America Online's™ (“AOL”) Instant Messenger (“IM”), or similar system. These systems in their present forms are well known in the art. The server ( 44 ) acts a reflector to forward or copy messages to all of the chat group members each time a new message is received from a group member. The client devices, such as a Personal Digital Assistant (“PDA”), personal computer (“PC”), or smart wireless telephone, are equipped with a chat or IM agent which allow each group member to receive messages and view them, as well as to author replies or new messages within certain groups.
[0011] Using the currently available technology, a user can conduct multiple individual “chats” with multiple other users simultaneously and in approximately real-time, or the user can conduct a group chat where all members can see all response. For example, the message flow diagram shown in FIG. 6 shows a first message ( 61 ) “Can you send me your status?” being authored by a first client ( 41 ), which is received by the server ( 46 ). The server ( 46 ) then “instantly” sends copies of the message ( 61 ′, 61 ″, 61 ′″) to each of the other client devices ( 42 , 43 , 44 ). In this example, the third client ( 43 ) responds or replies first by sending a second message ( 62 ) back to the server ( 46 ), which then sends copies of the second message (e.g. first reply) ( 62 ′, 62 ″, 62 ′″) to all other clients ( 41 , 42 , 44 ) in the chat or IM group. At some time later in this example, the second client ( 42 ) also replies to the first message ( 61 ′), which involves the third message (e.g. second reply) ( 63 ) being sent to the server ( 46 ), and then being copied or forwarded ( 63 ′, 63 ″, 63 ′″) to all other clients in the chat or IM group ( 41 , 43 , 44 ). In this manner, every message sent into the server for a certain group of clients is copied or forwarded to every other member (except the authoring member) in the group. The author's message is typically added to the thread display by the local client software, but may alternately be reflected by the server back to the author to provide a more positive indication of its distribution.
[0012] One drawback to this system, however, it that there is no way to have a “blind copy” chat with multiple people, wherein a first user can easily broadcast the same message to multiple members of a group, but control the reply message flow such that the replies are only received by the first user and not by the other members (e.g. the replies are not broadcast to the other members).
[0013] For example, some managers and project lead engineers like to use real-time messaging to ask questions from their group of employees or project team members. But, they may not desire for everyone in the group to see each others' responses, either for confidentiality purposes, or because they to not want to disturb the members except for the receipt of the broadcast message.
[0014] To accomplish this while taking advantage of the near-real-time nature of the IM or chat messaging systems, a manager can initiate multiple chat groups where each group actually only consists of two members—the manager and one member of his or her group. Then, the manager can manually send, often using a cut-and-paste operation in an IM user interface, the same message to each of the group members via a separate chat or IM group, as shown in FIG. 9 . In this small group example of just four members plus the manager, the manager has opened four different instances of the IM user interface ( 91 , 92 , 93 , 94 ), each of which is addressed to a different team member but which contains a manually reproduced copy of the manager's message. This will result in for different return messages, each in their respective user interface instances, which is clumsy and inefficient for the manager to use, especially for larger group sizes and/or for chats involving more than just a few messages and replies.
[0015] Another example of a need for real-time message broadcasting with private reply controls would be a polling operation, such as a marketing company or political polling organization, who would need to broadcast an identical message to a group of recipients, but who would want the replies to only be sent to the originator of the broadcast, and not to all of the other group members.
[0016] So, as just described, a user may utilize an IM or chat group system in a typical “many-to-many” fashion, as shown in FIG. 7 a , wherein one group is formed and every member in the group sees every message (new and replies) posted from any member, or confidentiality can be controlled by initiation by a primary group member ( 44 ) of multiple “one-on-one” groups ( 71 , 72 , 73 ), each of which only consists of the primary group member (e.g. a manager, group leader, dialogue or meeting facilitator, intermediary deal broker, negotiator, poll taker, etc.) and one other group member.
[0017] Thus, no available technology for IM, real-time, or chat messaging provides a one-to-many and many-to-one communications capability which would allow a primary user to send a unitary message to a plurality of group members, to control whether or not replies from those group members are distributed to the other members or not, and to receive a consolidated, unitary reply message from those group recipients.
SUMMARY OF THE INVENTION
[0018] The present invention provides a “Broadcast with Private Reply” system and method for cooperation with a real-time, “instant” or chat group system, which allows a primary user to designate whether or not replies to a message are distributed to all other members of a group, or whether those replies are only delivered to the primary member (e.g. the author of the message to which a reply is sent).
[0019] Alternate embodiments allow a user to select whether replies are delivered and displayed instantly as soon as they are transmitted by the replying party(ies), or to have all of the replies collected over a period of time and displayed in a consolidated, single reply message.
[0020] Another embodiment allows for the user to reply to the sequence of replies as they were received, and to optionally receive a report regarding which parties have replied and which have not.
[0021] The invention is suitable for implementation alternatively as code modifications to existing server products, such as Instant Messaging platforms, enterprise transaction processing systems, online transaction processors, and event-based messaging systems. Alternatively, the invention may be realized as functional extensions, such as “plug-ins”, for such systems, or for client-side components such as web browsers and instant messaging clients.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The following detailed description when taken in conjunction with the figures presented herein provide a complete disclosure of the invention.
[0023] FIG. 1 illustrates a user interface according to the invention for controlling the new real-time messaging with private reply control invention.
[0024] FIGS. 2 a and 2 b show a generalized computing platform architecture, and a generalized organization of software and firmware of such a computing platform architecture.
[0025] FIG. 3 a sets forth a logical process to deploy software to a client in which the deployed software embodies the methods and processes of the present invention.
[0026] FIG. 3 b sets forth a logical process to integrate software to other software programs in which the integrated software embodies the methods and processes of the present invention.
[0027] FIG. 3 c sets forth a logical process to deploy software to a client via a virtual private network, in which the deployed software embodies the methods and processes of the present invention.
[0028] FIG. 4 illustrates a typical IM or chat server topology of components.
[0029] FIG. 5 provides a more detailed view of a typical IM or chat server system.
[0030] FIG. 6 shows a message protocol diagram for distribution of messages in a typical chat or IM system.
[0031] FIGS. 7 ( a ) and 7 ( b ) illustrate with signal flow diagrams two methods discussed for communication within one large group, or a number of manually created two-party groups.
[0032] FIG. 8 shows a message protocol diagram for distribution and handling of messages according to the present invention.
[0033] FIG. 9 depicts a conventional method of using multiple, individual chat or IM group instances to control the flow of reply messages.
[0034] FIG. 10 provides a functional block diagram of the invention.
[0035] FIG. 11 illustrates a client-side embodiment of the present invention.
[0036] FIG. 12 shows details of BPRC IM/chat messages with embedded controls according to the present invention.
[0037] FIG. 13 shows a user interface having a consolidated, simulated multi-party reply message according to the invention.
[0038] FIG. 14 provides details of a logical process according to the invention.
[0039] FIG. 15 shows an example user interface for repeating the BPRC IM/chat process of the present invention.
[0040] FIG. 16 shows details of an enhanced BPRC IM/chat message with embedded controls in which sub-groups are indicated.
[0041] FIG. 17 illustrates a server-side embodiment of the present invention.
DESCRIPTION OF THE INVENTION
[0042] The present invention provides a broadcast with private reply control (“BPRC”) capability to an instant, real-time, or chat messaging system which extends the typical functions of the system beyond the typical ability to send and receive messages, and to add and delete members or other users to and from a “group” or “chat room”. The extended functionality allows a primary user (e.g. a message author or topic initiator) to designate whether or not replies to a message authored by the primary user and submitted into the group should be automatically distributed to all other members of the group, or if those replies should only be sent to the primary member. This allows the primary user to leverage the “instant” or real-time nature of such systems, as opposed to the slower or queued-type of schemes employed by electronic mail (“email”) systems, while enjoying greater control over the distribution of messages similar to that of email systems, all consolidated in a single user interface instance.
[0000] Suitable Messaging System
[0043] According to a preferred embodiment of the invention, the logical processes and functions of the invention are realized to cooperate with an existing client system, such as an IM client or chat client, to cooperate with an existing IM or chat server system, or a combination of both. In one available embodiment, as shown in FIG. 5 , a well-known IBM SameTime™ message suite ( 50 ) is extensible by addition of protocols 953 ), plug-ins ( 51 ), or applications programs ( 52 ). As such, the invention may be realized in such extensions so as to provide additional functionality to one or more client devices ( 54 ) and users according to the following description.
[0044] Alternate embodiments may include implementations in conjunction with enterprise transaction operating environments, online transaction processing (“OLTP”) systems, and event-based messaging products, such as, but not limited to, IBM's Customer Information Control System (“CICS”), IBM's WebSphere MQ™, IBM's Common Event Infrastructure (“CEI”).
[0045] Other products and platforms from other suppliers for instant messaging, event handling, transaction processing, or application serving, may be employed in alternate embodiments, as well. For example, the present invention is particularly well suited to employ directory and channels in instant messaging, such as those provided by the Sun Microsystems IM Architecture.
[0000] Messaging Protocol
[0046] In the present disclosure, the term “broadcast with private reply”, or “BPRC”, shall be used to mean that when the recipient of a message from a primary user posts a reply message into a chat or IM group, the reply message is only sent to the primary user (e.g. a “private reply”), and it is not sent to the other group members. Traditional email systems as well as conventional instant messaging systems lack a control such as this, in which the sender of a message, not the recipient, can restrict the flow of reply messages.
[0047] Turning to FIG. 8 , a messaging protocol realized by the present invention is illustrated using an example relative to the previous examples. When a primary user (e.g. a first client) sends a specially-controlled “Broadcast with Private Reply” ( 81 ) to a number of members of a group ( 42 , 43 , 44 ), it is first received by the server ( 46 ), which then forwards copies ( 81 ′, 81 ″, 81 ′″) of the message to each recipient group member ( 42 , 43 , 44 ), respectively.
[0048] When a recipient, such as the third client ( 43 ) replies to the message, the reply message ( 82 ) is received by the server ( 46 ), which then forwards the reply message ( 82 ′) only to the primary user ( 41 ), and not to the other group members ( 42 , 44 ). The reply message is preferably shown to the sender, e.g. the third client ( 43 ), as well, either by keeping a copy local to the client, or by sending a copy back to the third client.
[0049] The example of FIG. 8 also shows a second client ( 42 ) replying to the broadcast message, in which the replies ( 83 , 83 ′) are only sent to the primary user ( 41 ), but are not sent to the other group members ( 43 , 44 ), except for preferably showing the reply to the second client (e.g. the replying party).
[0050] Thus, in this manner, the replies to the original or initial message are blocked by the invention from being propagated to any other users except the user who broadcast the initial message.
[0000] BPRC IM/Chat Multiplexing/Demultiplexing
[0051] In order to accomplish this functionality, one embodiment of the invention provides that the basic IM server code is changed to offer the new functionality as described herein.
[0052] However, it is also desirable to realize a product or system which is interoperable with existing IM/Chat clients and servers in order to maintain full backwards compatibility with the installed base of millions of users and thousands of servers.
[0053] Therefore, a system as shown in FIG. 10 is another available embodiment of the present invention, in which the primary user's IM/chat client (e.g. client 1 ) ( 41 ) is provided with a demultiplexer ( 1051 ) for outbound BPRC messages, and a multiplexer ( 1050 ) for inbound BPRC messages, both of which cooperate ( 1052 ) with each other as described in the following paragraphs.
[0054] In this configuration, when the primary user authors a new IM/Chat message and designates it as a BPRC message, the unitary message ( 1055 ) is intercepted during transmission by the demultiplexer ( 1051 ), which then automatically submits multiple copies ( 1053 ) of the message into a plurality of one-on-one chat or IM groups being handled by the IM server ( 46 ).
[0055] The IM server then can route the messages ( 1053 ) within the two-party groups as previously described and as traditionally handled to the other clients ( 42 , 43 , 44 ) in the BPRC group, such that the core engine of the IM server may remain unchanged. Thus, what appears to the primary user as a unitary message into a multi-party group is transparently converted into multiple messages into a plurality of two-party groups, each client ( 42 , 43 , 44 ) being paired in a two-party group with the primary user ( 41 ).
[0056] As each of the parties ( 42 , 43 , 44 ) replies within their respective two-party group, a plurality of messages ( 1054 ) in a plurality of two-party groups are sent from the server ( 46 ) towards the primary user ( 41 ), but are intercepted by the multiplexer ( 1050 ).
[0057] According to one embodiment of the invention, these reply messages are associated upon receipt with the appropriate BPRC group as indicated by the demultiplexer, and are then “streamed” or forwarded in real-time to the primary user.
[0058] According to an alternate embodiment of the invention, the multiplexer collects these replies ( 1054 ) from a number of two-party groups over time, and associates them with the BPRC group as indicated by the demultiplexer ( 1051 ), preferably by a combination of time (e.g. within a certain number minutes, hours or days of the original message ( 1055 )), topic, original message content, session ID, window or GUI instance, etc. In this alternate embodiment, after the replies ( 1054 ) have been collected by the demultiplexer ( 1050 ), they are combined into a unitary message ( 1056 ) and presented to the primary user ( 41 ) as if it were a unitary message in a multi-party IM/chat group, not a collection of messages from multiple two-party groups.
[0059] However, because transmission was actually handled as a number of two-party groups, none of the replies are allowed to be transmitted to the other parties in the BPRC group, except the primary user ( 41 ), in either embodiment.
[0060] In an embodiment hybrid of the two foregoing embodiments, the primary user is allowed to choose between streaming or real-time reply receipt, or waiting for a consolidated reply, as the former provides faster replies but may cause repeated graphical user interface updates, and as the latter provides for more efficient GUI refreshes but is less immediate in providing the primary user with the earlier replies.
[0061] In another embodiment, the primary user is provided with an option to “replay” the sequence of received messages. According to yet another embodiment, a report is generated to the primary user showing which recipients replied and which did not.
[0062] In this manner, by providing the demultiplexer and multiplexers cooperative with a number of two-party IM/chat groups, the primary user ( 41 ) is allowed to author a message, and to receive reply messages just conveniently as if the group were being handled as a unitary, multi-party IM/chat group, while maintaining control on the distribution of the replies to the rest of the group, and while maintaining compatibility with legacy IM/chat servers and clients.
[0000] Client-Side Implementation
[0063] According to one embodiment, the multiplexer/demultiplexer functionality described in the foregoing paragraphs is realized in conjunction with the client devices or software running on the client devices, such as a plug-in to a browser or IM client program.
[0064] FIG. 11 illustrates such an implementation, wherein a browser, IM agent, or chat agent ( 1101 ) are provided with a functional extension, such as a plug-in or code modification, containing the logical processes of the BPRC Mux-Demux ( 1050 , 1051 ). The apparent multi-party messages ( 1055 ′, 1056 ′) are exchanged between the BPRC Mux/Demux ( 1050 , 1051 ) and the browser or agent ( 1101 ) locally, and the multiple two-party messages ( 1053 , 1054 ) are exchanged between the BPRC Mux/Demux ( 1050 , 1051 ) and a server (not shown in this diagram), typically over a communications network such as the Internet, a WAN, a wireless network, or the like.
[0000] Server-Side Implementation
[0065] According to one embodiment, the multiplexer/demultiplexer functionality described in the foregoing paragraphs is realized in conjunction with the IM/chat server or software running on the IM/chat server, such as a plug-in to an IM or chat server program or suite. In one embodiment, an extension to the IBM SameTime™ messaging software is provided.
[0066] FIG. 17 illustrates such an implementation, wherein an IM server suite ( 50 ) is provided with a functional extension, such as a plug-in or code modification, containing the logical processes of the BPRC Multiplexer/Demultiplexer ( 1050 , 1051 ). The apparent multi-party messages ( 1055 ′, 1056 ′) are exchanged between the BPRC Mux/Demux ( 1056 ′, 1055 ′) and the primary client device ( 41 ) remotely such as via a communications network, and the multiple two-party messages ( 1053 , 1054 ) are exchanged between the BPRC Mux/Demux ( 1050 , 1051 ) and the IM server suite ( 50 ) locally.
[0000] User Interface for BPRC Message Authoring
[0067] Turing to FIG. 1 , a user interface according to the preferred embodiment is shown, which includes a graphical user interface (“GUI”) window ( 1000 ) or dialog box produced in a conventional manner on the screen or display of a client device. It includes form entry boxes, drop-down lists, or other conventional methods to allow the user to specify or select a topic ( 1001 ), the text of a message ( 1002 ), a list of group invitees ( 1003 ), and to enable BPRC chatting ( 1004 ), as well as usual selectable actions such as a “send” and “cancel” button ( 1005 ).
[0000] BPRC Message Controls and Format
[0068] It will be readily recognized by those skilled in the art that many message formats and control schemes may be adopted to realize the present invention. FIG. 12 illustrates one available message format which embeds the BPRC controls in an eXentisible Markup Language (“XML”) style data structures ( 1055 ″, 1056 ′″).
[0069] In this arrangement, the original message ( 1055 ″) includes a topic field ( 1201 ) and an author designation (e.g. “from” field) ( 1203 ), and includes a special designation of a plurality of BPRC group members ( 1202 ) to which the message ( 1204 ) should be sent, and from whom replies should only be routed to the author ( 1203 ). Optionally, a maximum time for waiting ( 1205 ) can also be specified so that the BPRC Mux/Demux function can determine how long to optionally wait for additional replies (if all parties have not already replied).
[0070] The consolidated simulated multi-party message ( 1056 ′″) is created by collecting the individual two-party group replies as previously described, and placing the text of those two-party messages in to a single message field ( 1204 ′) of the reply message ( 1056 ′″), preferrably annotated to indicate which user provided which reply text strings or lines (e.g. Kimberly, Patrick, Andrew, etc.). The consolidated simulated multi-party message ( 1056 ″) and the individual two-party replies are correlated to the original message ( 1055 ″) preferably using the author's indications ( 1211 ), and/or correlated ( 1210 ) by the topic fields ( 1201 ).
[0071] For example, as the reply “Submitted 2 disclosures<LF>Interviewed 3 job candidates<LF>Finalized with dev on defect list” is received from Kimberly in the two-party IM group consisting of Kimberly and Bethany, where <LF> indicates a line feed or carriage return, the BPRC Demux determines that the topic matches that of a recently sent message from Bethany_K, and places that message in a queue for merging with other BPRC replies.
[0072] Then, as the reply “Completed USAB test<LF>Attended WECM Class” is received from user “Patrick”, it too is correlated by topic and sender to the BPRC simulated multi-party group for Bethany_K, and is queued for merging with other BPRC replies.
[0073] Likewise, when a reply message from “Andrew” is received from a two-party IM group consisting of Andrew and Bethany, it is queued for merging, as well.
[0074] When the time for replies has elapsed (e.g. a timeout for replying has expired), or when all of the original recipients have replied, the message text from each of the queued replies is extracted and concatenated into the message field of a consolidated message ( 1056 ″), and the rest of the fields for the consolidated message are generated accordingly (e.g. topic, to, etc.). This unitary message, which appears to be from a multi-party IM/chat group, is then sent to the primary user ( 41 ) for display and further conversation.
[0075] FIG. 13 illustrates such a consolidated simulated multi-party reply message, in which a GUI window or dialog box ( 1301 ) is provided a copy of the original message ( 1204 ), and the collected and concatenated reply messages ( 1204 ′).
[0076] Thus, a transparent conversion is accomplished between an original, unitary, multi-party IM/chat group message, to a plurality of two-party IM/chat group messages and corresponding replies, back to a unitary, consolidated simulated multi-party IM/chat group reply to the originator.
[0000] Logical Processes of the Invention
[0077] Turning to FIG. 14 , a logical process ( 1400 ) according to the present invention is shown in which a BPRC message is authored ( 1401 ), then demultiplexed ( 1402 ) into a plurality of two-party IM/chat group messages which are submitted ( 1403 ) to a plurality of two-party IM/chat groups via a server.
[0078] The logical process then correlates and queues received two-party IM/chat group messages while waiting ( 1404 ) for a present duration or until all parties have replied, after which a unitary, simulated multi-party IM/chat group reply message is created ( 1405 ) and sent ( 1406 ) to the primary client.
[0079] The process can be repeated ( 1407 ) if the primary client decides to reply to the replies. For example, the user interface shown in FIG. 15 allows the primary user to select any or all of the original BPRC recipient list ( 1501 ) for receiving the next message (e.g. the reply to the replies).
[0000] Enhanced Embodiment Using BPRC Sub-Groups
[0080] According to another embodiment of the invention, the BPRC list of recipients can be further divided into sub-groups such that a reply from a member of a sub-group is automatically transmitted to the primary party and to the other parties in the same sub-group, but is not transmitted to the members of other sub-groups. This enhanced functionality allows even greater control by the primary user in the dissemination and flow of information.
[0081] To accomplish this, when the invention determines when a sub-group ( 1202 ′) is indicated in the original message, such as shown in FIG. 16 . If a sub-group is found, then a reduced multi-party IM/chat group is utilized with the IM server ( 46 ) instead of a set of two-party IM/chat groups. In the example shown in FIG. 16 , the entire multi-party group would normally consist of the primary user, Bethany, with five other members, Wilbert, Patrick, Kimberly, Andrew and Marty. Using the invention as previously described (without sub-groups), the original message would be directed towards five different two-party IM/chat groups, namely:
(a) Bethany and Wilbert; (b) Bethany and Patrick; (c) Bethany and Kimberly; (d) Bethany and Andrew; and (e) Bethany and Marty.
[0087] However, using sub-groups as indicated in the example of FIG. 16 , the following reduced multi-party IM/chat groups would be utilized:
(a) Bethany, Wilbert and Patrick; (b) Bethany, Kimberly, and Andrew;
[0090] as well as one two-party IM/chat group:
(c) Bethany and Marty.
[0092] In this enhanced embodiment of the invention, when Bethany's original message is replied to by Patrick, it would be sent to Bethany (the primary user or originator) as well as to Wilbert, but not to Kimberly, Andrew or Marty. Likewise, a reply sent by Andrew would be copied to Kimberly and Bethany, but not to Wilbert, Patrick or Marty. A reply sent by Marty would only be copied to Bethany.
[0000] Suitable Computing Platform
[0093] The invention is preferably realized as a feature or addition to the software already found present on well-known computing platforms such as personal computers, web servers, and web browsers. These common computing platforms can include personal computers as well as portable computing platforms, such as personal digital assistants (“PDA”), web-enabled wireless telephones, and other types of personal information management (“PIM”) devices.
[0094] Therefore, it is useful to review a generalized architecture of a computing platform which may span the range of implementation, from a high-end web or enterprise server platform, to a personal computer, to a portable PDA or web-enabled wireless phone.
[0095] Turning to FIG. 2 a , a generalized architecture is presented including a central processing unit ( 21 ) (“CPU”), which is typically comprised of a microprocessor ( 22 ) associated with random access memory (“RAM”) ( 24 ) and read-only memory (“ROM”) ( 25 ). Often, the CPU ( 21 ) is also provided with cache memory ( 23 ) and programmable FlashROM ( 26 ). The interface ( 27 ) between the microprocessor ( 22 ) and the various types of CPU memory is often referred to as a “local bus”, but also may be a more generic or industry standard bus.
[0096] Many computing platforms are also provided with one or more storage drives ( 29 ), such as a hard-disk drives (“HDD”), floppy disk drives, compact disc drives (CD, CD-R, CD-RW, DVD, DVD-R, etc.), and proprietary disk and tape drives (e.g., Iomega Zip™ and Jaz™, Addonics SuperDisk™, etc.). Additionally, some storage drives may be accessible over a computer network.
[0097] Many computing platforms are provided with one or more communication interfaces ( 210 ), according to the function intended of the computing platform. For example, a personal computer is often provided with a high speed serial port (RS-232, RS-422, etc.), an enhanced parallel port (“EPP”), and one or more universal serial bus (“USB”) ports. The computing platform may also be provided with a local area network (“LAN”) interface, such as an Ethernet card, and other high-speed interfaces such as the High Performance Serial Bus IEEE-1394.
[0098] Computing platforms such as wireless telephones and wireless networked PDA's may also be provided with a radio frequency (“RF”) interface with antenna, as well. In some cases, the computing platform may be provided with an infrared data arrangement (“IrDA”) interface, too.
[0099] Computing platforms are often equipped with one or more internal expansion slots ( 211 ), such as Industry Standard Architecture (“ISA”), Enhanced Industry Standard Architecture (“EISA”), Peripheral Component Interconnect (“PCI”), or proprietary interface slots for the addition of other hardware, such as sound cards, memory boards, and graphics accelerators.
[0100] Additionally, many units, such as laptop computers and PDA's, are provided with one or more external expansion slots ( 212 ) allowing the user the ability to easily install and remove hardware expansion devices, such as PCMCIA cards, SmartMedia cards, and various proprietary modules such as removable hard drives, CD drives, and floppy drives.
[0101] Often, the storage drives ( 29 ), communication interfaces ( 210 ), internal expansion slots ( 211 ) and external expansion slots ( 212 ) are interconnected with the CPU ( 21 ) via a standard or industry open bus architecture ( 28 ), such as ISA, EISA, or PCI. In many cases, the bus ( 28 ) may be of a proprietary design.
[0102] A computing platform is usually provided with one or more user input devices, such as a keyboard or a keypad ( 216 ), and mouse or pointer device ( 217 ), and/or a touch-screen display ( 218 ). In the case of a personal computer, a full size keyboard is often provided along with a mouse or pointer device, such as a track ball or TrackPoint™. In the case of a web-enabled wireless telephone, a simple keypad may be provided with one or more function-specific keys. In the case of a PDA, a touch-screen ( 218 ) is usually provided, often with handwriting recognition capabilities.
[0103] Additionally, a microphone ( 219 ), such as the microphone of a web-enabled wireless telephone or the microphone of a personal computer, is supplied with the computing platform. This microphone may be used for simply reporting audio and voice signals, and it may also be used for entering user choices, such as voice navigation of web sites or auto-dialing telephone numbers, using voice recognition capabilities.
[0104] Many computing platforms are also equipped with a camera device ( 2100 ), such as a still digital camera or full motion video digital camera.
[0105] One or more user output devices, such as a display ( 213 ), are also provided with most computing platforms. The display ( 213 ) may take many forms, including a Cathode Ray Tube (“CRT”), a Thin Flat Transistor (“TFT”) array, or a simple set of light emitting diodes (“LED”) or liquid crystal display (“LCD”) indicators.
[0106] One or more speakers ( 214 ) and/or annunciators ( 215 ) are often associated with computing platforms, too. The speakers ( 214 ) may be used to reproduce audio and music, such as the speaker of a wireless telephone or the speakers of a personal computer. Annunciators ( 215 ) may take the form of simple beep emitters or buzzers, commonly found on certain devices such as PDAs and PIMs.
[0107] These user input and output devices may be directly interconnected ( 28 ′, 28 ″) to the CPU ( 21 ) via a proprietary bus structure and/or interfaces, or they may be interconnected through one or more industry open buses such as ISA, EISA, PCI, etc.
[0108] The computing platform is also provided with one or more software and firmware ( 2101 ) programs to implement the desired functionality of the computing platforms.
[0109] Turning to now FIG. 2 b , more detail is given of a generalized organization of software and firmware ( 2101 ) on this range of computing platforms. One or more operating system (“OS”) native application programs ( 223 ) may be provided on the computing platform, such as word processors, spreadsheets, contact management utilities, address book, calendar, email client, presentation, financial and bookkeeping programs.
[0110] Additionally, one or more “portable” or device-independent programs ( 224 ) may be provided, which must be interpreted by an OS-native platform-specific interpreter ( 225 ), such as Java™ scripts and programs.
[0111] Often, computing platforms are also provided with a form of web browser or micro-browser ( 226 ), which may also include one or more extensions to the browser such as browser plug-ins ( 227 ).
[0112] The computing device is often provided with an operating system ( 220 ), such as Microsoft Windows™, UNIX, IBM OS/2™, IBM AIX™, open source LINUX, Apple's MAC OS™, or other platform specific operating systems. Smaller devices such as PDA's and wireless telephones may be equipped with other forms of operating systems such as real-time operating systems (“RTOS”) or Palm Computing's PalmOS™.
[0113] A set of basic input and output functions (“BIOS”) and hardware device drivers ( 221 ) are often provided to allow the operating system ( 220 ) and programs to interface to and control the specific hardware functions provided with the computing platform.
[0114] Additionally, one or more embedded firmware programs ( 222 ) are commonly provided with many computing platforms, which are executed by onboard or “embedded” microprocessors as part of the peripheral device, such as a micro controller or a hard drive, a communication processor, network interface card, or sound or graphics card.
[0115] As such, FIGS. 2 a and 2 b describe in a general sense the various hardware components, software and firmware programs of a wide variety of computing platforms, including but not limited to personal computers, PDAs, PIMs, web-enabled telephones, and other appliances such as WebTV™ units. As such, we now turn our attention to disclosure of the present invention relative to the processes and methods preferably implemented as software and firmware on such a computing platform. It will be readily recognized by those skilled in the art that the following methods and processes may be alternatively realized as hardware functions, in part or in whole, without departing from the spirit and scope of the invention.
[0000] Software Deployment
[0116] According to one embodiment of the invention, the methods and processes of the invention are distributed or deployed as a service to by a service provider to a client's computing system(s).
[0117] Turning to FIG. 3 a , the deployment process begins ( 3000 ) by determining ( 3001 ) if there are any programs that will reside on a server or servers when the software is executed. If this is the case then the servers that will contain the executables are identified ( 309 ). The appropriate software for the server or servers is transferred directly to the servers storage via FTP or some other protocol or by copying through the use of a shared files system ( 310 ). The appropriate software is then installed on the servers ( 311 ).
[0118] Next a determination is made on whether the appropriate software is to be deployed by having users access the software on a server or servers ( 3002 ). If the users are to access the software on servers then the server addresses that will store the software are identified ( 3003 ).
[0119] In step ( 3004 ) a determination is made whether the software is to be developed by sending the software to users via e-mail. The set of users where the software will be deployed are identified together with the addresses of the user client computers ( 3005 ). The software is sent via e-mail to each of the user's client computers. The users then receive the e-mail ( 305 ) and then detach the software from the e-mail to a directory on their client computers ( 306 ). The user executes the program that installs the software on his client computer ( 312 ) then exits the process ( 3008 ).
[0120] A determination is made if a proxy server is to be built ( 300 ) to store the software. A proxy server is a server that sits between a client application, such as a Web browser, and a destination server. It intercepts all requests to the destination server to see if it can fulfill the requests itself. If not, it forwards the request to the destination server. The two primary benefits of a proxy server are to improve performance and to filter requests. If a proxy server is required then the proxy server is installed ( 301 ). The software is sent to the servers either via a protocol such as FTP or its copied directly from the source files to the server files via file sharing ( 302 ). Another embodiment would be to send a transaction to the servers that contained the software and have the server process the transaction, then receive and copy the software to the server's file system. Once the software is stored at the servers, the users via their client computers, then access the software on the servers and copy to their client computers file systems ( 303 ). Another embodiment is to have the servers automatically copy the software to each client and then run the installation program for the software at each client computer. The user executes the program that installs the software on his client computer ( 312 ) then exits the process ( 3008 ).
[0121] Lastly, a determination is made on whether the software will be sent directly to user directories on their client computers ( 3006 ). If so, the user directories are identified ( 3007 ). The software is transferred directly to the user's client computer directory ( 307 ). This can be done in several ways such as but not limited to sharing of the file system directories and then copying from the sender's file system to the recipient user's file system or alternatively using a transfer protocol such as File Transfer Protocol (“FTP”). The users access the directories on their client file systems in preparation for installing the software ( 308 ). The user executes the program that installs the software on his client computer ( 312 ) then exits the process ( 3008 ).
[0000] Software Integration
[0122] According to another embodiment of the present invention, software embodying the methods and processes disclosed herein are integrated as a service by a service provider to other software applications, applets, or computing systems.
[0123] Integration of the invention generally includes providing for the BPRC software to coexist with applications, operating systems and network operating systems software and then installing the BPRC software on the clients and servers in the environment where the BPRC software will function.
[0124] Generally speaking, the first task is to identify any software on the clients and servers including the network operating system where the BPRC software will be deployed that are required by the BPRC software or that work in conjunction with the BPRC software. This includes the network operating system that is software that enhances a basic operating system by adding networking features. Next, the software applications and version numbers will be identified and compared to the list of software applications and version numbers that have been tested to work with the BPRC software. Those software applications that are missing or that do not match the correct version will be upgraded with the correct version numbers. Program instructions that pass parameters from the BPRC software to the software applications will be checked to ensure the parameter lists matches the parameter lists required by the BPRC software. Conversely parameters passed by the software applications to the BPRC software will be checked to ensure the parameters match the parameters required by the BPRC software. The client and server operating systems including the network operating systems will be identified and compared to the list of operating systems, version numbers and network software that have been tested to work with the BPRC software. Those operating systems, version numbers and network software that do not match the list of tested operating systems and version numbers will be upgraded on the clients and servers to the required level.
[0125] After ensuring that the software, where the BPRC software is to be deployed, is at the correct version level that has been tested to work with the BPRC software, the integration is completed by installing the BPRC software on the clients and servers.
[0126] Turning to FIG. 3 b , details of the integration process according to the invention are shown. Integrating begins ( 320 ) by determining if there are any BPRC software programs that will execute on a server or servers ( 321 ). If this is not the case, then integration proceeds to ( 327 ). If this is the case, then the server addresses are identified ( 322 ). The servers are checked to see if they contain software that includes the operating system (“OS”), applications, and network operating systems (“NOS”), together with their version numbers, that have been tested with the BPRC software ( 323 ). The servers are also checked to determine if there is any missing software that is required by the BPRC software ( 323 ).
[0127] A determination is made if the version numbers match the version numbers of OS, applications and NOS that have been tested with the BPRC software ( 324 ). If all of the versions match and there is no missing required software the integration continues in ( 327 ).
[0128] If one or more of the version numbers do not match, then the unmatched versions are updated on the server or servers with the correct versions ( 325 ). Additionally if there is missing required software, then it is updated on the server or servers ( 325 ). The server integration is completed by installing the BPRC software ( 326 ).
[0129] Step ( 327 ) which follows either ( 321 ), ( 324 ), or ( 326 ) determines if there are any programs of the BPRC software that will execute on the clients. If no BPRC software programs execute on the clients the integration proceeds to ( 330 ) and exits. If this is not the case, then the client addresses are identified ( 328 ).
[0130] The clients are checked to see if they contain software that includes the operating system (“OS”), applications, and network operating systems (“NOS”), together with their version numbers, that have been tested with the BPRC software ( 329 ). The clients are also checked to determine if there is any missing software that is required by the BPRC software ( 329 ).
[0131] A determination is made if the version numbers match the version numbers of OS, applications and NOS that have been tested with the BPRC software 331 . If all of the versions match and there is no missing required software, then the integration proceeds to ( 330 ) and exits.
[0132] If one or more of the version numbers do not match, then the unmatched versions are updated on the clients with the correct versions ( 332 ). In addition, if there is missing required software then it is updated on the clients ( 332 ). The client integration is completed by installing the BPRC software on the clients ( 333 ). The integration proceeds to ( 330 ) and exits.
[0000] VPN Deployment
[0133] According to another aspect of the present invention, the methods and processes described herein may be embodied in part or in entirety in software which can be deployed to third parties as part of a service, wherein a third party virtual private network (“VPN”) service is offered as a secure deployment vehicle or wherein a VPN is build on-demand as required for a specific deployment.
[0134] A VPN is any combination of technologies that can be used to secure a connection through an otherwise unsecured or untrusted network. VPNs improve security and reduce operational costs. The VPN makes use of a public network, usually the Internet, to connect remote sites or users together. Instead of using a dedicated, real-world connection such as leased line, the VPN uses “virtual” connections routed through the Internet from the company's private network to the remote site or employee. Access to the software via a VPN can be provided as a service by specifically constructing the VPN for purposes of delivery or execution of the BPRC software (i.e. the software resides elsewhere) wherein the lifetime of the VPN is limited to a given period of time or a given number of deployments based on an amount paid.
[0135] The BPRC software may be deployed, accessed and executed through either a remote-access or a site-to-site VPN. When using the remote-access VPNs the BPRC software is deployed, accessed and executed via the secure, encrypted connections between a company's private network and remote users through a third-party service provider. The enterprise service provider (“ESP”) sets a network access server (“NAS”) and provides the remote users with desktop client software for their computers. The telecommuters can then dial a toll-free number to attach directly via a cable or DSL modem to reach the NAS and use their VPN client software to access the corporate network and to access, download and execute the BPRC software.
[0136] When using the site-to-site VPN, the BPRC software is deployed, accessed and executed through the use of dedicated equipment and large-scale encryption that are used to connect a companies multiple fixed sites over a public network such as the Internet.
[0137] The BPRC software is transported over the VPN via tunneling which is the process of placing an entire packet within another packet and sending it over the network. The protocol of the outer packet is understood by the network and both points, called tunnel interfaces, where the packet enters and exits the network.
[0138] Turning to FIG. 3 c , VPN deployment process starts ( 360 ) by determining if a VPN for remote access is required ( 361 ). If it is not required, then proceed to ( 362 ). If it is required, then determine if the remote access VPN exits ( 364 ).
[0139] If a VPN does exist, then the VPN deployment process proceeds ( 365 ) to identify a third party provider that will provide the secure, encrypted connections between the company's private network and the company's remote users ( 376 ). The company's remote users are identified ( 377 ). The third party provider then sets up a network access server (“NAS”) ( 378 ) that allows the remote users to dial a toll free number or attach directly via a broadband modem to access, download and install the desktop client software for the remote-access VPN ( 379 ).
[0140] After the remote access VPN has been built or if it has been previously installed, the remote users can access the BPRC software by dialing into the NAS or attaching directly via a cable or DSL modem into the NAS ( 365 ). This allows entry into the corporate network where the BPRC software is accessed ( 366 ). The BPRC software is transported to the remote user's desktop over the network via tunneling. That is the BPRC software is divided into packets and each packet including the data and protocol is placed within another packet ( 367 ). When the BPRC software arrives at the remote user's desktop, it is removed from the packets, reconstituted and then is executed on the remote users desktop ( 368 ).
[0141] A determination is made to see if a VPN for site to site access is required ( 362 ). If it is not required, then proceed to exit the process ( 363 ). Otherwise, determine if the site to site VPN exists ( 369 ). If it does exist, then proceed to ( 372 ). Otherwise, install the dedicated equipment required to establish a site to site VPN ( 370 ). Then build the large scale encryption into the VPN ( 371 ).
[0142] After the site to site VPN has been built or if it had been previously established, the users access the BPRC software via the VPN ( 372 ). The BPRC software is transported to the site users over the network via tunneling. That is the BPRC software is divided into packets and each packet including the data and protocol is placed within another packet ( 374 ). When the BPRC software arrives at the remote user's desktop, it is removed from the packets, reconstituted and is executed on the site users desktop ( 375 ). Proceed to exit the process ( 363 ).
CONCLUSION
[0143] The present invention has been set forth using a number of examples for illustration. It will be readily recognized by those skilled in the art that these examples do not represent the entire scope of the present invention, and that certain changes, modifications, and substitutions may be made in the selection of components, programming methodologies, computing platforms, and protocols, without departing from the spirit and scope of the present invention. Therefore, the scope of the invention should be determined by the following claims.
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A system and method for controlling the flow of reply messages cooperative with a multi-party Instant Messaging or chat service including a multi-party IM/chat group primary message having a text portion, a primary author indication portion, a blind-copy recipient list, wherein the blind-copy recipient list contains a plurality of recipients for the primary message; a demultiplexer for converting the primary message into a plurality of reduced multi-party messages, wherein each of the reduced multi-party messages are addressed to a sub-group of the blind-copy recipient list; a message submitter for submitting the reduced multi-party messages to an IM/chat service; a multiplexer which receives a plurality of reduced multi-party reply messages from the IM/chat service; and a reply message generator for extracting reply message text from the received reduced-party reply messages, and for generating a unitary simulated multi-party reply message containing the extracted reply message text for display to the primary author.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to drive mechanisms for vehicle sunroofs and, more particularly, to a drive mechanism for a vehicle sunroof having means for detecting the fully open and fully closed positions of the movable roof panel of the sunroof and shutting off the sunroof drive motor when the roof panel reaches either of its limits of movement.
2. Description of the Prior Art
A typical vehicle sunroof of the sliding type usually includes a roof panel which slidably moves beneath the stationary roof portion of the vehicle to reveal an opening in the roof. The movable roof panel usually is mounted on shoes which slidably engage guide rails provided along the sides of the sunroof frame. Movement of the panel is effected, in the case of powered units, by a drive motor which acts through a transmission to drive a pair of push-pull cables, each of which is coupled to the shoes on either side of the sunroof opening.
The drive motor of a powered sunroof is susceptible to overloading and burnout if electrical power continues to be delivered to the motor after the roof panel has reached either of its limits of movement, i.e., either its fully closed or fully open position. In order to prevent such overloading, means usually is provided for detecting the end positions of the roof panel and shutting off the motor when these limits are reached. Limit switches usually are positioned adjacent the path of travel of the roof panel, these switches directly sensing the presence of the panel when it reaches either limit of movement. In installing this type of sunroof, however, it is often quite difficult initially to adjust the positions of the switches relative to the sunroof opening so that they correctly sense the end positions of the slidable roof panel. This is due to the fact that the switches, which must be installed before the roof panel, become concealed once the roof panel has been installed. In most cases, due to manufacturing and assembly inaccuracies, repeated adjustment is required at the time of sunroof installation. This results in excessive manufacturing time for each vehicle. Also contributing to excessive manufacturing time is the necessity of separately installing limit switches and associated connectors--additional parts which augment an already lengthy list of parts for any contemporary automobile.
Another type of roof panel position detector is disclosed in West German Pat. No. 19 06 084, published Oct. 15, 1970. In the sunroof there disclosed, a pinion meshes with one of the sunroof drive cables and is rotated whenever the roof panel moves. A worm gear is mounted on the pinion shaft, and a longitudinally slidably guided, internally threaded collar surrounds and meshes with the worm gear. The collar has two trip cams which actuate adjacent limit switches to control the drive motor when the collar is moved longitudinally by the action of the driven pinion and the engaged threaded surfaces of the worm and collar. This detection mechanism significantly reduces the need for repeated roof panel removal and adjustment, but does not solve other problems associated with sunroof mechanisms. For example, the detection mechanism itself constitutes one more item which requires installation time in the vehicle, occupies additional space in an area where space is at a premium, and requires separate access through the sunroof frame for installation and removal for repair or replacement.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to obviate the above noted disadvantages and shortcomings of the prior art by providing a mechanism for reliably and accurately detecting the end positions of a sunroof panel without the need for readjustment once the panel is installed in the vehicle roof.
Another object of the invention is to provide such a mechanism which occupies very little space, requires no separate access for installation or removal, and requires no additional installation time in the vehicle.
Another object of the invention is to provide such a mechanism which can be preassembled and properly adjusted before installation in the vehicle.
Another object of the invention is to provide such a mechanism which is an integral part of a unitary drive mechanism for the vehicle sunroof.
These and other objects of the present invention are accomplished by providing a drive mechanism for a vehicle sunroof having a movable roof panel, the drive mechanism comprising a motor and a rotatable drive shaft operatively coupled to and driven by the motor. Transmission means is connected to the drive shaft, and is adapted to be operatively coupled to the movable roof panel, for transmitting motive power from the drive shaft to the roof panel. Roof panel position indicating means has indicia corresponding to the limits of movement of the roof panel, and is driven by reduction gear means which interconnects the drive shaft and the indicating means and effects movement of the indicating means at a reduced rate. Switch means is provided which is operatively coupled to the indicating means, senses the position of the indicia and shuts off the motor when the roof panel reaches either of its limits of movement.
Preferably the drive mechanism of the invention is adapted to be installed as a single unit in the sunroof. To this end, the drive mechanism comprises a housing to which the motor is attached and in which the drive shaft is journaled. The transmission means also is contained within the housing, and the other elements are physically associated with the housing such that the entire drive mechanism may be installed or removed as a unit.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features of the invention are set out with particularity in the appended claims, but the invention will be understood more fully and clearly from the following detailed description of the invention as set forth in the accompanying drawings, in which:
FIG. 1 is a plan view of a vehicle sunroof and a drive mechanism therefor according to the present invention;
FIG. 2 is a plan view of the drive mechanism itself;
FIG. 3 is a sectional view of the drive mechanism taken along line 3--3 in FIG. 2;
FIG. 4 is a plan view of a reduction gear which forms a part of the drive mechanism; and
FIG. 5 is a sectional view of the reduction gear and the element driven thereby taken along line 5--5 in FIG. 4.
DETAILED DESCRIPTION
Referring to FIG. 1, a vehicle roof 1 has a sunroof opening 1a in which is situated a slidable roof panel 2. Roof panel 2 also covers a rearwardly offset opening 24 in the vehicle headliner or inner roof. The end portions of roof panel 2 are broken away in FIG. 1 to reveal the underlying structure. Roof panel 2 is retractable beneath roof 1 to open roof opening 1a and headliner opening 24. A frame 3 is situated below roof 1 and surrounds the front and sides of opening 1a and the sides and rear of the retracted position of roof panel 2. Weatherstripping (not shown) is provided around the perimeter of roof opening 1a, and is adapted to close the gap between opening 1a and the periphery of roof panel 2 and inhibit leakage of wind and water, in a known conventional manner. Conventional drainage channels (also not shown) are provided for carrying away any rain water which may accumulate within frame 3.
Frame 3 is provided with a pair of guide rails 4 along which roof panel 2 is guided. Roof panel 2 is supported on a number of shoes 5 secured to the inside of the panel. Each shoe is slidably disposed on and retained by guide rails 4. Movement of roof panel 2 is effected by a pair of toothed drive cables 7, the ends of which are attached to shoes 5. Cables 7 are a known type of push-pull cable normally used in sunroof drives, having a spiral wire wound around the cable core. A drive mechanism 6 is secured to frame 3 by bolts or other suitable fasteners (not shown) and operatively engages the spirals of cables 7 to move roof panel 2 fore and aft.
Referring to FIGS. 2 and 3, drive mechanism 6 includes a housing 25 to which an electric motor 8 is secured by bolts 26. Electric power is delivered to motor 8 through leads 27. A worm gear 28 mounted on motor shaft 29 engages a roller gear 30 which is freely rotatable about a drive shaft 10. Drive shaft 10 is journaled in bearings 41, 42 which are secured in housing 25. The lower face of roller gear 30 engages the friction disk 31 of a clip clutch 32. Slip clutch 32 has a conical spring 33 which bears against the upper surface of a pinion 34 and urges friction disk 31 into engagement with roller gear 30. Slip clutch 32 and pinion 34 are keyed to drive shaft 10. Motive power is delivered by rotating pinion 34 to cables 7 by means of a reduction gear 9 and a geared output shaft 11, both of which are journaled in housing 25.
The roof panel position indicating mechanism now will be described with reference to FIGS. 3, 4 and 5. The upper end of drive shaft 10 drives a cam plate 16 which is rotatable coaxially of drive shaft 10 and is retained on a grooved extension 35 of drive shaft 10 by a snap ring 36. Cam plate 16 is driven by drive shaft 10 through a reduction gear 14 so that it slowly travels through a predetermined arc of rotation between the fully open and fully closed positions of roof panel 2. Reduction gear 14 is a so-called "KHV" planetary gear reduction unit. Gear reduction systems of this type have been used in, for example, automobile window regulator systems. Gear reduction unit 14 comprises an eccentric drive cam 37 keyed to drive shaft 10. Cam 37 slidably rotates within an externally toothed planetary ring gear 38. The teeth of ring gear 38 mesh with the internal teeth of a stationary sun gear 39, which is fixed to housing 25 and is coaxial with drive shaft 10. As seen in FIG. 4, clockwise rotation of cam 37 causes counterclockwise rotation of ring gear 38 as it meshes with the teeth of sun gear 38, but at a greatly reduced rate. The motion of ring gear 38 is transmitted to cam plate 16 by a pin 15 which is secured to planetary gear 38 and engages a slot 40 in cam plate 16.
Cam plate 16 is provided with a peripheral cam surface 22 including two cam grooves 17, 18 at separate circumferential and elevational positions on its periphery. Cam groove 18 is higher than cam groove 17. A pair of microswitches 19, 20 are secured to housing 25 adjacent cam surface 22. Switch 19 has an actuator 23 which is adapted to contact cam surface 22, while switch 20 has an actuator 21 which also is adapted to contact cam surface 22. The open or closed conditions of switches 19, 20 are controlled by contact of actuators 23, 21 with the cam surface 22.
The operation of the drive mechanism now will be described with reference to FIG. 2. Actuator 21 of microswitch 20 is there illustrated as engaged with the cam surface 22 of cam plate 16, but not in contact with cam groove 18. Switch 20 therefore is actuated to indicate that roof panel 2 is in its fully closed position, and will disconnect electric power to motor 8 through known conventional circuitry. When motor 8 is operated in reverse to slide panel 2 to its fully open position, cam plate 16 is rotated in the direction of arrow A to place cam groove 18 in contact with actuator 21. During this movement, contact 23 of switch 19 rides along cam groove 17. At the point where panel 2 reaches its fully open position, actuator 23 rides up out of cam groove 17 onto the outer periphery of cam surface 22. Switch 19 therefore is actuated to disconnect electric power from motor 8. At the same time, actuator 21 of switch 20 is engaged with cam groove 18, and is actuated to permit reverse rotation of cam plate 16 (in the direction of arrow B) when the operator desires to close roof panel 2. At substantially any intermediate position of roof panel 2, actuators 21, 23 are engaged with their respective cam grooves 18, 17 to actuate switches 20, 19 so that roof panel 2 can selectively be moved in either direction.
The above-described mechanism readily accomplishes the stated objectives. The unitary nature of the drive mechanism, with its preadjusted switches and cam plate, enable it to be installed quickly and easily with no adjustment required subsequent to installation of the roof panel 2. Once drive mechanism 6 is installed on frame 3 and coupled to cables 7, with the cam plate 16 in the position corresponding to the fully closed position of roof panel 2, all that is required is the installation of roof panel 2 on guides 5 in the closed position. Should repair of replacement of the drive mechanism be required, it is a simple matter to remove it as a whole from frame 3 with little disruption. The roof panel position detector (cam plate, switches, etc.) occupies very little space, requires no separate access for installation or removal, and requires no additional installation time in the vehicle.
It will be apparent to those skilled in the art that numerous changes and modifications may be made within the scope of the invention. For example, cam plate 16 may take the form of any type of roof panel position indicating member having indicia corresponding to the limits of movement of the roof panel. Hence, cam plate 16 may take the form of a rotatable disc having two permanent magnets located at predetermined positions on its periphery, the magnets causing actuation of Hall effect sensors or reed switches when in close proximity thereto. Alternatively, plate 16 may have two apertures at predetermined locations, with an optical sensor or sensors positioned thereabove to "read" the location of the apertures and trigger switches accordingly. Any type of reduction gear may be used to produce a slow rotation of cam plate 16. Other variations and modifications will be apparent to those skilled in the art without departing from the true spirit and scope of the invention, which is to be limited only by the appended claims.
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A drive mechanism for a vehicle sunroof having a roof panel, the drive mechanism providing for accurate and reliable shut-off of the sunroof drive motor when the roof panel reaches either its fully closed or fully open position. The drive mechanism includes a rotatable cam plate which is mounted directly on the housing of the drive mechanism, the drive mechanism being installable as a unit in the sunroof assembly and the cam plate actuating limit switches for controlling the motor.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of co-pending patent application Ser. No. 12/462,093 filed on Jul. 29, 2009, which in turn claims the benefit of provisional patent application Ser. No. 61/207,774 filed Feb. 17, 2009 by the present inventors.
FIELD OF THE INVENTION
The subject disclosure generally pertains to paint sprayers and more specifically to means for protecting a bearing from detrimentally high air pressure.
BACKGROUND
Many paint sprayers comprise an air compressor that supplies pressurized air to a portable paint gun. High-pressure air discharging from the compressor and flowing through the paint gun draws up liquid paint from a canister, and a nozzle on the spray gun then sprays the mixture of paint and air to a target surface. Although such paint sprayers are effective, there seems to be an ongoing need to improve their quality and longevity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows one example of a paint sprayer with its motor shown in cross-section and its paint gun shown schematically.
FIG. 2 is similar to FIG. 1 but showing the paint sprayer's valve in an open position rather than the closed position of FIG. 1 .
FIG. 3 is a cross-sectional view showing the paint sprayer's annular seal and FIG. 3 a is an enlarged detail of circled section 3 a of FIG. 3 .
FIG. 4 is a cross-sectional view similar to FIG. 3 but showing another example seal arrangement.
DETAILED DESCRIPTION
FIGS. 1-3 and FIG. 3 a show one example of a paint sprayer 10 . In this particular example, paint sprayer 10 comprises an outboard motor bracket 12 , an inboard motor bracket 14 with a bearing bore 16 ; a stator 18 interposed between outboard motor bracket 12 and inboard motor bracket 14 ; an outboard rolling element bearing 20 supported by outboard motor bracket 12 ; an inboard rolling element bearing 22 that includes an outer race 24 , an inner race 26 , and a plurality of rollers 28 interposed between races 24 and 26 . The terms, “roller” and “rollers” refer to any shaped element meant for rolling between two bearing races. Examples of such rollers include, but are not limited to, spherical balls, cylinders, cones segments, etc. In some examples, a bearing retainer 30 holds inboard bearing 22 in place. In other examples, inboard bearing 22 is held in place by an adhesive and/or an interference fit between the bearing's outer race and the bore in which the bearing is installed.
Outer race 24 is supported by inboard motor bracket 14 . Outer race 24 and inner race 26 provide a first axial face 32 and a second axial face 34 that are substantially concentric, face away from outboard bearing 20 , and are radially spaced apart from each other. In some examples, axial faces 4 and/or 4 are the outermost axial surface faces that face away form outboard bearing 20 . For the illustrated example, first axial face 32 is on outer race 24 , and second axial face 34 is on inner race 26 ; however, the nomenclature of the terms, “first” and “second” could be reversed, i.e., first axial face 32 could be on inner race 26 and second axial face 34 could be on outer race 24 .
For this example, paint sprayer 10 further comprises a shaft 36 extending through bearing bore 16 of inboard motor bracket 14 . Shaft 36 is supported by inboard bearing 22 and outboard bearing 20 . This example of paint sprayer 10 also comprises a rotor 38 supported by shaft 36 ; a discharge volute 40 (sometimes known as a discharge horn) adjacent to inboard motor bracket 14 and defining a discharge opening 42 ; a turbine housing 44 adjacent to discharge volute 40 and defining a suction inlet 46 ; and a plurality of turbine wheels 48 attached to shaft 36 and disposed within turbine housing 44 such that shaft 36 , rotor 38 , and the plurality of turbine wheels 48 rotate as a unit at a rotational speed that may vary in response to changing discharge pressure. The present invention is particularly effective with rotor 38 and stator 18 being a universal motor with rotor 38 rotating at speeds in excess of 10,000 revolutions per minute.
This example of paint sprayer 10 also includes a paint canister 50 to hold a liquid 52 (e.g., paint, stain, etc.) and a paint gun 54 connected to paint canister 50 . Paint gun 54 has an air inlet 56 , a spray outlet 58 , and a paint gun valve 60 . A finger trigger 61 moves paint gun valve 60 between an open position ( FIG. 2 ) and a closed position ( FIG. 1 ) to respectively open or obstruct flow from air inlet 56 to spray outlet 58 . To convey pressurized air to paint gun 54 , a hose 62 connects discharge opening 42 of discharge volute 40 to air inlet 56 of paint gun 54 .
To prevent high pressure, high temperature air from flushing the lubricant out from within inboard bearing 22 , paint sprayer 10 includes an annular seal 64 . Seal 64 encircles shaft 36 and axially engages first axial face 32 and second axial face 34 of inboard bearing 28 with an upstream surface 66 of seal 64 facing away from inboard bearing 22 . Seal 64 is held against first axial face 32 (on race 26 as illustrated, or on race 24 ) and seal 64 is pneumatically urged against second axial face 34 with an axial pneumatic pressure 68 against upstream surface 66 . The axial pneumatic pressure 68 increases with the rotational speed of the plurality of turbine wheels 48 , wherein the rotational speed of the plurality of turbine wheels 48 increases in response to paint gun valve 60 moving from the open position to the closed position.
In some examples of paint sprayer 10 , seal 64 has a deflection coefficient of 0.0005 to 0.02. Such a deflection coefficient allows seal 64 to flexibly press in axial sealing contact against second axial face 34 of inboard bearing 22 yet provides seal 64 with sufficient stiffness to avoid excessive distortion of the seal. The deflection coefficient is a ratio defined as a numerator divided by a denominator, wherein the numerator is the axial pneumatic pressure 68 (against upstream surface 66 ) multiplied by a difference between the seal's outer diameter 70 and inner diameter 72 . The denominator of the deflection coefficient is an axial material thickness 74 of seal 64 multiplied by a Young's modulus of elasticity (i.e., specifically the tensile modulus of elasticity at 73° F.) of the seal's material.
The axial pneumatic pressure 68 , outer diameter 70 , inner diameter 72 , the axial material thickness 74 , and the Young's modulus of elasticity can be in any units that render the deflection coefficient a dimensionless ratio. For example, the axial pneumatic pressure can be units of psig (pounds per square-inch), diameters 70 and 72 can be in units of inches, the Young's modulus of elasticity can be in units of psi (pounds per square-inch), and the axial material thickness 74 can be in units of inches.
The axial pneumatic pressure is in terms of gage pressure rather than absolute pressure, the seal's axial material thickness 74 is taken at a radial midpoint between races 24 and 26 , and the Young's modulus of elasticity is with respect to tension rather than flexural. The Young's modulus of elasticity is with respect to the material being tested at 73° Fahrenheit, wherein the 73° F. is for testing purpose only, and that the actual temperature of seal 64 during operation can be dramatically higher than that.
In some examples, outer diameter 70 of seal 64 is about 1.0 inch, inner diameter 72 is about 0.5 inches, thickness 74 is about 0.032 inches, and seal 64 is comprised mostly or entirely of polytetrafluoroethylene. With a Young's modulus of elasticity of about 70,000 psi, this example provides a deflection coefficient of about 0.002 when pressure 68 is at 10 psig. In some examples, seal 64 is comprised of polytetrafluoroethylene impregnated with an additive such as molybdenum or graphite for lubricity. Other examples of seal 64 are made of other materials and/or different dimensions.
In some examples, the rotation of impellers 48 provides a discharge pressure 68 (axial pneumatic pressure against the seal's upstream surface 66 ) of about 10 psig. In other examples, the discharge pressure ranges from 5 to 15 psig.
Some examples of paint sprayer 10 includes a bypass bleed line 76 connecting discharge opening 42 of discharge volute 40 in restricted fluid communication with atmosphere to place upstream surface 66 of seal 64 in restricted fluid communication with atmosphere, thereby limiting pneumatic pressure buildup within discharge volute 40 , limiting the axial pneumatic pressure 68 against upstream surface 66 of seal 64 , and providing at least some airflow through discharge volute 40 when valve 60 is in the closed position. The point at which bypass bleed line 76 connects to paint sprayer 4 can be anywhere downstream of at least one impeller 48 and upstream of valve 60 . The expression, “restricted fluid communication” means that for a given pressure differential, the airflow through line 76 is less than the airflow through hose 62 when valve 60 is fully open. There are many ways of providing bleed line 76 with restricted airflow. Examples of such ways include, but are not limited to, line 76 having a smaller inner diameter than hose 62 or an orifice, capillary or some type of valve in series-flow relationship with line 76 . In some examples, bypass bleed line 76 includes a pressure relief valve that open in response to pressure 68 within discharge volute 40 reaching some predetermined limit.
To establish a predetermined axial position of the impeller nearest discharge volute 40 , some examples of paint sprayer 10 include a sleeve 78 on shaft 36 . Once installed, sleeve 78 is considered as being part of shaft 36 , i.e., shaft 36 includes sleeve 78 . Sleeve 78 axially engages inner race 26 of inboard bearing 22 and axially engages an axial surface of the nearest impeller 48 . In some examples, sleeve 78 radially engages an inner periphery 80 of seal 64 . In other examples, radial clearance 79 exists between sleeve 78 and the seal's inner periphery 80 .
It should be noted that the expression, “paint sprayer” and “paint gun” refer to any devices for spraying any liquid including, but not limited to, paint. The illustrated example of paint sprayer 10 has four impellers for four sequential stages of compression; however, paint sprayer 10 can have any number of impellers, more or less than four. Although bypass bleed line 76 limits pressure 68 in discharge volute 40 , the pressure is not limited to any particular value and may continue to increase with increasing rotational speed of impellers 48 . Outer race 24 of inboard bearing 22 can be a single piece as shown in the example, or outer race 24 can include additional pieces including, but not limited to, annular shims, rings, collars, spacers, sleeves, bushings, etc., wherein such additional pieces are fixed relative to outer race 24 . Inner race 26 of inboard bearing 22 can be a single piece as shown in the example, or inner race 26 can include additional pieces including, but not limited to, annular shims, rings, collars, spacers, sleeves, bushings, etc., wherein such additional pieces are fixed relative to inner race 26 . In some examples, as shown in FIG. 3 , inboard bearing 22 includes its own integral seals or shields 81 that are considered generally non-removable from bearing 22 .
It should also be noted that various multiple component parts of paint sprayer 10 could be combined into single parts and vice versa. For the example shown in FIGS. 1-3 , for instance, inboard motor bracket 14 and discharge volute 40 are a one-piece integral extension of each other. Canister 50 can be attached directly to paint gun 54 as shown, but in other examples of paint sprayer 10 , canister 50 is a separate piece with a long hose connecting the relatively remote canister 50 to paint gun 54 . In either case, a venturi 82 can be used to enable pressurized air flowing through paint gun 54 to draw in liquid 52 up from within canister 50 .
Additional information related to paint sprayer 10 is found in U.S. Pat. No. 6,952,062, which is specifically incorporated by reference herein.
In some examples of paint sprayer 10 , surprising and unexpected improvement in bearing protection and bearing life was achieved when seal 64 or 64 ′ was comprised mostly or entirely of metal instead of plastic with some radial clearance (e.g., 0.010 inches) at the metal seal's inner periphery ( FIG. 3 a ) or at the metal seal's outer periphery (seal 64 ′ of FIG. 4 ). Although seal 64 can be made of various metals and alloys, seal 64 being made of steel or brass works particularly well. In some examples, seal 64 is comprised of steel with outer diameter 70 of seal 64 being about 1.0 inch, inner diameter 72 being about 0.5 inches, and thickness 74 being about 0.020 inches. In some examples, the outer diameter of the seal is a few thousandths of an inch less than the adjacent bearing's outer diameter, and/or the inner diameter of the seal is a few thousandths of an inch greater than the shaft's outer diameter (or a few thousandths of an inch less than the outer diameter of a shaft's sleeve or spacer).
Although certain example methods, apparatus, and articles of manufacture have been described herein, the scope of the coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus, and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.
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A paint sprayer includes a motor-driven multi-stage turbine for compressing air, which subsequently flows through a venturi in a paint gun to draw in paint or some other liquid from a canister. To prevent the high-pressure air from expelling lubricant from the motor's inboard bearing, a pressure responsive annular seal axially deflects and sealingly engages an axial face of the bearing. To avoid subjecting the seal and bearing to excess air pressure and temperature created by the turbine, a bypass bleed line diverts some air to atmosphere when the paint gun is closed.
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This is a division of application Ser. No. 09/348,046, filed Jul. 6, 1999 now U.S. Pat. No. 6,242,622.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a transition metal compound useful as an olefin polymerization catalyst component, an olefin polymerization catalyst using said transition metal compound and process for producing an olefin polymer using said olefin polymerization catalyst with a high activity.
2. Description of the Related Art
Many processes for producing an olefin polymer with a metallocene complex have been already reported. For example a process for producing an olefin polymer with a metallocene complex and an aluminoxane is reported in Japanese Patent Publication (Kokai) No.58-19306. The metallocene complex disclosed therein is a complex having only one transition metal atom in its molecule.
It is disclosed in Japanese Patent Publication (Kokai) No.4-91095 to use a metallocene complex having a structure in which two transition metal atoms are contained in its molecule and two η 5 -cyclopentadienyl groups coordinate on each of the transition metal atoms, as an olefin polymerization catalyst component.
However, when these metallocene complexes having the structure in which two η 5 -cyclopentadienyl groups coordinate on one transition metal atom are used as the olefin polymerization catalyst component, there are problems that the molecular weight of an olefin polymer obtained is low and the comonomer reaction rate in copolymerization is low, and the more improvement of activity has been desired from an industrial viewpoint.
Although metallocene complexes in which two transition metal atoms are contained in its molecule and only one η 5 -cyclopentadienyl group coordinates on each of transition metal atom are disclosed in Japanese Patent Publication (Kokai) Nos. 3-163088 and 3-188092, they are complexes having a peculiar structure in which excessive anionic ligands against the valence number of a transition metal atom are combined, and its polymerization activity is not confirmed.
Although a metallocene complex in which two transition metal atoms are contained in its molecule and only one η 5 -cyclopentadienyl group coordinates per one transition metal atom is disclosed in Japanese Patent Publication (Kokai) No.7-126315, it is a complex having a structure in which those two η 5 -cyclopentadienyl groups are linked, and there are problems in that the olefin polymerization catalyst using it as a catalyst component has low comonomer reaction rate in copolymerization and the melting point of a copolymer improvement of activity has been desired from an industrial viewpoint.
SUMMARY OF THE INVENTION
Under these situations, the objects of the present invention are to provide a transition metal compound useful as a highly active olefin polymerization catalyst component at an efficient reaction temperature in the industrial process of important olefin polymerization from an industrial view point, and to provide a highly active olefin polymerization catalyst using said transition metal compound and a process for producing an olefin polymer using said olefin polymerization catalyst.
In order to attain the above-mentioned objects, the present inventors have intensively studied a process for producing an olefin polymer using a metallocene transition metal compound, in particular, a mono cyclopentadienyl transition metal compound as one of catalyst components, and have thus completed the present invention.
The present invention relates to a transition metal compound represented by the general formula [I] or [II] described below, an olefin polymerization catalyst component comprising said transition metal compound, an olefin polymerization catalyst prepared by a process comprising contacting a transition metal compound selected from the group consisting of transition metal compounds represented by the general formulas [I] and [II], and [(B) described below and/or (C)] described below, and a process for producing an olefin polymer with said olefin polymerization catalyst.
(wherein M 1 indicates a transition metal atom of the Group IV of the Periodic Table or the Elements; A indicates an atom of the Group XVI of the Periodic Table of the Elements; J indicates an atom of the Group XIV of the Periodic Table of the Elements; Cp 1 indicates a group having a cyclopentadiene type anion skeleton; each of X 1 , R 1 , R 2 , R 3 , R 4 , R 5 and R 6 independently indicates a hydrogen atom, a halogen atom, an alkyl group, an aralkyl group, an aryl group, a substituted silyl group, an alkoxy group, an aralkyloxy group, an aryloxy group or a di-substituted amino group; X 2 indicates an atom of Group XVI of the Periodic Table of the Elements; R 1 , R 2 , R 3 , R 4 , R 5 and R 6 may be optionally combined with each other to form a ring; and a plural number of M 1 , A, J, Cp 1 , X 1 , X 2 , R 1 , R 2 , R 3 , R 4 , R 5 and R 6 may be respectively the same or different.)
(B) at least one aluminum compound selected from (B1) to (B3) described below:
(B1) an organoaluminum compound indicated by the general formula E 1 a AlZ 3-a ;
(B2) a cyclic aluminoxane having a structure indicated by the general formula {—Al(E 2 )—O—} b ; and
(B3) a linear aluminoxane leaving a structure indicated by the general formula E 3 {—Al(E 2 )—O—} c AlE 3 2 (wherein each of E 1 , E 2 and E 3 is a hydrocarbon group, and all of E 2 , all of E 2 and all of E 3 may be the sane or different; Z represents a hydrogen atom or a halogen atom; and all of Z may be the same or different; a represents a number satisfying an expression of 0<a≦3; b represents an integer of 2 or more; and c represents an integer of 1 or more).
(C) any one of boron compounds of (C1) to (C3) described below:
(C1) a boron compound represented by the general formula BQ 1 Q 2 Q 3 ;
(C2) a boron compound represented by the general formula G + (BQ 1 Q 2 Q 3 Q 4 ) − ; and
(C3) a boron compound represented by the general formula (L-H) − (BQ 1 Q 2 Q 3 Q 4 ) − (wherein B is a boron atom in the trivalent valence state; Q 1 to Q 4 are a halogen atom, a hydrocarbon group, a halogenated hydrocarbon group, a substituted silyl group, an alkoxy group or a di substituted amino group which may be the same or different; G + is an inorganic or organic cation; L is a neutral Lewis base; and (L H) + is a Brnsted acid).
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a flow chart for assisting the understanding of the present invention. The flow chart is a typical example of the mode of operation of the present invention, but the present invention is not limited thereto.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is further illustrated in detail below
(A) Transition metal compound:
In the general formula [I] or [II], the transition metal atom represented by M 1 indicates a transition metal element of the Group IV of the Periodic Table of the Elements (Revised edition of IUPAC Inorganic Chemistry Nomenclature 1989), and examples thereof include a titanium atom, a zirconium atom, a hafnium atom and the like. A titanium atom or a zirconium atom is preferable.
Examples of the atom of the Group XVI of the Periodic Table of the Elements indicated as A in the general formula [I] or [II] include an oxygen atom, a sulfur atom, a selenium atom and the like, and an oxygen atom is preferable.
Examples of the atom of the Group XIV of the Periodic Table of the Elements indicated as J in the general formula [I] or [II] include a carbon atom, a silicon atom, a germanium atom and the like, and a carbon atom or a silicon atom is preferable.
Examples of the group having a cyclopentadiene type anion skeleton indicated as the substituent group, Cp 1 , include an η 5 -(substituted)cyclopentadienyl group, an η 5 -(substituted)indenyl group, an η 5 (substituted) fluorenyl group and the like. Specific examples include an η 5 -cyclopentadienyl group, an η 5 -methylcyclopentadienyl group, an η 5 -dimethylcyclopentadienyl group, an η 5 -trimethylcyclopentadienyl group, an η 5 -tetramethylcyclopentadienyl group, an η 5 -ethylcyclopentadienyl group, an η 5 -n-propylcyclopentadienyl group, an η 5 -isopropylcyclopentadienyl group, an η 5 -n-butylcyclopentadienyl group, an η 5 -sec-butylcyclopentadienyl group, an η 5 -tert-butylcyclopentadienyl group, an η 5 -n-pentylcyolopentadienyl group, an η 5 -neopentylcyclopentadienyl group, an η 5 -n-hexylcyclopentadienyl group, an η 5 -n-octylcyclopentadienyl group, an η 5 -phenylcyclopentadienyl group, an η 5 -naphthylcyclopentadienyl group, an η 5 -trimethylsilylcyclopentadienyl group, an η 5 -triethylsilylcyclopentadienyl group, an η 5 -tert-butyldimethylsilylcyclopentadienyl group, an η 5 -indenyl group, an η 5 -methylindenyl group, an η 5 -dimethylindenyl group, an η 5 -ethylindenyl group, an η 5 -n-propylindenyl group, an η 3 -isopropylindenyl group, an η 5 -n-butylindenyl group, an η 5 -sec butylindenyl group, an η 5 -tert-butylindenyl group, an η 5 -n-pentylindenyl group, an η 5 -neopentylindenyl group, an η 5 -n hexylindenyl group, an η 5 -n-octylindenyl group, an η 5 -n-decylindenyl group, an η 5 -phenylindenyl group, an 72 5 -methylphenylindenyl group, an η 5 -naphthylindenyl group, an η 5 -trimethylsilylindenyl group, an η 5 -triethylsilylindenyl group, an η 5 -tert-butyldimethylsilylindenyl group, an η 5 -tetrahydroindenyl group, an η 5 -fluorenyl group, an η 5 -methylfluorenyl group, an η 5 -dimethylfluorenyl group, an η 5 -ethylfluorenyl group, an η 5 -diethylfluorenyl group, an η 5 n-propylfluorenyl group, an η 5 -di-n-propylfluorenyl group, an η 5 -isopropylfluorenyl group, an η 5 -diisopropylfluorenyl group, an η 5 -n-butylfluorenyl group, η 5 -sec-butylfluorenyl group, an η 5 -tert-butylfluorenyl group, an η 5 -di-n-butylfluorenyl group, an η 5 -di-sec-butylfluorenyl group, an η 5 -di-tert-butylfluorenyl group, η 5 -n-pentylfluorenyl group, an η 5 -neopentylfluorenyl group, an η 5 n-hexylfluorenyl group, an η 5 -n-octylfluorenyl group, an η 5 -n-decylfluorenyl group, an η 5 -n-dodecylfluorenyl group, an η 5 -phenylfluorenyl group, an η 5 -diphenylfluorenyl group, an η 5 -methylphenylfluorenyl group, an η 5 -naphthylfluorenyl group, an η 5 -trimethylsilylfluorenyl group, an η 5 -bis-trimethylsilylfluorenyl group, an η 5 -triethylsilylfluorenyl group, an η 5 -tert-butyldimethylsilylfluorenyl group and the like. An η 5 -cyclopentadienyl group, an η 5 -methylcyclopentadienyl group, an η 5 -tert-butyloyclopentadienyl group, an η 5 -tetramethylcyclopentadienyl group, an η 5 -indenyl group or an η 5 -fluorenyl group is preferable.
As the halogen atom in the substituent, X 1 , R 1 , R 2 , R 3 , R 4 , R 5 or R 6 , a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom are illustrated. A chlorine atom or a bromine atom is preferable and a chlorine atom is more preferable.
As the alkyl group in the substituent, X 1 , R 1 , R 2 , R 3 , R 4 , R 5 or R 6 , an alkyl group having 1 to 20 carbon atoms is preferred, and examples include a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, a sec-butyl group, a tert-butyl group, a n-pentyl group, a neopentyl group, a sec-amyl group, a n-hexyl group, a n-octyl group, a n-decyl group, a n-dodecyl group, a n-pentadecyl group, a n-eicosyl group and the like, and a methyl group, an ethyl group, an isopropyl group, a tert-butyl group or a sec-amyl group is more preferable.
All of these alkyl groups may be substituted with a halogen atom such as a fluorine atom, a chlorine atom, a bromine atom or an iodine atom. Examples of the alkyl group having 1 to 20 carbon atoms which is substituted with the halogen atom, include a fluoromethyl group, a difluoromethyl group, a trifluoromethyl group, a chloromethyl group, a dichloromethyl group, a trichloromethyl group, a bromomethyl group, a dibromomethyl group, a tribromomethyl group, an iodomethyl group, a tribromomethyl group, a triiodomethyl group, a fluoroethyl group, a difluoroethyl group, a trifluoroethyl group, a tetrafluoroethyl group, a pentafluoroethyl group, a chloroethyl group, a dichloroethyl group, a trichloroethyl group, a tetrachloroethyl group, pentachloroethyl group, a bromoethyl group, a dibromoethyl group, a tribromoethyl group, a tetrabromoethyl group, pentabromoethyl group, a perfluoropropyl group, a perfluorobutyl group, a perfluoropentyl group, a perfluorohexyl group, a perfluorooctyl group, a perfluorododecyl group, a perfluoropentadecyl group, a perfluorceicosyl group, a perchloropropyl group, a perchlorobutyl group, a perchloropentyl group, a perchlorohexyl group, a perchlorooctyl group, a perchlorododecyl group, a perchloropentadecyl group, a perchloroeicosyl group, a perbromopropyl group, a perbromobutyl group, a perbromopentyl group, a perbromohexyl group, a perbromooctyl group, a perbromododecyl group, a perbromopentadecyl group, a perbromoeicosyl group and the like.
Further, all of these alkyl groups may be partially substituted with an alkoxy group such as a methoxy group, an ethoxy group or the like, an aryloxy group such as a phenoxy group or the like or an aralkyloxy group such as a benzyloxy group or the like, etc.
As the aralkyl group in the substituent, X 1 , R 1 , R 2 , R 3 , R 4 , R 5 or R 6 , an aralkyl group having 7 to 20 carbon atoms is preferable, and examples thereof include a benzyl group, a (2-methylphenyl)methyl group, a (3-methylphenyl)methyl group, a (4-methylphenyl)methyl group, a (2,3-dimethylphenyl)methyl group, a (2,4-dimethylphenyl)methyl group, a (2,5-dimethylphenyl)methyl group, a (2,6-dimethylphenyl)methyl group, a (3,4-dimethylphenyl)methyl group, a (3,5-dimethylphenyl)methyl group, a (2,3,4-timethylphenyl)methyl group, a (2,3,5-timethylphenyl)methyl group, a (2,3,6-timethylphenyl)methyl group, a (3,4,5-timethylphenyl)methyl group, a (2,4,6-timethylphenyl)methyl group, a (2,3,4,5-tetramethylphenyl)methyl group, a (2,3,4,6-tetramethylphenyl)methyl group, a (2,3,5,6-tetramethylphenyl)methyl group, a (pentamethylphenyl)methyl group, an (ethylphenyl)methyl group, a (n-propylphenyl)methyl group, an (isopropylphanyl)methyl group, a (n-butylphenyl)methyl group, a (sec-butylphenyl)methyl group, a (tert-butylphenyl)methyl group, a (n-pentylphenyl)methyl group, a (neopentylphenyl)methyl group, a (n-hexylphenyl)methyl group, a (n-octylphenyl)methyl group, a (n-decylphenyl)methyl group, a (n-dodecylphenyl)methyl group, a naphthylmethyl group, an anthracenylmethyl group and the like, and a benzyl group is more preferable.
All of these aralkyl groups may be partially substituted with a halogen atom such as a fluorine atom, a chlorine atom, a bromine atom or an iodine atom, an alkoxy group such as a methoxy group, an ethoxy group or the like, an aryloxy group such as a phenoxy group or the like or an aralkyloxy group such as a benzyloxy group or the like, etc.
As the aryl group in the substituent, X 1 , R 1 , R 2 , R 3 , R 4 , R 5 or R 6 , an aryl group having 4 to 20 carbon atoms is preferable, and examples thereof include a phenyl group, a 2-tolyl group, a 3-tolyl group, a 4-tolyl group, a 2,3-xylyl group, a 2,4-xylyl group, a 2,5-xylyl group, a 2,6-xylyl group, a 3,4-xylyl group, a 3,5-xylyl group, a 2,3,4-trimethylphenyl group, a 2,3,5-trimethylphenyl group, a 2,3,6-trimethylphenyl group, a 2,4,6-trimethylphenyl group, a 3,4,5-trimethylphenyl group, a 2,3,4,5-tetramethylphenyl group, a 2,3,4,6-tetramethylphenyl group, a 2,3,5,6-tetramethylphenyl group, a pentamethylphenyl group, an ethylphenyl group, a n-propylphenyl group, an isopropylphenyl group, a n-butylphenyl group, a sec-butylphenyl group, a tert-butylphenyl group, a n-pentylphenyl group, a neopentylphenyl group, a n-hexylphenyl group, a n-octylphenyl group, a n-decylphenyl group, a n-dodecylphenyl group, a n-tetradecylphenyl group, a naphthyl group, an anthracenyl group and the like, and a phenyl group is more preferable.
All of these aryl groups may be partially substituted with a halogen atom such as a fluorine atom, a chlorine atom, a bromine atom, an iodine atom or the like, an alkoxy group such as a methoxy group, an ethoxy group or the like, an aryloxy group such as a phenoxy group or the like or an aralkyloxy group such as a benzyloxy group or tho like, etc.
The substituted silyl group in the substituent, X 1 , R 1 , R 2 , R 3 , R 4 , R 5 or R 6 is a silyl group substituted with a hydrocarbon group, and examples of the hydrocarbon group include alkyl groups having 1 to 10 carbon atoms such as a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, a sec-butyl group, a tert-butyl group, an isobutyl group, a n-pentyl group, a n-hexyl group, a cyclohexyl group and the like, and aryl groups such as a phenyl group and the like, etc. Examples of such substituted silyl group having 1 to 20 carbon atoms include mono-substituted silyl groups having 1 to 20 carbon atoms such as a methylsilyl group, an ethylsilyl group, a phenylsilyl group and the like; di-substituted silyl groups having 2 to 20 carbon atoms such as a dimethylsilyl group, a diethylsilyl group, a diphenylsilyl group and the like; and tri-substituted silyl groups having 3 to 20 carbon atoms such as a trimethylsilyl group, a triethylsilyl group, a tri-n-propylsilyl-group, a triisopropylsilyl group, a tri-n-butylsilyl group, a tri-sec-butylsilyl group, a tri-tert-butylsilyl group, a tri-isobutylilyl group, a tert-butyl-dimethylsilyl group, a tri-n-pentylsilyl group, a tri-n-hexylsilyl group, a tricyclohexylsilyl group, a triphenylsilyl group and the like, and a trimethylsilyl group, a tert-butyldimethylsilyl group or a triphenylsilyl group is preferable.
All of the hydrocarbon groups of these substituted silyl groups may be partially substituted with a halogen atom such as a fluorine atom, a chlorine atom, a bromine atom or an iodine atom, an alkoxy group such as a methoxy group, an ethoxy group or the like, an aryloxy group such as a phenoxy group or the like or an aralkyloxy group such as a benzyloxy group or the like, etc.
As the alkoxy group in the substituent X 1 , R 1 , R 2 , R 3 , R 4 , R 5 or R 6 , an alkoxy group having 1 to 20 carbon atoms is preferable, and examples thereof include a methoxy group, an ethoxy group, a n-propoxy group, an isopropoxy group, a n-butoxy group, a sec-butoxy group, a tert-butoxy group, a n-pentoxy group, a neopentoxy group, a n-hexoxy group, a n-octoxy group, a n-dodecoxy group, a n-pentadecoxy group, a n-eicosoxy group and the like, and a methoxy group, an ethoxy group or a tert-butoxy group is preferable.
All of these alkoxy groups may be partially substituted with a halogen atom such as, a fluorine atom, a chlorine atom, a bromine atom, an iodine atom or the like, an alkoxy group such as a methoxy group, an ethoxy group or the like, an aryloxy group such as a phenoxy group or the like or an aralkyloxy group such as a benzyloxy group or the like, etc.
As the aralkyloxy group in the substituent, X 1 , R 1 , R 2 , R 3 , R 4 , R 5 or R 6 , an aralkyloxy group having 7 to 20 carbon atoms is preferable, and examples thereof include a benzyloxy group, a (2-methylphenyl)methoxy group, a (3-methylphenyl)methoxy group, a (4-methylphenyl)methoxy group, a (2,3-dimethylphenyl)methoxy group, a (2,4-dimethylphenyl)methoxy group, a (2,5-dimethylphenyl)methoxy group, a (2,6-dimethylphenyl)methoxy group, a (3,4-dimethylphenyl)methoxy group, a (3,5-dimethylphenyl methoxy group, a (2,3,4-trimethylphenyl)methoxy group, a (2,3,5-trimethylphenyl)methoxy group, a (2,3,6-trimethylphenyl)methoxy group, a (2,4,5-trimethylphenyl)methoxy group, a (2,4,6-trimethylphenyl)methoxy group, a (3,4,5-trimethylphenyl)methoxy group, a (2,3,4,5-tetramethylphenyl)methoxy group, a (2,3,4,6-tetramethylphenyl)methoxy group, a (2,3,5,6-tetramethylphenyl)methoxy group, a (pentamethylphenyl)methoxy group, an (ethylphenyl)methoxy group, a (n-propylphenyl)methoxy group, an (isopropylphenyl)methoxy group, (n-butylphenyl)methoxy group, a (sec-butylphenyl)methoxy group, a (tert-butylphenyl)methoxy group, a (n-hexylphenyl)methoxy group, a (n-octylphenyl)methoxy group, a (n-decylphenyl)methoxy group, a naphthylmethoxy group, an anthracenylmethoxy group and the like, and a benzyloxy group is more preferable.
All of these aralkyloxy groups may be partially substituted with a halogen atom such as a fluorine atom, a chlorine atom, a bromine atom or an iodine atom, an alkoxy group such as a methoxy group, an ethoxy group or the like, at aryloxy group such as a phenoxy group or the like or an aralkyloxy group such as a benzyloxy group or the like, etc.
As the aryloxy group in the substituent, X 1 , X 2 , R 1 , R 2 , R 3 , R 4 , R 5 or R 6 , an aryloxy group having 6 to 20 carbon atoms is preferable, and examples thereof include a phenoxy group, a 2-methylphenoxy group, a 3-methylphenoxy group, a 4-methylphenoxy group, a 2,3-dimethylphenoxy group, a 2,4-dimethylphenoxy group, a 2,5-dimethylphenoxy group, a 2,6-dimethylphenoxy group, a 3,4-dimethylphenoxy group, a 3,5-dimethylphenoxy group, a 2,3,4-trimethylphenoxy group, a 2,3,5-trimethylphenoxy group, a 2,3,6-trimethylphenoxy group, a 2,4,5-trimethylphenoxy group, a 2,4,6-trimethylphenoxy group, a 3,4,5-trimethylphenoxy group, a 2,3,4,5-tetramethylphenoxy group, a 2,3,4,6-tetramethylphenoxy group, a 2,3,5,6-tetramethylphenoxy group, a pentamethylphenoxy group, an ethylphenoxy group, a n-propylphenoxy group, an isopropylphenyl group, a n-butylphenoxy group, a sec-butylphenoxy group, a tert butylphenoxy group, a n-hexylphenoxy group, a n-octylphenoxy group, a n-decylphenoxy group, a n-tetradecylphenoxy group, a naphthoxy group, an anthracenoxy group and the like.
All of these aryloxy groups may be partially substituted with a halogen atom such as a fluorine atom, a chlorine atom, a bromine atom or an iodine atom, an alkoxy group such as a methoxy group, an ethoxy group or the like, an aryloxy group such as a phenoxy group or the like or an aralkyl oxy group such as a benzyloxy group or the like, etc.
The di-substituted amino group in the substituent, X 1 , R 1 , R 2 , R 3 , R 4 , R 5 or R 6 is an amino group substituted with two hydrocarbon groups and examples of the hydrocarbon group include alkyl groups having 1 to 10 carbon atoms such as a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, a sec-butyl group, a tert-butyl group, an isobutyl group, a n-pentyl group, a n-hexyl group, a cyclohexyl group and the like; aryl groups having 6 to 10 carbon atoms such as a phenyl group and the like; aralkyl groups having 7 to 10 carbon atoms, etc. Examples of such di-substituted amino group substituted with the hydrocarbon group having 1 to 10 carbon atoms include a dimethylamino group, a diethylamino group, a di-n-propylamino group, a diisopropylamino group, a di-n-butylamino group, a di-sec-butylamino group, a di-tert-butylamino group, a di-isobutylamino group, a tert-butylisopropylamino group, a di-n-hexylamino group, a di-n-octylamino group, a di-n-decylamino group, a diphenylamino group, a bistrimethylsilylamino group, a bis-tert-butyldimethylsilylamino group and the like, and a dimethylamino group or an diethylamino group is preferable.
All of these di-substituted amino groups may be partially substituted with a halogen atom such as a fluorine atom, a chlorine atom, a bromine atom or an iodine atom, an alkoxy group such as a methoxy group, an ethoxy group or the like, an aryloxy group such as a phenoxy group or the like or an aralkyloxy group such as a benzyloxy group or the like, etc.
The substituent, R 1 , R 2 , R 3 , R 4 , R 5 and R 6 may be optionally combined with each other to form a ring.
Each of R 1 is preferably an alkyl group, an aralkyl group, an aryl group or a substituted silyl group, independently.
Each of X 1 is preferably a halogen atom, an alkyl group, an aralkyl group, an alkoxy group, an aryloxy group or a di-substituted amino group, independently. An alkoxy group is more preferable.
Examples of the atom of Group XVI of the Periodic Table of the Elements indicated as X 2 in the general formula [I] or [II] include an oxygen atom, a sulfur atom, a selenium atom and the like, and an oxygen atom is preferable.
Examples of such transition metal compound [I] include μ-oxobis{isopropylidene(η 5 -cyclopentadienyl)(2-phenoxy)titanium chloride}, μ-oxobis{isopropylidene(η 5 -cyclopentadienyl)(2-phenoxy)titanium methoxide}, μ-oxobis{isopropylidene(η 5 -cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium chloride}, μ-oxobis{isopropylidene(η 5 -cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide}, μ-oxobis{isopropylidene(η 5 -methylcyclopentadienyl) (2-phenoxy)titanium chloride}, μ-oxobis{isopropylidene(η 5 -methylcyclopentadienyl) (2-phenoxy)titanium methoxide}, μoxobis{isopropylidene(η 5 -methylcyclopentadienyl) (3-tert-butyl-5-methyl-2-phenoxy)titanium chloride}, μ-oxobis{isopropylidene (η 5 -methylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide}, μ-oxobis{isopropylidene (η 5 -tetramethylcyclopentadienyl)(2-phenoxy)titanium chloride}, μ-oxobis{isopropylidene(η 5 -tetramethylcyclopentadienyl)(2-phenoxy)titanium methoxide}, μ-oxobis{isopropylidene(η 5 -tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl 2-phenoxy)titanium chloride}, μ-oxobis{isopropylidene(η5-tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide}, μ-oxobis{dimethylsilylene(η 5 -cyclopentadienyl)(2-phenoxy)titanium chloride}, μoxobis{dimethylsilylene(η 5 -cyclopentadienyl)(2-phenoxy)titanium methoxide}, μ-oxobis{dimethylsilylene(η 5 -cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium chloride}, μ-oxobis{dimethylsilylene(η 5 -cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide}, μ-oxobis{dimethylsilylene-(η 5 -methylcyclopentadienyl)(2-phenoxy)titanium chloride}, μ-oxobis{dimethylsilylene(η 5 -methylcyclopentadienyl)(2-phenoxy)titanium methoxide}, μ-oxobis{dimethylsilylene(η 5 -methylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium chloride}, μ-oxobis{dimethylsilylene(η 5 -methylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide}, μ-oxobis{dimethylsilylene(η 5 -tetramethylcyclopentadienyl)(2-phenoxy)titanium chloride}, μ-oxobis{dimethylsilylene(η 5 -tetramethylcyclopentadienyl)(2-phenoxy)titanium methoxide}, μ-oxobis{dimethylsilylene(η 5 -tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium chloride}, μ-oxobis{dimethylsilylene(η 5 -tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide} and the like.
Examples of such transition metal compound [II] include di-μ-oxobis{isopropylidene(η 5 -cyclopentadienyl)(2-phenoxy)titanium}, di-μ-oxobis{isopropylidene(η 5 -cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium}, di-μ-oxobis{isopropylidene(η 5 -methylcyclopentadienyl)(2-phenoxy)titanium}, di-μ-oxobis{isopropylidene(η 5 -methylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium, di-μ-oxobis{isopropylidene(η 5 -tetramethylcyclopentadienyl)(2-phenoxy)titanium}, di-μ-oxobis{isopropylidene(η 5 -tetramethyl cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium}, di-μoxobis{dimethylsilylene (η 5 -cyclopentadienyl)(2-phenoxy)titanium}, di-μ-oxobis{dimethylsilylene(η 5 -cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium}, di-μ-oxobis{dimethylsilylene(η 5 -methylcyclopentadienyl) (2-phenoxy)titanium)}, di-μ-oxobis{dimethylsilylene (η 5 -methylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium}, di-μ-oxobis{dimethylsilylene(η 5 -tetramethylcyclopentadienyl)(2-phenoxy)titanium}, di-μ-oxobis{dimethylsilylene(η 5 -tetramethyl cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium} and the like.
The transition metal compound represented by the general formula [I] or [II] can be produced, for example, by reacting a transition metal compound obtained according to the method described in the WO 97/03992 with 0.5-fold by mole or 1-fold by mole of water. Wherein a method of directly reacting a transition metal compound with a required amount of water, a method of charging a transition metal compound in a solvent such as a hydrocarbon containing a required amount of water, or the like, a method of charging a transition metal compound in a solvent such as a dry hydrocarbon or the like and further flowing an inert gas containing a required amount of water, or the like, etc. can be adopted.
(B) Aluminum compound
The aluminum compound (B used in the present invention is at least one organoaluminum compound rejected from (B1) to (B3) described below;
(B1) an organoaluminum compound indicated by the general formula E 1 a AlZ 3-a ;
(B2) a cyclic aluminoxane having a structure indicated by the general formula {—Al(E 2 )—O—} b ; and
(B3) a linear aluminoxane having a structure indicated by the general formula E 3 {—Al(E 3 )—O—} c AlE 3 2 (wherein each of E 1 , E 2 and E 3 is a hydrocarbon group; all of E 1 , all of E 2 and all of E 3 may be the same or different; Z represents a hydrogen atom or a halogen atom; all of Z may be the same or different; a represents a number satisfying an expression of 0<a≦3; b represents an integer of 2 or more; and c represents an integer of 1 or more).
As the hydrocarbon group in E 1 , E 2 or E 3 , a hydrocarbon group having 1 to 8 carbon atoms is preferable and an alkyl group is more preferable.
Specific examples of the organoaluminum compound (B1), indicated by the general formula E 1 a AlZ 3-a include trialkylaluminums such as trimethylaluminum, triethylaluminum, tri-n-propylaluminum, triisopropylaluminum, triisobutylaluminum, tri-n-hexylaluminum and the like; dialkylaluminum chlorides such as dimethylaluminum chloride, diethylaluminum chloride, di-n-propylaluminum chloride, diisopropylaluminum chloride, diisobutylaluminum chloride, di-n-hexylaluminum chloride and the like; alkylaluminum dichlorides such as methylaluminum dichloride, ethylaluminum dichloride, n-propylaluminum dichloride, isopropylaluminum dichloride, isobutylaluminum dichloride, n-hexylaluminum dichloride and the like; and dialkylaluminum hydrides such as dimethylaluminum hydride, diethylaluminum hydride, di-n-propylaluminum hydride, diisopropylaluminum hydride, diisobutylaluminum hydride, di-n-hexylaluminum hydride and the like, etc.
Trialkylaluminum is preferable and triethylaluminum or triisobutylaluminum is more preferable.
Specific examples of E 2 and E 3 in the cyclic aluminoxane(B2) having a structure indicated by the general formula {—Al(E 2 )—O—} b and the linear aluminoxane(B3) having a structure indicated by the general formula E 3 {—Al(E 3 )—O—} c AlE 3 2 include alkyl groups such as a methyl group, an ethyl group, a n-propyl group, an isopropyl group, a n-butyl group, an isobutyl group, a n-pentyl group, a neopentyl group and the like. b is an integer of 2 or more, and c is an integer of 1 or more. Preferably, each of E 2 and E 3 is a methyl group or an isobutyl group, b is 2 to 40 and c is 1 to 40.
The above-mentioned aluminoxane is prepared by various methods. The method is not specifically limited, and the aluminoxane may be prepared according to publicly known processes.
For example, the aluminoxane is prepared by contacting a solution of a trialkylaluminum (e.g. trimethylaluminum or the like) dissolved in a suitable organic solvent (e.g. benzene, an aliphatic hydrocarbon or the like) with water. Further, there is exemplified a process for preparing the aluminoxane by contacting a trialkylaluminum (e.g. trimethylaluminum, etc.) with a metal salt containing crystal water (e.g. copper sulfate hydrate, etc.).
(C) Boron compound
As the boron compound (C) in the present invention, any one of the boron compound (C1) represented by the general formula BQ 1 Q 2 Q 3 , the boron compound (C2) represented by the general formula G + (BQ 1 Q 2 Q 3 Q 4 ) − and the boron compound (C3) represented by the general formula (L-H) + (BQ 1 Q 2 Q 3 Q 4 ) − can be used.
In the boron compound (C1) represented by the general formula BQ 1 Q 2 Q 3 , B represents a boron atom in the trivalent valence state; Q 1 to Q 3 are respectively a halogen atom, a hydrocarbon group, a halogenated hydrocarbon group, a substituted silyl group, an alkoxy group or a di-substituted amino group and they may be the same or different. Each of Q 1 to Q 3 is preferably a halogen atom, a hydrocarbon group having 1 to 20 carbon atoms, a halogenated hydrocarbon group having 1 to 20 carbon atoms, a substituted silyl group having 1 to 20 carbon atoms, an alkoxy group having 1 to 20 carbon atoms or a di-substituted amino group having 2 to 20 carbon atoms, and each of more preferable Q 1 to Q 3 is a halogen atom, a hydrocarbon group having 1 to 20 carbon atoms or a halogenated hydrocarbon group having 1 to 20 carbon atoms. Each of the more preferable Q 1 to Q 2 is a fluorinated hydrocarbon group having 1 to 20 carbon atoms which contains at least one fluorine atom, and in particular, each of Q 1 to Q 4 is preferably a fluorinated aryl group having 6 to 20 carbon atoms which contains at least one fluorine atom.
Specific examples of the compound (C1) include tris(pentafluorophenyl)borane, tris(2,3,5,6-tetrafluorophenyl)borane, tris(2,3,4,5-tetrafluorophenyl)borane, tris(3,4,5-trifluorophenyl)borane, tris(2,3,4-trifluorophenyl)borane, phenylbis(pentafluorophenyl)borane and the like, and tris(pentafluorophenyl)borane is most preferable.
In the boron compound (C2) represented by the general formula G + (BQ 1 Q 2 Q 3 Q 4 ) − , G + is an inorganic or organic cation; B is a boron atom in the trivalent valence state; and Q 2 to Q 4 are the same as defined in Q 1 to Q 3 in the above-mentioned (C1).
Specific examples of G + as the inorganic cation in the compound represented by the general formula G + (BQ 1 Q 2 Q 3 Q 4 ) − include a ferrocenium cation, an alkyl-substituted ferrocenium cation, a silver cation and the like, and the G + as the organic cation includes a triphenylmethyl cation and the like. G + is preferably a carbenium cation, and a triphenylmethyl cation is particularly preferred. As the (BQ 1 Q 2 Q 3 Q 4 ), tetrakis(pentafluorophenyl)borate, tetrakis(2,3,5,6-tetrafluorophenyl)borate, tetrakis(2,3,4,5-tetrafluorophenyl)borate, tetrakis (3,4,5-trifluorophenyl)borate, tetrakis(2,3,4-trifluorophenyl)borate, phenyltris(pentafluoroplenyl)borate, tetrakis(3,5-bistrifluoromethylphenyl)borate and the like are mentioned.
These specific combinations include ferrocenium tetrakis(pentafluorophenyl)borate, 1,1′-dimethylferrocenium tetrakis(pentafluorophenyl) borate, silver tetrakis(pentafluorophenyl)borate, triphenylmethyl tetrakis(pentafluorophenyl)borate, triphenylmethyl tetrakis(3,5-bistrifluoro methylphenyl)borate and the like, and triphenylmethyl tetrakis(pentafluorophenyl)borate is most preferable,
Further, in the boron compound (C3) represented by the formula (L-H) + (BQ 1 Q 2 Q 3 Q 4 ) − , L is a neutral Lewis base; (L-H) + is a Brnsted acid; B is a boron atom in the trivalent valence state; and Q 1 to Q 4 are the same as Q 1 to Q 3 in the above-mentioned Lewis acid (C1).
Specific examples of (L-H) + as the Brnsted acid in the compound represented by the formula (L-H) + (BQ 1 Q 2 Q 3 Q 4 ) include a trialkyl-substituted ammonium, an N,N-dialkylanilinium, a dialkylammonium, a triarylphosphonium and the like, and examples of (BQ 1 Q 2 Q 3 Q 4 ) − include those as previously described.
These specific combinations include triethylammonium tetrakis(pentafluorophenyl)borate, tripropylammonium tetrakis(pentafluorophenyl)borate, tri(n-butyl)ammonium tetrakis(pentafluorophenyl)borate, tri(n-butyl)ammonium tetrakis(3,5-bistrifluoromethylphenyl)borate, N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate, N,N-diethylanilinium tetrakis(pentafluorophenyl)borate, N,N-2,4,6-pentamethylanilinium tetrakis(pentafluorophenyl) borate, N,N-dimethylanilinium tetrakis(3,5-bistrifluoromethylphenyl)borate, diisopropylammonium tetrakis(pentafluorephenyl)borate, dicyclohexylammonium tetrakis(pentafluorophenyl)borate, triphenylphosphonium tetrakis(pentafluorophenyl)borate, tri(methylphenyl)phosphonium tetrakis(pentafluorophenyl)borate, tri(dimethylphenyl)phosphonium tetrakis(pentafluorophenyl)borate and the like, and tri(n-butyl)ammonium tetrakis(pentafluorophenyl)borate or N,N-dimethylanilinum tetrakis(pentafluorophenyl)borate is most preferable.
[Polymerization of olefin]
In the present invention, the olefin polymerization catalyst is prepared by a process comprising contacting the transition metal compound(A) represented by the general formula [I] and/or [II] and [the above-mentioned (B) and/or the above-mentioned (C)]. In case of an olefin polymerization catalyst prepared by using the transition metal compound (A) and the above-mentioned (B), the fore-mentioned cyclic aluminoxane (B2) and/or the linear aluminoxane (B3) is preferable as (B). Further, as another preferable mode of an olefin polymerization catalyst, an olefin polymerization catalyst prepared by using the transition metal compound, (A), the above-mentioned(B) and the above-mentioned (C) is illustrated, and the fore-mentioned (B1) is also easily used as said (B).
In the present invention, the transition metal compound (A) represented by the general formula [I] and/or [II] and the above-mentioned (B), or further the above-mentioned(C) can he charged in an arbitrary order during polymerization to be used, but a reaction product obtained by previously contacting an arbitrary combination of those compounds may be also used.
The used amount of respective components is not specifically limited, and it is desirable to usually use the respective components so that the molar ratio of the (B)/transition metal compound (A) is 0.1 to 10000 and preferably 5 to 2000, and the molar ratio of the (C)/transition metal compound (A) is 0.01 to 100 and preferably 0.5 to 10.
When the respective components are used in a solution condition or a condition in which they are suspended or slurried in a solvent, the concentration of the respective components is appropriately selected according to the conditions such as the ability of all apparatus for feeding the respective components in a polymerization reactor. The respective components are desirably used so that the concentration of the transition metal compound (A) is usually 0.001 to 200 mmol/L, more preferably 0.001 to 100 mmol/L and most preferably 0.05 to 50 mmol/L; the concentration of (B) usually 0.01 to 5000 mmol/L converted to Al atom, more preferably 0.1 to 2500 mmol/L and most preferably 0.1 to 2000 mmol/L; and the concentration of (C) is usually 0.001 to 500 mmol/L, more preferably 0.01 to 250 mmol/L and most preferably 0.05 to 100 mmol/L.
As olefins which can be applied to the polymerization in the present invention, olefins having 2 to 20 carbon atoms such as, particularly, ethylene and an α-olefin having 3 to 20 carbon atoms, diolefins having 4 to 20 carbon atoms and the like can be used, and two or more monomers can also be used, simultaneously. Specific examples of the olefin include straight-chain olefins such as ethylene, propylene, butene-1, pentane-1, hexene-1, heptene-1, octene-1, nonene-1, decene-1 and the like; branched olefins such as 3-methylbutene-1, 3-methylpenten-1, 4-methylpentene-1, 5-methylhexene-1 and the like; vinylcyclohexane, etc., but the present invention should not be limited to the above-mentioned compounds. Specific examples of the combination of monomers in case of conducting copolymerization include ethylene and propylene, ethylene and butene-1, ethylene and hexene-1, ethylene and octene-1, propylene and butene-1 and the like, but the present invention should not be limited thereto.
The present invention can be effectively applied to the particular preparation of the copolymer of ethylene and an α-olefin such as in particular, propylene, butene-1, 4 -methylpentene-1, hexene-1, octene-1 or the like.
Polymerization processes should not be also specifically limited, and there can be a solvent polymerization or slurry polymerization in which an aliphatic hydrocarbon such as butane, pentane, hexane, heptane, octane or the like; an aromatic hydrocarbon such as benzene, toluene or the like; or a halogenated hydrocarbon such as methylene dichloride or the like used as a polymerization medium. Further, high pressure ionic polymerization in which the polymerization of an olefin is conducted without a solvent under which an olefin polymer is melt in a high temperature and high pressure olefin in a supercritical liquid condition, and further, a gas phase polymerization in a gaseous monomer and the like are possible. Further, either of a continuous polymerization and a batch-wise polymerization are possible.
The polymerization temperature can be usually adopted at a range of −50° C. to 350° C. and preferably 0° C. to 300° C., and in particular, a range of 50° C. to 300° C. is preferable. The polymerization pressure can be adopted at a range of atmospheric pressure to 350 MPa and preferably atmospheric pressure to 300 MPa, and in particular, a range of atmospheric pressure to 200 MPa is preferable.
In general, the polymerization time is appropriately determined according to the kind of a desired polymer and a reaction apparatus, and the conditions are not specifically limited and a range of 1 minute to 20 hours can be adopted. Further, a chain transfer agent such as hydrogen or the like can also be added to adjust the molecular weight of a copolymer in the present invention.
The process for polymerizing the olefin polymer of the present invention is suitably carried out by a high-pressure ionic polymerization process, in particular.
Specifically, it is preferably carried out under a pressure of 30 MPa or more and at a temperature of 300° C. or more. It is more preferably carried out under a pressure of 35 to 350 MPa and at a temperature of 135 to 350° C.
The polymerization form can be carried out in either a batch-wise manner or a continuous manner, but the continuous manner is preferable. As a reactor, a stirring vessel type reactor or a tubular reactor can be used. The polymerization can be performed in a single reaction zone. Alternatively, the polymerization can also be performed by partitioning one reactor into a plurality of reaction zones or connecting a plurality of reactors in series or parallel. In case of using a plurality of reactors, a combination of a vessel reactor and a vessel reactor or a combination of a vessel reactor and a tubular reactor may be used. In a polymerization process using a plurality of reaction zones or a plurality of reactors, polymers having different characteristics can also be produced by changing the temperature, pressure and gas composition of respective reaction zones or reactors.
EXAMPLE
The present invention is further illustrated in detail according to Examples and Comparative Examples below, but the present invention is not limited thereto.
Properties of the polymers in Examples were measured according to methods described below.
(1) Melt index (MFR) was measured at 190° C. according to the method defined in JIS K-6760. (Unit: g/10 min.)
(2) Density was determined according to JIS K-6760,
Wherein the value of density described as density (without annealing) is a value obtained by measuring without an annealing treatment in JIS K-6760.(Unit; g/cm 3 )
(3) Melting point of copolymer:
It was measured under the following conditions using DSC7 manufactured by Perkin-Elmer Co.
Heating: heating to 150° C. and maintaining until the change of calorie is stabilized
Cooling: 150 to 10° C. (5° C./min.) and maintaining for 10 minutes
Measurement: 10 to 160° C. (5° /C.min.)
(4) Content of α-olefin:
It was determined from the characteristic absorption of ethylene and α-olefin using an infrared spectrometer (FT-TR7300, manufactured by NIPPON BUNKO Inc.) and was represented as a short-chain branch (SCB) number per 1000 carbon atoms.
(5) Weight average molecular weight (Mw), number average molecular weight (Mn) and molecular weight distribution (Mw/Mn):
They were determined under the following conditions using gel permeation chromatograph (150, C, manufactured by Waters Co.).
Column: TSA gel GMH-HT
Measurement temperature: set at 145° C.
Measurement concentration: 10 mg/10 ml orthodichlorobenzene
(6) Intrinsic viscosity ([η]):
100 mg of a copolymer obtained was dissolved in 50 ml of tetralin at 135° C. and the solution was set in an oil bath maintained at 135° C. Using an Ubbelohde viscometer, the intrinsic viscosity was determined by the falling speed of the tetralin solution in which said sample was dissolved. (Unit: dl/g)
Reference Example 1
[Synthesis of transition metal compound: dimethylsilylene(η 5 -tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dimethoxide)]
In a Schlenk tube, 0.131 g (4.1 mmol) of methanol was dissolved in 10 ml of anhydrous diethyl ether and a diethyl ether solution (3.9 ml, 4.1 mmol) of methyllithium having a concentration of 1.05 mol/L was added dropwise at −78° C. thereto. The resulting mixture was heated to 20° C., the formation of lithium methoxide was confirmed by gas generation, and the resulting reaction solution was again cooled to −78° C. Into the reaction solution, 20 ml of an anhydrous diethyl ether suspension liquid of 0.919 g (2.0 mmol) of dimethylsilylene(η 5 -tetramethylcyclopentadienyl) (3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride which was previously prepared in another Schlenk tube was transferred, and then, the resulting reaction mixture was gradually heated to room temperature to obtain a reaction solution. After concentrating the reaction solution, 20 ml of toluene was added and an insoluble product was separated by filtration. The filtrate was concentrated to obtain dimethylsilylene (η 5 -tetramethylcyclopentadienyl)(3-tert-butyl-b-methyl-2-phenoxy)titanium dimethoxide of yellow crystals (0.86 g, 95%).
1 H NMR (270 MHz, C 6 D 6 ); δ 7.26 (m, 2H), 4.13(s, 6H), 2.33 (s, 3H), 1.97(s, 6H), 1.89(s, 6H), 1.59(s, 9H), 0.55(s, 6H)
Reference Example 2
[Synthesis example of transition metal compound: μ-oxobis{dimethylsilylene(η 5 -tetramethyl cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide (Compound 1)]
Under a nitrogen atmosphere, 10.00 g of dimethylsilylene(η 5 -tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl -2-phenoxy titanium dimethoxide (the compound obtained by the same method as in Reference Example 1) was dissolved in 50 ml of heptane, 0.30 g of distilled water was added thereto, and the mixture was stirred at the same temperature for 12 hours. The solid produced was separated by filtration, rinsed with 5.0 ml of heptane, and then dried under vacuum to obtain μ-oxobis{dimethylsilylene(η 5 -tetramethyl cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide} of a yellow solid (5.51 g, 56%).
Mass spectrum (m/e) 855. Calculated value: 855
1 H-NMR (C 6 D 6 ); δ 7.25 (d, J=2.0 Hz, 2H), 7.16 (d, J=2.0 Hz, 2H), 3.99(s, 6H), 2.37(s, 6H), 2.30 (s, 6H), 2.06(s, 6H), 1.86(s, 6H), 1.71(s, 6H), 1.27(s, 18H), 0.83(s, 6H), 0.63(s, 6H)
Reference Example 3
[Synthesis example of transition metal compound: di-μ-oxobis{dimethylsilylene(η 5 -tetramethyl cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium} (compound 2)]
In a Schlenk tube, 1.50 g (3.3 mmol) of dimethylsilylene(η 5 -tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dimethoxide was dissolved in 20 ml of toluene, 10 ml of water was added thereto, and the resulting liquid mixture was stirred at 70° C. for 1 hour. After concentrating the organic layer which was obtained by phase separation, the concentrate was recrystallized from 10 ml of heptane to obtain di-μ-oxobis{dimethylsilylene(η 5 -tetramethyl cyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium} of yellow crystals (0.40 g, 33%). Mass spectrum (m/e) 808. Calculated value: 808
1 H-NMR (270 MHz, C 6 D 6 ); δ 7.28 (m, 4H), 2.32(s, 12H), 1.97(s, 6H), 1.78(s, 6H), 1.59(s, 6H), 1.53(s, 18H), 0.78(s, 6H), 0.58(s, 6H)
EXAMPLE 1
Using an autoclave type reactor having an inner volume of 1 liter equipped with a stirrer, polymerization was carried out by continuously feeding ethylene and hexene-1 into the reactor. Regarding the polymerization conditions, the total pressure was set to 80 MPa and the concentration of hexene-1 based on the total of ethylene and hexene-1 was set to 28.8% by mole. A heptane solution (which was adjusted to be the concentration of Compound 1 of 0.185 μmol/g, the concentration of triisobutylaluminum of 18.5 μmol/g and a molar ratio of Al atom to Ti atom of 50.) in which μ-oxobis{diethylsilylene(η 5 -tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide} (Compound 1) and triiosobutylaluminum were mixed and a toluene solution (0.90 μmol/g) of N,N-dimethylaniliniumtetrakis (pentafluorophenyl)borate were respectively prepared in separate vessels. Each of the solutions was continuously fed in the reactor at a feeding rate of 100 g/hour and 140 g/hour. The polymerization reaction temperature was at 222° C., and a molar ratio of boron atom to Ti atom was set to 3.4. As a result, an ethylene-hexene-1 copolymer having MFR of 8.39, a density (without annealing) of 0.883 g/cm 3 , SCB of 36.0, a weight average molecular weight (Mw) of 62000 and a molecular weight distribution (Mw/Mn) of 1.9 was produced at a rate of 74 ton per 1 mole of Ti atom.
Comparative Example 1
Using an autoclave type reactor having an inner volume of 1 liter equipped with a stirrer, polymerization was carried out by continuously feeding ethylene and hexene-1 into the reactor. The total pressure was set to 80 MPa and the concentration of hexene-1 based on the total of ethylene and hexene-1 was set to 34% by mole. A hexane solution (0.7 μmol/g) of dimethylsilylene(η 5 -tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium dichloride, a heptane solution of triisobutylaluminum (33 μmol/g) and further a toluene solution (1.2 μmol/g) of N,N-dimethylaniliniumtetrakis(pentafluoroplenyl)borate were respectively prepared in separate vessels and continuously fed into the reactor at feeding rates of 290 g/hour, 350 g/hour and 580 g/hour, respectively. The polymerization reaction temperature was set at 215° C., and a molar ratio of boron atom to Ti atom was set to 3.3. As a result, an ethylene-hexene-1 copolymer having MFR of 4.2, a density (without annealing) of 0.881 g/cm 3 , a melting point of 67.3° C., SCB of 40.4, Mw of 66000 and Mw/Mn of 1.8 was produced in a rate of 14 ton per 1 mole of Ti atom.
EXAMPLE 2
After replacing the atmosphere of an autoclave type reactor having an inner volume of 0.4 liter equipped with a stirrer with argon, 185 ml of cyclohexane as a solvent and 15 ml of hexene-1 as an α-olefin were charged and the reactor was heated to 180° C. After the elevation of temperature, ethylene was fed while adjusting at an ethylene pressure of 2.5 Mpa. After the system was stabilized, 0.2 mmol of triisobutylaluminum, 0.5 ml (namely, 0.5 μmol of Compound 1 and 25 μmol of triisobutylaluminum) of a heptane solution (which was adjusted to be the concentration of Compound 1 of 1 μmol/ml, the concentration of triisobutylaluminum of 50 μmol/ml and a molar ratio of Al atom to Ti atom of 25.) in which μ-oxobis{dimethylsilylene(η 5 -tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide} (Compound 1) and triisobutylaluminum were mixed, were charged and successively, 1.5 μmol of N,N-dimethylaniliniumtetrakis(pentafluorophenyl)borate was charged as a slurry in heptane. Polymerization was carried out for 2 minutes. As a result of the polymerization, 2.53 g of an ethylene-hexene-1 copolymer having [η] of 0.85 dl/g, SCB of 31.4 and melting points of 78.6° C. and 90.8° C. was obtained. Polymerization activity per 1 mole of Ti atom was 2.53×10 4 g-polymer/mol-Ti atom per 2 minutes.
EXAMPLE 3
After replacing the atmosphere of an autoclave type reactor having an inner volume of 0.4 liter equipped with a stirrer with argon, 185 ml of cyclohexane as a solvent and 15 ml of hexene-1 as an α-olefin were charged and the reactor was heated to 180° C. After the elevation of temperature, ethylene was fed while adjusting at an ethylene pressure of 2.5 Mpa. After the inner of system was stabilized, 0.2 mmol of triisobutylaluminum, 0.5 ml (namely, 0.5 μmol of Compound 1 and 25 μmol of triisobutylaluminum) of a heptane solution (which was adjusted to be the concentration of Compound 1 of 1 μmol/ml, the concentration of triisobutylaluminum of 50 μmol/ml and a molar ratio of Al atom to Ti atom of 25.) in which μ-oxobis{dimethylsilylene(η 5 -tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium methoxide} (Compound 1) and triisobutylaluminum were mixed, were charged and successively. 3 μmol of N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate was charged as a slurry in heptane (a slurry concentration of 1 μmol/ml). Polymerization was carried out for 2 minutes. As a result of the polymerization, 5.33 g of an ethylene-hexene-1 copolymer having [η] of 0.67 dl/g, SCB of 35.0, melting points of 74.2° C. and 88.6° C., Mw of 43000 and Mw/Mn of 2.7 was obtained. Polymerization activity per 1 mole of Ti atom was 5.33×10 6 g-polymer/mol-Ti atom per 2 minutes.
EXAMPLE 4
After replacing the atmosphere of an autoclave type reactor having an inner volume of 0. 4 liter equipped with a stirrer with argon, 185 ml of cyclohexane as a solvent and 15 ml of hexene-1 as an α-olefin were charged and the reactor was heated to 180° C. After the elevations of temperature, ethylene was fed while adjusting at an ethylene pressure of 2.5 Mpa. After the system was stabilized, 0.2 mmol of triisobutylaluminum, 0.5 ml (namely, 0.5 μmol of Compound 2 and 25 μmol of triisobutylaluminum) of a heptane solution (which was adjusted to be the concentration of Compound 2 of 1 μmol/ml, the concentration of triisobutylaluminum of 50 μmol/ml and a molar ratio of Al atom to Ti atom of 25.) in which di-μ-oxobis{dimethylsilylene(η 5 -tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium} (Compound 2) and triisobutylaluminum were mixed, were charged and successively, 1.5 μmol of N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate was charged as a slurry in heptane (a slurry concentration of 1 μmol/ml). Polymerization was carried out for 2 minutes. As a result of the polymerization, 2.55 g of an ethylene-hexene-1 copolymer having [η] of 0.84 dl/g, SCB of 30.7 and melting points of 80.2° C. and 93.0° C. was obtained. Polymerization activity per 1 mole of Ti atom was 2.55×10 6 g-polymer/mol-Ti atom per 2 minutes.
EXAMPLE 5
After replacing the atmosphere of an autoclave type reactor having an inner volume of 0.4 liter equipped with a stirrer with argon, 185 ml of cyclohexane as a solvent and 15 ml of hexene-1 as an α-olefin were charged and the reactor was heated to 180° C. After the elevation of temperature, ethylene was fed while adjusting at an ethylene pressure 2.5 Mpa. After the system was stabilized, 0.2 mmol of triisobutylaluminum, 0.5 ml (namely, 0.5 μmol of Compound 2 and 25 μmol of triisobutylaluminum) of a heptane solution (which was adjusted to be the concentration of Compound 2 of 1 μmol/ml, the concentration of triisobutylaluminum of 50 μmol/ml and a molar ratio of Al atom to Ti atom of 25.) in which di-μ-oxobis{dimethylsilylene(η 5 -tetramethylcyclopentadienyl)(3-tert-butyl-5-methyl-2-phenoxy)titanium} (Compound 2) and triisobutylaluminum were mixed, were charged and successively, 3 μmol of N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate was charged as a slurry in heptane (a slurry concentration of 1 μmol/ml). Polymerization was carried out for 2 minutes. As a result of the polymerization, 3.92 g of an ethylene-hexene-1 copolymer having [η] of 0.73 dl/g, SCB of 33.0, melting points of 78.9° C. and 91.5° C. Mw of 48000 and Mw/Mn of 2.5 was obtained. Polymerization activity per 1 mole of Ti atom was 3.92×10 6 g-polymer/mol-Ti atom per 2 minutes.
As described above in detail, according to the present invention, a transition metal compound useful an a highly active olefin polymerization catalyst component at an efficient reaction temperature in the industrial process of an olefin polymerization, and a highly active olefin polymerization catalyst using said transition metal compound and a process for producing an olefin polymer using said olefin polymerization catalyst are provided. Further, the transition metal compound of the present invention is also effective as an olefin polymerization catalyst component having a high comonomer reaction rate in compolymerization and providing an olefin polymer with a high molecular weight, and has a remarkable value for utilization.
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A specified transition metal compound having two transition metals and two cyclopentadiene type anion skeletons in its molecule and said metals are linked through an atom of Group XVI of the Periodic Table of the Elements, an olefin polymerization catalyst component comprising said transition metal compound, an olefin polymerization catalyst comprising said transition metal compound, a specific organoaluminum compound, and a specific boron compound, and a process for producing an olefin polymer using said olefin polymerization catalyst.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to computer security and more specifically to systems and methods for identifying and authenticating a user.
[0003] 2. Description of the Related Art
[0004] Internet commerce has increased dramatically over the last several years. As a result, several different on-line payment methods have been created. In one payment method, the buyer simply types a credit card number into an on-line payment webpage to pay for the goods or services provided by an on-line merchant. In another payment method, the buyer uses an on-line payment service to pay for the goods or services provided by an on-line merchant. The on-line payment service allows the buyer to pay the on-line merchant via the Internet using funds that are available in a bank account or on a credit card. The on-line payment service holds the account information, not the on-line merchant, and therefore the on-line payment service may protect the buyer from unlawful use of the buyer's account.
[0005] Even though on-line payment services are effective in providing a more secure means of on-line payment between the buyer and the on-line merchant as compared to paying by a credit card number or a personal check, on-line payment services typically require a single factor of authentication to verify that the buyer is actually the owner of the account. For example, the on-line payment service may require the buyer to input an email address and a password to make an on-line payment. However, the single factor of authentication, such as the email address and password, can be easily stolen by a computer hacker. This may result in the unlawful use of the buyer's account, which is a common form of identity theft.
[0006] In addition to Internet commerce, many banks now offer on-line banking which allows customers to access their accounts via the Internet. On-line banking allows a customer to perform routine transactions, such as account transfers, balance inquiries, bill payments, and stop-payment requests from a remote computer. In addition, some banks allow their customers to apply for loans and credit cards on-line as well. Similar to on-line payment services, to access the account information or apply for a loan or a credit card on-line, a bank usually requires only one factor of authentication to verify that an on-line customer is actually the owner of the account. For example, the bank may require the customer to input a username and a password to access the account. Again, the single factor of authentication, such as the username and password, can be easily stolen by a computer hacker, which may result in the unlawful use of the customer's account.
[0007] As the foregoing illustrates, there is a need in the art for a way to verify the identities of on-line customers that is more secure than current approaches.
SUMMARY OF THE INVENTION
[0008] The present invention generally relates to a computer security system for use in the identification and authentication of a user prior to an on-line transaction. In one aspect, a method for enrolling a user in a system configured to identify and authenticate the user is provided. The method includes collecting a username and password to identify the user. The method further includes extracting device data from a user machine to uniquely identify the machine. The method also includes generating a user profile based upon the device data and the username and password. Additionally, the method includes transmitting the user profile to a server machine to be stored.
[0009] In another aspect, a computer-readable medium including a set of instructions that when executed by a processor cause the processor to enroll a user in a system configured to identify and authenticate the user is provided. The processor performs the step of collecting a username and password to identify the user. The processor also performs the step of extracting device data from a user machine to uniquely identify the machine. Further, the processor performs the step of generating a user profile based upon the device data and the username and password. Additionally, the processor performs the step of transmitting the user profile to a server machine to be stored.
[0010] In yet a further aspect, a system for identifying and authenticating a user is provided. The system includes a server machine that includes a user profiles database. The system also includes a computing device having a processor and a memory. The memory includes a security agent program configured to collect a username and password to identify the user. The security agent program is also configured to extract device data from a user machine to uniquely identify the machine. Further, the security agent program is configured to generate a user profile based upon the device data and the username and password. Additionally, the security agent program is configured to transmit the user profile to the server machine for storage in the user profiles database.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0012] FIG. 1 is a conceptual block diagram of a system configured to identify and authenticate the identity of a user, according to one embodiment of the invention.
[0013] FIG. 2 is a flow chart of method steps for enrolling a user in a security service, according to one embodiment of the invention.
[0014] FIG. 3 is a flow chart of method steps for securely accessing a user account, according to one embodiment of the invention.
[0015] FIGS. 4A and 4B are a flow chart of method steps for making a secured payment, according to one embodiment of the invention.
[0016] FIG. 5 is a conceptual block diagram of a system through which a secured payment may be made, according to one embodiment of the invention.
[0017] FIGS. 6-8 are conceptual illustrations depicting how the security agent of FIG. 1 interacts with a merchant payment web page when a secured payment is made, according to one embodiment of the invention.
DETAILED DESCRIPTION
[0018] In general, the invention relates to a computer security system for use in the identification and authentication of a user prior to an on-line transaction. The system will be described herein in relation to a single user. However, it should be understood that the systems and methods described herein may be employed with any number of users without departing from the principles of the present invention. The description of the invention is separated into four sections: the architecture, the enrollment process, a secure access transaction, and a secure payment transaction. To better understand the novelty of the system of the present invention and the methods of use thereof, reference is hereafter made to the accompanying drawings.
Architecture
[0019] FIG. 1 is a conceptual block diagram of a system 100 configured to identify and authenticate the identity of a user, according to one embodiment of the invention. The system 100 includes a user machine 105 , which may be any type of individual computing device such as, for example, a desk-top computer, a lap-top computer, a hand-held phone device, or a personal digital assistant. Generally, the user machine 105 is configured to be a communication link between the user and the other components in the system 100 . The user machine 105 includes a security agent 110 . Generally, the security agent 110 is a software entity that runs on the user machine 105 . As described in further detail herein, the security agent 110 , among other things, is configured to create an identity profile 115 of a user and of user machine 105 , collect certain data from the user machine 105 or manage secure access or secure payment transactions made from user machine 105 . Additionally, the security agent 110 is designed to offer protection against phishing, pharming, Trojan programs or worms.
[0020] As also shown, the user machine 105 includes the profile 115 , which represents the identity of the user. The profile 115 is unique for each user. As described in further detail herein, once the profile 115 has been created for the user, the identity of the user can be subsequently verified by a series of interactions between the security agent 110 and the authentication server 125 based on the profile 115 . The profile 115 includes data about the user and the user machine 105 and can be used to establish a multifactor identification for the user whenever the user attempts to conduct transactions via the user machine 105 . The first factor of authentication is a username and/or password, which relates to “what the user knows.” The second factor of authentication is unique information about the user machine 105 , which relates to “what the user has.” The third factor of authentication is unique information about the user, such as biometric identity, which relates to “who the user is.”
[0021] As will be discussed below in the enrollment process, the username and/or password is created by the user after the identity of the user is established. The username and/or password are typically a combination of characters and numbers, which the user can easily remember. In one embodiment, the user machine 105 transmits the username and/or password in a cryptographically protected form, so access to the actual username and/or password will be difficult for a snooper who gains internal access to the user machine 105 .
[0022] With respect to the second factor of authentication, the unique information about the user machine 105 is generally a combination of select information associated with the user machine 105 . The information may be static or dynamic. For instance, the information may include the International Mobile Equipment Identity (IMEI), which is a number unique to every mobile phone, the International Mobile Subscriber Identity (IMSI), which is a unique number associated with network mobile phone users, and/or the geolocation of the user machine 105 , which is a real-world geographic location of a network connected computer or mobile device. The information about the user machine 105 may also include machine-level attributes. For instance, the information may include various parameters available through a PCI configuration space, like the Device ID or the Vendor ID for different system devices, the data residing in the SMM memory space, or other memory hardware attributes, such as memory type, memory clock speed, amount of memory, hard drive serial number, size of hard drive, maker of hard drive etc., and/or chipset information or graphics card information, which can be used to read hidden and/or unhidden registers within those subsystems. Further, the information may include data at different locations in firmware or BIOS or information available in a Microcode patch or a checksum of a portion of the firmware within the user machine 105 .
[0023] In addition to the foregoing, the information about the user machine 105 may also be system-level attributes. For instance, the information may include a MAC address, hard drive serial number, hardware configuration information, such as interrupt routing, GPIO routing, PCI Device Select routing or a hardware configuration map, operating system registry, CPU type, CPU version or CPU clock speed. The information about the user machine 105 may also include system pattern extraction. For instance, the information may include a directory structure and/or a list of installed applications, such as a word processor or other computer tools.
[0024] The third factor of authentication consists of unique information about the user, such as a biometric identity. The biometric data may include the specific typing pattern of the user since each user's typing behavior is unique. Typically, typing authentication works by requesting that a user seeking access to a computer or a password-protected file just type a short passage into the computer so that the user's typing pattern can be analyzed and matched against a known pattern. Additionally, the biometric data may also be generated by a biometric device, such as a fingerprint device or an iris pattern device, included within the user machine 105 .
[0025] The system 100 further includes a network 120 , which may be any type of data network, such as a local area network (LAN), a metropolitan area network (MAN), a wide area network (WAN), or the Internet. The network 120 is configured to act as a communication pathway between the user machine 105 , the authentication server 125 , and an institution server 140 . The authentication server 125 stores a copy of the profile 115 generated during the enrollment process in a user profiles database 130 . Additionally, the authentication server 125 interacts with the agent 110 via the network 120 during the secure access transaction and the secure payment transaction, as described below. The institution server 140 stores sensitive information for the user e.g. financial account information, confidential data, etc. The institution server 140 may be part of a bank, a building society, a credit union, a stock brokerage, or other businesses holding sensitive data. Generally, the institution server 140 interacts with the agent 110 via the network 120 during the enrollment process, a secure access transaction or a secure payment transaction, as described below.
Enrollment Process
[0026] FIG. 2 is a flow chart of method steps for enrolling a user in a security service, according to one embodiment of the invention. Although the method steps are described in the context of the system of FIG. 1 , any system configured to perform the method steps, in any order, is within the scope of the invention. Generally, the enrollment process 200 is used to verify the identity of the user, establish multi-factors of authentication and bind the verified identity of the user to the multi-factors of authentication. As will be discussed herein, verifying the user identity during the enrollment process 200 may include having the user answer specific personal questions e.g. amount of last check deposited, date of last withdrawal, previous residential address, etc. The answers are then checked against a known answer from a data source, such as the institution and/or third party consumer data base to verify that the user is who the user claims to be. Some examples of the multi factors of authentication are—the identification of the user, the identification of the machine, the biometric identity of the user, etc. It should be noted that the enrollment process is a one-time process for each user. After the enrollment process 200 is complete, the user is able to perform the secure access transaction 300 or the secure payment transaction 400 , described below, without having to repeat the enrollment steps. The process of verifying identity significantly reduces the chance of a malicious party claiming to be the user. The process of binding the verified identity to the multi-factors of authentication eliminates the cumbersome process of proving the identity of the user at every transaction while providing the same level of security as though the user answered the identity questions, such as the specific personal questions each time.
[0027] The enrollment process 200 begins in step 205 , where the user accesses an enrollment webpage. In one embodiment, the enrollment webpage is generated by the institution server 140 and downloaded to the user machine 105 when the user attempts to electronically access an account held with the institution. The enrollment webpage is configured to educate the user about the enrollment process and subsequently start the user identification process of step 210 .
[0028] In step 210 , the user is asked specific personal questions in which only the user knows the answer in order to generate a verified user identity. The questions may relate to dynamic data that frequently changes and is known only by the institution, such as “when was your last deposit,” “what was the last check number,” “who was the check written to” or “who last deposited money in the financial institution”, “what was your last take home pay amount.” The personal questions may relate to static data that does not change, such as “what car did you drive before your current car,” “what is your social security number, date of birth, mother's maiden name” or “what address did you live at before your current address.” In step 215 , the answers given by the user is compared to known answers in a data source, such as data at the institution or data held at third party data bases, to verify the identity of the user. If the answers do not match the known answers in the data source, then, in step 220 , an exception process is activated. The exception process may include a verification of the user over the phone. Additionally, the exception process may include the user making a personal appearance at a specific location. The exception process in step 220 may be any type of process known in the art to verify the identity of the user.
[0029] In step 225 , the security agent 110 is downloaded to the user machine 105 after the identity of the user is established. In one embodiment, the security agent 110 is downloaded directly from the institution server 140 via the network 120 . In another embodiment, the security agent 110 is downloaded via the network 120 from the authentication server 125 . In any case, the security agent 110 is configured to interact with both the authentication server 125 and the institution server 140 .
[0030] In step 230 , a user name and password is selected to establish the first factor of authentication. In one embodiment, the user selects the user name and password. In another embodiment, the authentication server 125 or the institution sever 140 generates the user name and/or the password. In any case, the user name and/or password are used during the secure access transaction 300 and the secure payment transaction 400 , described below.
[0031] In step 235 , unique information from the user machine 105 is extracted by the security agent 110 to establish the second factor of authentication. As set forth above, the information may include any number of different types of data associated with the user machine 105 . Again, the information may include the IMEI or the IMSI which relate to mobile devices. The information may include the geolocation of the user machine 105 . The information may also include machine level attributes, such as a Device ID, a Vendor ID, data at a SMM memory space, a memory type, a memory clock, hard drive serial number, chipset information, data at different locations in firmware, or information available in Microcode patch, a checksum of firmware, or BIOS. Further, the information may include system level attributes, such as a MAC address, a hard drive serial number, interrupt routing, GPIO routing, PCI DevSel routing, a map of hardware configuration, or an operating system registry. Additionally, the information may relate to system pattern extraction, such as a directory structure or a list of installed applications. No matter what type of select data is extracted from the user machine 105 , the data or a combination of different types of data should be unique to the user machine 105 in order to establish the second factor of authentication.
[0032] In step 240 , the biometric information is collected in order to establish the third factor of identity. As set forth herein, the biometric data may include specific typing patterns of the user or biometric data generated by a biometric device, such as a fingerprint device or an iris pattern device. Although each factor of authentication was discussed in steps 230 , 235 and 240 , it should be understood, however, that any of the factors may be an optional factor of authentication in the enrollment process 200 without departing from principles of the present invention.
[0033] In step 245 , the verified user identity from step 215 is connected (or bound) to the user identity profile 115 which generally comprises the data collected in steps 230 - 240 . The connecting (or binding) of the verified user identity to the factors of authentication allows the user to engage in the secure access transaction 300 or the secure payment transaction 400 without having to repeat the enrollment steps. In other words, the binding of the identity with the factors of authentication eliminates the cumbersome process of proving the identity of the user at every transaction while providing the same level of security as though the user answered the identity questions (the specific personal questions) every time.
[0034] In step 250 , a copy of the profile 115 is stored in the user profiles database 130 in the authentication server 125 . During the secure access transaction 300 and the secure payment transaction 400 , the security agent 110 interacts with the authentication server 125 by comparing the data from the user and the user machine with the user profile 115 stored in the user profiles database 130 to establish the identity of the user before proceeding with the transaction. It should be noted that in one embodiment the user is able to use the secure access transaction 300 and the secure payment transaction 400 without providing any sensitive personal data, such as a credit card number, a debit card number, etc. In another embodiment, the user interacts directly with an institution to verify the identity of the user. Then the institution issues a one-time credential, such as an account number and/or password. The one-time credential is used during the authentication process of the user to establish the identity of the user before proceeding with the secure access transaction 300 or the secure payment transaction 400 .
Secure Access Transaction
[0035] FIG. 3 is a flow chart of method steps for securely accessing a user account, according to one embodiment of the invention. Although the method steps are described in the context of the system illustrated in FIG. 1 , any system configured to perform the method steps in any order is within the scope of the invention. Generally, the secure access transaction 300 is a transaction where the user attempts to electronically access an account held at the institution via the institution server 140 . Some examples of an institution may be a financial institution, a government agency, a medical institution or a business. During the secure access transaction 300 , the security agent 110 interacts with the authentication server 125 via the network 120 to ensure that the user is properly authenticated prior to giving the user access to the relevant accounts held at the institution.
[0036] The secure access transaction 300 begins with the security agent 110 interacting with the user at a log-on webpage of the institution. In one embodiment, the security agent 110 automatically activates after the security agent 110 detects the log-on webpage of the institution. For instance, the security agent may detect the institution log-on webpage by reading the source code of the webpage, such as the HTML code or by reading a trigger, such as a header or an identification number embedded in the log-on webpage. In another embodiment, the user activates the security agent 110 to perform the secure access transaction 300 . For instance, the user may select a button on the webpage to activate the security agent 110 . In a further embodiment, the institution activates the security agent 110 and requires the user to use the security agent 110 during the secure access transaction 300 .
[0037] In step 305 , the security agent 110 prompts the user to enter his or her username and/or password in order to determine the first factor of authentication. In step 310 , the username and/or password entered in step 305 is compared to the username and/or password previously stored in the user profiles database 130 . If the username and/or password does not match the user profile in the user profiles database 130 , then an exception process is activated in step 315 to determine that the user is who the user claims to be. The exception process in step 315 may be any type of standard industry process known in the art to aid a user who has forgotten a user name and/or password. For instance, the exception process may include requiring the user to go through the enrollment process 200 again to create a new user name and/or password. The exception process may also include having the user answer a security question in order to determine that the user is who the user claims to be. The exception process may also include sending the user name and/or password to a user email address or sending a text message to a user cellphone.
[0038] In step 320 , the security agent 110 collects information which is associated with the user machine 105 in order to establish the second factor of authentication. As previously set forth herein, the information associated with the user machine 105 may include a variety of different information, such as information related to the IMEI, the IMSI, the geolocation, machine level attributes, system level attributes, or system pattern extraction.
[0039] In step 325 , the security agent 110 collects biometric information from the user in order to establish the third factor of identity. Again, the biometric data may include specific typing patterns of the user or biometric data generated by a biometric device, such as a fingerprint device or an iris pattern device. Although each factor of authentication was discussed in steps 305 , 320 and 325 , it should be understood, however, that any of the factors may be an optional factor of authentication in the secure access transaction 300 without departing from principles of the present invention.
[0040] In steps 330 and 335 , the authentication server 125 verifies that the identity data collected in steps 320 and 325 matches the data included in the user profile previously stored in the user profiles database 130 on the authentication server 125 . If the idenity data collected in steps 320 and 325 does not match the user profile in the user profiles database 130 , then an exception process is activated in step 340 . Depending on the type of mismatch, the exception process in step 340 may include limited access to the account or the exception process may require the collection of additional data or that the user to go through the enrollment process 200 again. For instance, if there is small mismatch, such as a wrong geolocation due to the user travelling or a different hard drive serial number due the user upgrading the user machine, then the user may still be allowed access to the account after collecting additional data. If there is a large mismatch, then the user may be required to go through the enrollment process 200 again in order to establish the identity of the user and the factors of authentication. If the identity data collected in steps 320 and 325 does match the user profile in the user profiles database 130 , then the user is allowed access in step 345 to the account at the institution.
Secure Payment Transaction
[0041] FIGS. 4A and 4B are a flow chart of method steps for making a secure payment, and FIG. 5 is a conceptual block diagram of a system 500 through which a secure payment may be made, according to one embodiment of the invention. Although the method steps are described in the context of the system illustrated in FIG. 5 , any system configured to perform the method steps in any order is within the scope of the invention. Generally, the secure payment transaction 400 is a transaction where the user purchases a product or a service from an on-line merchant 505 . During the secure payment transaction 400 , the security agent 110 interacts with the authentication server 125 via the network 120 to ensure that the user is properly identified and authenticated prior to the user finalizing the purchase of the product or the service from the on-line merchant 505 . The security agent 110 also is configured to interact with the different elements of system 500 to facilitate the actual on-line payment. Additionally, in the secure payment transaction 400 , the institution server 140 is represented as a user financial institution server.
[0042] The secure payment transaction 400 begins with the security agent 110 interacting with the user at a payment webpage of the online merchant 505 . In one embodiment, the security agent 110 automatically activates after the security agent 110 detects the payment webpage of the online merchant 505 . For instance, the security agent may detect the online merchant 505 payment webpage by reading the source code of the webpage, such as the HTML code for credit card information e.g. card type, expiry date, CVV2 code, etc. or by reading a trigger, such as a header or an identification number embedded in the payment webpage. In another embodiment, the user activates the security agent 110 to perform the secure payment transaction 400 . For instance, the user may select a button on the webpage to activate the security agent 110 . In a further embodiment, the online merchant 505 activates the security agent 110 and requires the user to use the security agent 110 during the secure payment transaction 400 .
[0043] In step 405 , the security agent 110 prompts the user to enter his or her username and/or password in order to determine the first factor of authentication. In one embodiment, the user enters his or her username and/or password through the standard key entry method of the user machine 105 . In another embodiment, referring now to FIG. 6 , the security agent 110 prompts the user to enter a username and/or password directly in a box 615 by using a keypad 610 on the security agent 110 . The keypad 610 is manipulated by using a mouse (not shown) to push the buttons on the keypad 610 . Placing the keypad 610 on the security agent 110 is a security mechanism designed to prevent a keylogger from monitoring and stealing the password. In other words, if the password were entered into the box 615 by using a standard keyboard (not shown), then a keylogger may be able to monitor the keystrokes of the user and steal the password. As a further security mechanism, the location of the keys on keypad 610 will systematically change between uses to prevent a mouse logger from monitoring and stealing the password. Additionally, since the security agent 110 directly communicates with the authentication server 125 rather than through a conventional webpage, the threat of “phishing” by presenting the user with bogus webpages is eliminated. One skilled in the art will recognize that the security mechanisms set forth herein may be equally applicable to any transaction that involves the security agent 110 , such as the enrollment process 200 or the secure access transaction 300 .
[0044] The security agent 110 is also configured to encrypt the data transmissions generated by the security agent 110 as the security agent 110 interacts with other components in the system. In one embodiment, the security agent 110 has a cryptographic system that uses two keys, such as a public key that is known by other components in the system 500 and a private key that is known only to the recipient of the data transmission. For instance when the security agent 110 wants to send a secure data transmission to the authentication server 125 , the security agent 110 uses the public key to encrypt the data. The authentication server 125 then uses the private key to decrypt the data. An important element of this cryptographic system is that the public and private keys are related in such a way that only the public key can be used to encrypt data and only the corresponding private key can be used to decrypt the data. As a further security mechanism, the public private key pair may be randomly changed for each session or from time to time. One skilled in the art will recognize that the security mechanisms set forth herein may be equally applicable to any transaction that involves the security agent 110 , such as the enrollment process 200 or the secure access transaction 300 .
[0045] In step 410 , the username and/or password entered in step 405 is compared to the username and/or password previously stored in the user profiles database 130 . If the username and/or password does not match the data in the user profiles database 130 , then an exception process is activated in step 415 to determine that the user is who the user claims to be. The exception process in step 415 may be any type of standard industry process known in the art to aid a user who has forgotten a user name and/or password. For instance, the exception process may include requiring the user to go through the enrollment process 200 again to create a new user name and/or password. The exception process may also include having the user answer a security question in order to determine that the user is who the user claims to be. The exception process may also include sending the user name and/or password to a user email address or sending a text message to a user cellphone.
[0046] In step 420 , the security agent 110 collects information which is associated with the user machine 105 in order to establish the second factor of authentication. As previously set forth herein, the information associated with the user machine 105 may include a variety of different information, such as information related to the IMEI, the IMSI, the geolocation, machine level attributes, system level attributes, or system pattern extraction.
[0047] In step 425 , the security agent 110 collects biometric information from the user in order to establish the third factor of authentication. Again, the biometric data may include specific typing patterns of the user or biometric data generated by a biometric device, such as a fingerprint device or an iris pattern device. Although each factor of authentication was discussed in steps 405 , 420 and 425 , it should be understood, however, that any of the factors may be an optional factor of authentication in the secure payment transaction 400 without departing from principles of the present invention.
[0048] In steps 430 and 435 , the authentication server 125 verifies that the identity data collected in steps 420 and 425 matches the data included in the user profile previously stored in the user profiles database 130 on the authentication server 125 . If the identity data collected in steps 420 and 425 does not match the user profile in the user profiles database 130 , then an exception process is activated in step 440 . Depending on the type of mismatch, the exception process in step 440 may allow a payment of a reduced amount to be made during the secured payment transaction or the exception process may require the user to go through the enrollment process 200 again. For instance, if there is small mismatch, such as a wrong geolocation due to the user travelling or a different hard drive serial number due the user upgrading the user machine, then the user may still be allowed to make an online payment after collecting additional data. If there is a large mismatch, then the user may be required to go through the enrollment process 200 again in order to establish the identity of the user and the factors of authentication before proceeding in the secure payment transaction 400 . If the identity data collected in steps 420 and 425 does match the user profile in the user profiles database 130 , then the security agent connects to the user financial institution server 140 in step 445 via the network 120 .
[0049] In step 450 , the security agent 110 requests financial account information from the institution server 140 about the user's account(s) held at the institution. Typically, the financial information relates to the different accounts that are available to make a payment to the on-line merchant 505 , such as a savings account or a checking account. Additionally, the financial information may include credit cards, lines of credit, equity lines of credit, and the like. In one embodiment, a bank line of credit can be established during the enrollment process or during the merchant transaction process. The bank line of credit then can be considered a virtual credit card for purposes of the merchant transaction. Therefore, in addition to a conventional credit card, this virtual credit card and/or savings account and/or checking account may be used as a payment means for the on-line transaction in step 460 , below.
[0050] In step 455 , the user selects an account for payment in the secure payment transaction 400 . Referring now to FIG. 7 , after the security agent 110 obtains the financial information from the institution server 140 , the security agent 110 displays an account list 705 which is a list of accounts available to pay the on-line merchant 505 . Essentially, the security agent 110 becomes an automatic teller machine, whereby the user selects the account from the list of accounts presented by the security agent 110 , and then the security agent 110 facilitates the payment to the on-line merchant 505 , as discussed below.
[0051] In step 460 , the authentication server 125 creates a one-time use personal account number which is used in the secured payment transaction 400 . The one-time use personal account number is a sixteen digit number. Similar to the conventional credit card number, the one-time use personal account number includes a number prefix, commonly referred to as Network Identification Number, which is the sequence of digits at the beginning of the number that indicates the entity to which a credit card number belongs. In one embodiment, the authentication server 125 creates an expiration date which is used in the secured payment transaction 400 . In another embodiment, the authentication server 125 creates a one time use security code.
[0052] In step 465 , the one-time use personal account number is entered into the merchant webpage. In one embodiment, the security agent 110 populates a payment field 810 of the payment page 625 of the on-line merchant 505 with the one-time use personal account number. In another embodiment, the security agent 110 populates an expiration date field 815 of the payment page 625 of the on-line merchant 505 with the expiration date. In one embodiment, the security agent 110 may hide data in the payment field 810 with a phrase such as “securepay,” as shown in FIG. 8 . Alternatively, the security agent 110 can hide data in the payment field 810 of the payment page 625 with “*********” reflecting the format of a conventional credit card number. In another embodiment, the user may populate the payment field 810 with the one-time use personal account number. In another embodiment, the user may populate the expiration date field 815 with the expiration date. In a further embodiment, the user may select a button on the payment page 625 to input the one-time use personal account number.
[0053] The utilization of the one-time use personal account number has several benefits. For instance, the one-time use personal account number has the same format as a conventional credit card number and therefore the on-line merchant 505 does not have to modify the format of the payment webpage 625 in order to accept the payment from the security agent 110 . Another benefit of the one-time use personal account number is that the personal account number can only be used one time and therefore even if the number is stolen, the personal account number has no value beyond the current transaction. Further, the number cannot be processed through traditional credit card processing networks due to the format of the number.
[0054] Referring back to FIG. 4B , in step 470 , the one-time personal account number is sent to a payment processor 510 . In step 475 , the payment processor 510 extracts server data from the one-time personal account number, such as the Network Identification Number, which is the sequence of digits at the beginning of the one-time use personal account number, in order to determine the personal account number belongs to the authentication server 125 . In step 480 , the payment processor 510 sends the one-time personal account number and transaction details to the authentication server 125 . The transaction details may include the merchant name, the merchant ID, and the amount of the transaction.
[0055] In step 485 , the authentication server 125 replaces the one-time personal account number with a user real personal account number that relates to the account which the user selected in step 455 . In step 490 , the authentication server 125 sends the real personal account number and the transaction details to the user financial institution for authorization. At this point, the user financial institution server 140 verifies that the user account has sufficient funds to cover the payment transaction. If there are insufficient funds in the selected account, then the security agent 110 prompts the user to select another account for payment. If there are sufficient funds in the selected account, then a payment authorization is sent to the payment processor 510 and security agent 110 in step 495 . In step 498 , the institution server 140 interacts with the merchant financial server 515 via the settlement network 520 to transfer the funds from the institution server 140 to the merchant financial server 515 .
[0056] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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The present invention generally relates to a computer security system for use in the identification and authentication of a user prior to an on-line transaction. In one aspect, a method for enrolling a user in a system configured to identify and authenticate the user is provided. The method includes collecting a username and password to identify the user. The method further includes extracting device data from a user machine to uniquely identify the machine. The method also includes generating a user profile based upon the device data and the username and password. Additionally, the method includes transmitting the user profile to a server machine to be stored. In another aspect, a computer-readable medium including a set of instructions that when executed by a processor cause the processor to enroll a user in a system configured to identify and authenticate the user is the provided. In yet a further aspect, a system for identifying and authenticating a user is provided.
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RELATED APPLICATION
[0001] The present application claims priority to and incorporates by reference U.S. Provisional Patent Application No. 62/088,168 filed on Dec. 5, 2014.
BACKGROUND OF THE INVENTION
[0002] 1. Field
[0003] The present invention relates to a ground engagement or soil tillage tool. In particular, the invention comprises a ripper used penetrate and break up soil that includes a leading edge configured to decrease wear and reduce drag, while providing superior performance.
[0004] 2. Background
[0005] Rippers are devices used with various types of equipment to engage with the ground for the purpose of fracturing, breaking up, and mixing the soil. Rippers are commonly used in agricultural and construction settings to engage soils for a variety of purposes. Rippers typically are attached to the end of tines and then are towed behind or used in combination with various types of equipment to prepare soils for further processing.
[0006] Rippers undergo substantial wear and tear as they impact soil, and as such are a wear part that needs periodic replacement or repair. Wear coating is commonly used to reduce the amount of wear. Typically, wear coating such as tungsten carbide is slathered on the parts in a haphazard way; with the hope that the more of the surface that is covered the longer the device will last. However, this approach suffers from a number of drawbacks.
[0007] First, wear coating dulls the cutting or ripping edges thereby interfering with the ability of the ripper to cleanly and efficiently engage the soil. Additionally, wear coating placed unnecessarily is a waste of time and money, and does not end up increasing the life of the parts.
[0008] An additional factor in the effectiveness and longevity of rippers is the design and configuration of the devices. Again, prior art devices are not efficiently designed. Design features also impact the materials from which the rippers can be made, as well as the ease of manufacturing.
[0009] Accordingly, there is a need for an improved ripper that eliminates or substantially eliminates the drawbacks of the prior art.
BRIEF DESCRIPTION OF THE FIGURES
[0010] FIG. 1 shows perspective views of a ripper.
[0011] FIG. 2 shows a top, bottom, side, front, back, and perspective views of a top cap of the ripper.
[0012] FIG. 3 shows a top bottom, side, front, and back views of the top cap.
[0013] FIG. 4 shows a top, bottom, side, front, back, and perspective views of a main body of the ripper.
[0014] FIG. 5 shows a side, bottom, and front view of the main body of the ripper.
[0015] FIG. 6 shows side, bottom, and perspective views of a bracket of the ripper.
[0016] FIG. 7 shows flat and front views a wing of the ripper.
DETAILED DESCRIPTION OF THE INVENTION
[0017] In the Figures is shown a ripper 10 , which is a device used as an attachment to agricultural, construction, and industrial machines for ground engagement purposes. The ripper 10 is comprised of the following principle components; a main body 12 (shown best in FIGS. 4-5 ), a top cap 14 (shown best in FIGS. 2-3 ), a bracket 16 (shown best in FIG. 6 ), and a wing 18 (shown best in FIG. 7 ). The parts of the ripper 10 are integrated into a single device, but perform different functions therein. Multiple views of the integrated ripper 10 are shown in FIG. 1 .
[0018] The main body 12 forms the core of the ripper 10 and provides space for attaching the various other parts of the ripper and includes configurations that are important to the success of the device in overcoming the problems in the prior art. In particular, the main body 12 is fabricated from heated treated alloy, or similar materials. The main body 12 includes a curved rear portion 20 for receipt of the wing 18 . The curvature of the rear portion 20 allows the wings 18 to have a greater range of position and in particular, to allow the wings 18 to sweep further outward and downward. The main body 12 also includes a tapered front section 22 that is shaped to better receive the top cap 14 . The main body 12 includes a shelf 24 that acts as a stop that fits into a pocket 26 on the top cap 14 . This provides for a secure, repeatable, and precise placement of the top cap 14 on the main body 12 . The nose of the main body is also tapered so that, along with the shelf 24 , the top cap 14 and main body 12 fit in mated alignment.
[0019] The main body 12 also includes downward depending ridges 28 located on the bottom rear portion of the main body 12 . The ridges 28 form a saddleback into which the bracket 16 sits. The saddleback design provides for repeatable attachment of the main body 12 to the bracket 16 , and better resists rotational, twisting, and side-to-side stresses between the main body 12 and the bracket 16 when the ripper 10 is in use, which substantially reduces failure of the device. Additionally, the saddleback design allows for consistent repeatable placement of the ripper 10 on equipment by creating a uniform pocket for the bracket 16 . This allows precise control of the elevation of the ripper 10 in operation on equipment.
[0020] The top cap 14 includes a tapered and rounded nose 30 that forms the impact surface of the device. This is the portion of the device that first impacts the ground, and as such undergoes the principal share of the wear. This surface is therefore typically hardened with a wear coating such as tungsten carbide to reduce wear.
[0021] The top cap 14 has rounded V-shaped profile, which creates less resistance during operation, requires less horsepower to fracture the soil, and creates a better wear angle. The rounded v-shape creates a sharper longer edge for better penetration. The effect is that the edge will stay sucked into the ground and stay there. The shorter and rounder nose of prior art devices tends to bounce out of the soil, rather than penetrate.
[0022] Unlike conventional prior art device, the present device utilizes wear coating on the back or underside of the impact surface 32 . Placing the wear coating on the back, non-impact, edge of the wear part produces surprising advantages. The presence of the wear coating on the backside supports the impact front side surface from wear and better prevents wear than coating the front side. This is counter intuitive, and the prior art teaches away from such an approach. The prior art teaches putting the wear coating on the impact surface, or merely applies wear coating haphazardly to the entire part or working edge of the part without any distinction between the impact edge and the non-impact edge.
[0023] Additionally, in those situations where the sharpness of the face matters, coating the backside preserves a sharp cutting face. Coating the front side with a substance such as tungsten carbide defeats this advantage due to the fact that carbide coatings dull the face and interferes with the flow of edge through the surface it is applied to. Still further, the wear coating lasts longer on the non-impact surface since it is not in the path of abrasion as it would be with front side coating. Also, coating the backside reduces the amount of wear coating that needs to be applied in those cases where coating is applied to both sides of a wear part. These advantages are not realized if the coating is applied to the impact surface of applied generally to all surfaces.
[0024] The use of the wear coating on the backside, and as otherwise described herein, produces a lower draft as the flow of soil is not being interfered with to the extent as devices that use wear coating on the top surface. This also allows the ripper 10 to be operated at a higher speed without damage.
[0025] Wear coating is also, preferably, applied to the main body 12 at the inflection point 34 (see drawings FIGS. 1 and 4 ). When the ripper 10 is assembled the inflection point creates a recessed pocket behind the forward edge of the top cap 14 . When the recessed pocket is filled with wear coating it becomes the lowest most exposed point of the ripper. As the lower edge of the top cap 14 wears, the wear coated inflection point 34 becomes both an impact surface and a wear surface. When wear coating is applied in this manner it provides an efficient and cost effective means of increasing the wear life of the ripper.
[0026] The bracket 16 is the point of attachment between the ripper 10 and the equipment that it is utilized with. The bracket 16 is generally U-shaped, and is attached to the underside of the main body 12 between the saddleback ridges 28 for a maximum secure fit therebetween. The bracket 16 includes holes in the sides for use to secure the bracket 16 to the equipment. The bracket 16 also includes a plate 17 attached to the bracket 16 to protect the head and nut of fasteners used to connect to the ripper 10 to equipment. The fasteners can experience residual impact from soil, debris, or stones during operation that might cause the fasteners to wear, break or come lose. The plate 17 protects against this occurrence. The bracket 16 is also shown in FIG. 6 , without the plate 17 .
[0027] The ripper 10 includes a wing 18 . The wing 18 extends on either side of the ripper 14 and is used to create a furrow in the soil below the surface. The width of the wing 18 will vary depending on the application. Typical widths for the wing 18 are 5″, 7″, and 10″. Longer width displaces more soil, vary the turbulence and distribution of soil, and break up clods. In some circumstances, a wing is not needed, and a blank would be inserted to fill the gap between the top cap 14 and the main body 12 . Wear coating can be placed on the bottom side of the edge of the wing 18 to protect the part from wear in the same manner as described above. The coating on the bottom, as mentioned, protects the wing 18 but does not interrupt the flow of material over the top of the part and allows for use with little resistance.
[0028] The wing 18 may also include a vertical fin (pointing down or up) that can be attached to each end of the wing, this would aid in breaking up clogs of dirt.
[0029] The main body 12 is preferably made of hardened alloy steel, the top cap 14 is preferably made from a high wear resistant casting, and the bracket 18 is preferably made from mild steel. The wings 18 are preferably made from hardened alloy plate. Other materials can be substituted depending on the circumstances.
[0030] These and other advantages will be apparent to those of ordinary skill in the art.
[0031] While the various embodiments of the invention have been described in reference to the Figures, the invention is not so limited. 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 to 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 to the extent allowed by applicable law and regulations. In case of conflict, the present specification, including definitions, will control.
[0032] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention. Those of ordinary skill in the art that have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention.
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The present invention comprises a ripper used penetrate and break up soil that includes a leading edge configured to decrease wear and reduce drag, while providing superior performance. The ripper is comprised of a main body, a top cap, a wing, and a bracket.
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FIELD OF THE INVENTION
The present application relates to power supply strips for electronic equipment, and particularly to a power supply system for use with servers and other computing equipment.
BACKGROUND
Data centers typically involve a large number of rack-mounted servers that are housed together in cabinets. Recent increases in processor speeds and reductions in the size of processors have meant that more processing power is provided by each server within a cabinet, and consequently the amount of power required to operate the server cabinets has increased dramatically. Additionally, power is typically needed for fans and other cooling equipment, due to the large amount of heat generated by the processors. A typical server cabinet in a data center contains 42 1U dual-power supply servers in each cabinet. Power demands for such a cabinet far exceed typical single-phase 120V 20 A power circuits, and thus three-phase power circuits must be used.
A problem arises when designing power supplies for server cabinets because the rated amperages of servers do not correlate with the amount of power that the device typically consumes. As an example, a device that is rated as 220 A, 220V and thus requires a power supply of 440 kW will typically not draw more than 2 kW. Most servers, and hence the cabinets that they are stacked within thus have a significantly overweighted power supply because the data center must dedicate the rated amount to the circuit.
It is desirable to be able to move the overweighting of the power supply circuit from each individual server to the cabinet itself. In this way, the distribution of power within the cabinet can be managed appropriately.
SUMMARY
In accordance with one aspect of the exemplary embodiments, a power supply strip for electronic equipment including a power supply cable for connection to a power source, a housing connected to the power supply cable, and a plurality of conductor rails located within the housing. One or more power receptacle modules is insertable into the housing, each comprising at least one power receptacle. Each power receptacle module is connectable to selected conductor rails such that the or each power receptacle is configurable to provide a desired power supply configuration. With a three-phase power supply, the rails can be selectable between A-phase, B-phase, C-phase, Neutral and Ground.
In one arrangement, the power supply cable is connectable to a three-phase power supply, and wherein five conductor rails are provided. The five conductor rails can be connected respectively to A-phase, B-phase, C-phase, Neutral and Ground. Each power receptacle module can comprise three power receptacles, and wherein the three power receptacles in one module are connectable to the A, N, G conductor rails, to the B, N, G conductor rails, and to the C, N, G conductor rails respectively.
In another arrangement, a plurality of power receptacle modules are provided for insertion into the housing. The at least one power receptacle can be selectable and changeable by the user to provide differing power supplies for different pieces of electronic equipment.
The conductor rails can extend the length of the housing. In some arrangements, the conductor rails can comprise a generally V-shaped valley in a resilient material, the valley comprising coating of a conductive material and the resilient material being surrounded on at least three sides by an insulator. The resilient material may be conductive, and the conductive coating can be copper.
In some arrangements, a plurality of different power supply receptacles can be provided, which are selectable by a user to provide different power outputs. The power supply receptacles can be selected from the group including L5-20, L5-20R, L5-15R, 5-20R, L6-20R, L6-30R and 5-15R receptacles.
In various arrangements, at least one blank expansion module can be provided that is insertable in the housing. The housing can define at least one power module port for receiving a power receptacle module. The power module port and power receptacle module can comprise complementary guide rails to ease insertion of the power receptacle module into the power module port.
The power receptacle module can comprise a plurality of male conductors that are connectable to the selected conductor rails. In some arrangements, wire connectors can be provided, that are attachable between the male conductors of the power receptacle module and the conductor rails. The wire connectors can have connection pins that are a pressure fit into the conductor rails. Alternatively, the male conductors can be a direct pressure fit into the conductor rails.
The housing can be dimensioned so as to be rack mountable within a server cabinet so that the power strip can be used for powering servers and other equipment stored within the cabinet.
The above-described and other features and advantages of the present disclosure will be appreciated and understood by those skilled in the art from the following detailed description, drawings, and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a power supply strip according to arrangements of the present invention.
FIG. 2 is a top perspective view of a power module for the power supply strip of FIG. 1 .
FIG. 3 is a bottom perspective view of a power module for the power supply strip of FIG. 1 .
FIG. 4 is an end sectional view of an empty section of the power supply strip of FIG. 1 .
FIG. 5 is an expanded close up view of one of the power supply rails shown in FIG. 4 .
FIG. 6 is an end sectional view of a section of the power supply strip of FIG. 1 , with a power module inserted therein.
FIG. 7 is a side sectional view of a section of the power supply strip of FIG. 1 , with a power module inserted therein.
DETAILED DESCRIPTION OF THE INVENTION
The exemplary embodiments of the present disclosure are described with respect to a power supply strip for electronic equipment. It should be understood by one of ordinary skill in the art that the exemplary embodiments of the present disclosure can be applied to other types of power supply arrangements.
Referring to the drawings, an exemplary power supply strip for electronic equipment is illustrated. The strip 10 comprises a housing 12 connected to an electrical supply cable 14 . The housing 12 may be formed with a steel construction, or may be formed of any suitable material. The housing is preferably UL listed and sized to be rack mounted within a server cabinet, although any suitable size and shape may be employed. In certain arrangements, the housing 12 may be 4-5 feet long. The electrical supply cable 14 may be any suitable cable. In one arrangement, the cable may be a 5-wire 200% ground, 200% neutral #10 conductor flexible copper whip capable of carrying a three-phase power supply, and may for example be ¾ in width. Various amperage monitors 11 (typically one each for A, B, C phases, Neutral and Ground), an RJ-45 jack 13 and an optional 3-pole breaker 15 may be provided.
The housing 12 may be arranged to comprise a plurality of power module ports 16 . Each power module port 16 is sized to receive one power module 18 , which are illustrated in FIGS. 1-3 . Each power module 18 can be sized to fit within a power module port 16 only one way, and may be screwed into place using screws 20 or any other suitable connection mechanism. Each power module 18 may have three three-prong receptacles 22 , although of course any suitable socket or receptacle arrangement may be used. In one arrangement, the receptacles 22 can be L5-20 receptacles. Available receptacles for each power module 18 may include L5-20R, L5-15R, 5-20R, L6-20R, L6-30R and 5-15R, which may be selectable by the user depending on the particular application. It will be appreciated that any type of receptacle arrangement can be provided for the power strip 10 , and that the selection of the particular power receptacle type that is used within each power module 18 may be made by the user to provide differing amp and voltage ratings to different pieces of electronic equipment, depending on the power requirements of that piece of equipment. For example, an L5-15R receptacle can provide 15 Amps, while an L6-30R receptacle can provide 30 Amps. All three receptacles 22 on one power module 18 may be the same type of receptacle, or they may be different receptacles. The power modules 18 may be supplied pre-wired with selected power receptacle types, and the user may simply select different power modules 18 that are appropriate for their requirements. Alternatively, the user may select the individual receptacles 22 . If the user does not need as many power modules 18 as there are power module ports 16 , one or more blank expansion modules (not shown) may be used to cover the power module port 16 . The blank expansion modules may simply be plates or may be the same general shape and size as the power modules 18 .
Underneath the power module 18 , three connection pins or male conductors 24 may be provided for each receptacle 22 . Typically, with a three-phase power supply, each of the three receptacles 22 on one power module will have a connection pin 26 for a different phase, as well as a connection for neutral and ground. For example, one of the receptacles can have connections for A-phase power, Neutral and Ground, the second receptacle can have connections for B-phase power, Neutral and Ground, and the third receptacle can have connections for C-phase power, Neutral and Ground. Guide rails 28 may be provided to help place the power module 18 within the power module port 16 of the housing 12 .
Referring now to FIGS. 4 and 5 , an end sectional view through the housing 12 is shown. Five conductor rails or raceways 30 are supplied in the bottom of the housing 12 , and run the entire length of the housing 12 . Each conductor rail 30 is connected to one of the A, B, C, N or G phases of the power supply cable 14 . Each conductor rail 30 comprises a conductor 32 , such as copper, arranged on the surface of a generally V-shaped valley in a resilient conductive material 34 . The rail 30 is surrounded (apart from the surface covered by the conductor 32 ) by an insulator 36 . It will be appreciated that the conductor 32 , resilient material 34 and insulator 36 may each be formed of any suitable material.
When one or more power modules 18 are connected into the housing 12 , as shown in FIGS. 6 and 7 , wire conductors 38 can be soldered 40 or otherwise connected between the connection pins 24 and connection pins 42 that are inserted into the rails 30 . The resilient material 34 in the rails 30 holds the connection pins 42 under tension in a pressure fit arrangement. In this way, the relevant A, B, C, N or G phase pin receptacle of each receptacle 22 of the power module 18 may be connected to the relevant power supply line. In an alternative arrangement (not shown), the connection pins 24 on the power module 18 can be arranged to fit directly in the rails 30 , in a pressure fit arrangement. In this arrangement, each connection pin 24 is placed at an appropriate location to align with a chosen rail 30 when the power module 18 is pushed into the housing 12 . This removes the need to use wire conductors 38 .
The power strip 10 of the present invention enables a user to match the power receptacle 22 or receptacle to the power supply needs of the individual piece of electronic equipment being supplied. This means that the user can manage the power supply within a cabinet, without the need to supply multiple power circuits to a single cabinet.
The illustrations of arrangements described herein are intended to provide a general understanding of the structure of various embodiments, and they are not intended to serve as a complete description of all the elements and features of apparatus and systems that might make use of the structures described herein. Many other arrangements will be apparent to those of skill in the art upon reviewing the above description. Other arrangements may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Figures are also merely representational and may not be drawn to scale. Certain proportions thereof may be exaggerated, while others may be minimized. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.
Thus, although specific arrangements have been illustrated and described herein, it should be appreciated that any arrangement calculated to achieve the same purpose may be substituted for the specific arrangement shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments and arrangements of the invention. Combinations of the above arrangements, and other arrangements not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description. Therefore, it is intended that the disclosure not be limited to the particular arrangement(s) disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments and arrangements falling within the scope of the appended claims.
The Abstract of the Disclosure is provided to comply with 37 C.F.R. §1.72(b), requiring an abstract that will allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
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A power supply strip for electronic equipment including a power supply cable for connection to a power source, a housing connected to the power supply cable, and a plurality of conductor rails located within the housing. One or more power receptacle modules is insertable into the housing, each comprising at least one power receptacle. Each power receptacle module is connectable to selected conductor rails such that the or each power receptacle is configurable to provide a desired power supply configuration. With a three-phase power supply, the rails can be selectable between A-phase, B-phase, C-phase, Neutral and Ground.
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BACKGROUND OF THE INVENTION
This invention relates to an adjustable holster for a handgun, revolver or pistol.
There have been known in the past holsters that are adjustable have been known in the past holsters that are adjustable to various selected angles and positions on the upper leg of wearer for quick draw purposes. Typical of such is that described in U.S. Pat. No. 5,167,355 to Hill involving a ratchet means to rotate tile holster to any angle about a fender which attached to a waist belt. This patented holster, however, does not permit other adjustments, e.g., vertical and rotational, which may well be necessary to reach the most desirable position for the holster for any unique individual.
Accordingly, it is an object of this invention to provide a holster that is adjustable in several directions. It is another object to provide a holster that is adjustable lengthwise of and rotationwise about, a vertical support rod. Still other objects will become apparent from the more detailed description of the invention which follows.
BRIEF SUMMARY OF THE INVENTION
This invention relates to a holster assembly for a handgun where the holster has two sidewalls, a back wall, an open front, an open top and an open bottom. This holster is longitudinally and rotatably attached to an elongated substantially vertical support rod closely spaced inwardly from the holster. An arcuate strap serving as an upper body rest is adjustably attached to the upper end of the vertical rod, and a lower thigh rest is adjustably attached to a lower portion of the vertical rod.
In specific and preferred embodiments of the invention the upper body rest is an arcuate strap which rests against the body contours of the wearer, perhaps at the waist, the hip, or the upper thigh, and is tiltable through a limited angle. The lower thigh rest is a pad which can be adjusted longitudinally along the rod and can be adjusted rotationally around the rod.
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 front elevational view of the holster of this invention;
FIG. 2 is an outside elevational view of the holster of this invention;
FIG. 3 is a rear elevational view of the holster of this invention;
FIG. 4 is an outside elevational view of the assembly of the rod support, the upper body rest, and the lower thigh rest;
FIG. 5 is a rear elevational view of the assembly of FIG. 4;
FIG. 6 is a top plan view of the assembly of FIG. 4; and
FIG. 7 is a front elevational view of the assembly of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
The advantages and operational features of this invention are best appreciated by reading the following description referring to the attached drawings.
The holster assembly of this invention includes as principal Components the handgun holster 25, the vertical rod support 10, the upper body rest 11, and the lower thigh rest 12. These components are adjustably fastened together so as to permit the precise positioning of the handgun grip where the wearer wants it for quick draw.
The holster 25 may be any of many styles none of which being critical to the operation of this invention. The holster 25 shown in these drawings is particularly adapted to competitive sports including activities involving quick draw and firing of a handgun. Holster 25 has an inside (adjacent the wearer's body) sidewall 26, an outside (spaced away from the wearer's body) sidewall 27, a back wall 37, an open top 28, an open front 29, an open bottom 30, and a muzzle strap 31. There also is included a trigger guard restraint mechanism 34 which adds retention to the weapon from rocking forward in the holster while providing an adjustable tension draw to the top of the holster and which preferably is included with the holster style shown in the drawings, but may be omitted with other styles of holsters. The details of the preferred trigger guard restraint are described and claimed in our U.S. Pat. No. 5,100,036 which issued Mar. 31, 1992. Outside screw 35 and rear screw 36 hold trigger guard restraint 34 in place in the interior cavity near open top 28 of holster 25.
Support rod 10 serves as a rigid spine to which all other components are attached in an adjustable manner. Rod 10 is a cylindrical rigid rod about the same length as holster 25 from top 28 to bottom 30. Rod 10 is spaced inwardly, i.e., toward the wearer's body, from holster sidewall 26 and positioned generally parallel to inside wall 26, and generally vertical in the same sense that holster 25 hangs vertically on the wearer's body. At the upper end of rod 10 there is a generally triangular flat head 15 to which upper body rest is attached. Holster 25 is attached to rod 10 by way of two spaced clamps 32 and 33. Lower thigh rest 12 is also attached to rod 10 by way of clamp 19, normally positioned between holster clamps 32 and 33. Clamps 19, 32 and 33 are generally similar in that they comprise two opposing jaws that wrap around rod 10 and are tightened together by a screw 20. When screw 20 is loosened it permits the component to which it is attached, e.g., holster 25 or thigh rest pad 12, to be moved slidably lengthwise of rod 10 or rotationally around rod 10. Thus, holster 25 and thigh rest pad 12 can be positioned to suit the wearer, and can be tightened in the desired position. Lower thigh rest pad 12 is merely a box like pad of suitable thickness to rest against the thigh of the wearer while preventing contact by other items, such as clamps 19, 32 33, screws 20, rod 10, etc. Rest 12 may be hard, soft, contoured, flat, or have any other desired characteristic. In the preferred embodiment as shown, rest 12 is a smooth hard, flat-surfaced pad.
At the upper end of rod 10 is head 15 to which upper body rest 11 is attached. Rest 11 is made with an interior concave surface 38 and an exterior convex surface 39 such that it resembles a curved or arcuate strap, the shape of the concave surface 38 being such that it fits the general contours of the body of the wearer where it rests. This may be at the waist, at the hip, or on the upper thigh of the wearer. A central portion of body rest 11 is formed into outer flap 40 which is folded downwardly and fastened with spacer 42, screw 23, and nut 18 to head 15. This arrangement leaves a tunnel space 41 to serve as a belt loop to receive a belt from which the holster is suspended. Head 15 is fashioned with an arcuate slot 17 through which screw 23 passes and this permits tilting of rest 11 with respect to rod 10 through angle 43, which may be about 300°-60°, preferably about 45°. Once the proper tilt has been reached body rest 11 can be fixed in place by tightening screw 23 against nut 18. Rest 11 pivots or tilts about screw 16 which is attached to head 15 and to flap 40, but does not extend through the concave-convex strap portion of rest 11.
As an added feature, which is not a critical portion of the invention, the strap portion of body rest 11 may be covered with pads of Velcro fastener in order to be more secure. It is a common practice for competition shooter's uniforms to include an underbelt and/or an overbelt of Velcro fastener material to be worn with handgun holsters. For this reason the drawings show pads of fabric loops 13 on concave surface 38 of body rest 11 and pads of fabric hooks 14 on convex surface 39 of body rest 11. These pads 13 and 14 can be fastened to an underbelt worn between body rest 11 and the body of the wearer, or they may be fastened to an overbelt threaded through loop 41 and worn around the body of the wearer. It is, of course, entirely optional to include or not to include pads 13 and 14 on body rest 11; since the holster assembly of this invention is entirely operational without pads 13 and 14.
It may be seen that the holster assembly of this invention permits the gun grip to be raised, lowered, or moved circumferentially about the thigh of the wearer. The adjustment of the positions of body rest. 11 and thigh rest 12 permit the handgun and holster to be positioned at different angles with respect to the thigh where the holster hangs.
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.
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Handgun holster attached to a vertical support rod parallel to and spaced apart from the holster. There also is attached to the rod an arcuate strap as an upper body rest and a pad as a lower thigh rest, each rest being adjustable and clampable to selected positions for the convenience of the wearer. Preferably, this holster is for use in sports competition, where it is important to be able to draw quickly and fire.
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RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/119,903 filed 4 Dec. 2008 under 35 U.S.C. 119(e).
[0002] This application claims the benefit of U.S. Provisional Application Ser. No. 61/219,377 filed 22 Jun. 2009 under 35 U.S.C. 119(e).
FIELD
[0003] This disclosure relates to stoppage devices, and more specifically to methods and devices to plug a drain pipe of a toilet using pressure.
BACKGROUND
[0004] In order to maintain hygienic and aesthetic toilet bowls, toilet bowls are cleaned and disinfected periodically or as needed. Conventional apparatus for cleaning and disinfecting toilet bowls includes a mechanized toilet bowl cleaner as described in US patent application 2009/0044322 or a manual brush apparatus as described in US patent application 2003/0209458.
BRIEF DESCRIPTION
[0005] The above-mentioned shortcomings, disadvantages and problems are addressed herein, which will be understood by reading and studying the following specification.
[0006] In one aspect, a device includes an inflation bulb includes a release valve an inflatable bladder, and a hollow semi-rigid tube joining the inflation bulb to the bladder.
[0007] In another aspect, a device includes an inflation bulb including a release valve, a malleable apparatus having rounded contours, and a hollow semi-rigid tube joining the inflation bulb to the malleable apparatus having rounded contours.
[0008] In yet another aspect, a device consists of an inflation bulb having a release valve, a malleable apparatus having rounded contours, and a hollow semi-rigid tube joining the inflation bulb to the malleable apparatus having rounded contours.
[0009] In still another aspect, an apparatus includes a pressuring apparatus having a housing, the housing of the pressuring apparatus having an exterior and an interior, the housing of the pressuring apparatus having a passage between the pressuring apparatus housing interior and the pressuring apparatus housing exterior, the pressuring apparatus passage forming an opening on the exterior of the pressuring apparatus housing, the pressuring apparatus passage having a center, a tube having a first end and a second end, the tube having a passage through the longitudinal axis of the tube from the first end to the second end, the first end being operably coupled to the pressuring apparatus coincident with the opening of the exterior of the pressuring apparatus, and an inflatable/deflatable apparatus coupled to the tube, the inflatable/deflatable apparatus having a housing, the housing of the inflatable/deflatable apparatus having an exterior and an interior, the housing of the inflatable/deflatable apparatus having a passage between the interior of the inflatable/deflatable apparatus housing and the exterior of the inflatable/deflatable apparatus housing, the inflatable/deflatable apparatus passage forming an opening on the exterior of the inflatable/deflatable apparatus housing, the passage of the inflatable/deflatable apparatus having a center, the second end of the tube operably coupled to the inflatable/deflatable apparatus coincident with the opening of the exterior of the inflatable/deflatable apparatus.
[0010] In a further aspect, an apparatus consists of a pressuring apparatus, the pressuring apparatus further including a housing, the housing of the pressuring apparatus further including an exterior and an interior, the housing of the pressuring apparatus further including a passage between the pressuring apparatus housing interior and the pressuring apparatus housing exterior, the pressuring apparatus passage forming an opening on the exterior of the pressuring apparatus housing, the pressuring apparatus passage further including a center, a tube, the tube further including a first end and a second end, the tube further including a passage through the longitudinal axis of the tube from the first end to the second end, the first end operably coupled to the pressuring apparatus coincident with the opening of the exterior of the pressuring apparatus, and an inflatable/deflatable apparatus, the inflatable/deflatable apparatus coupled to the tube, the inflatable/deflatable apparatus further including a housing, the housing of the inflatable/deflatable apparatus further including an exterior and an interior, the housing of the inflatable/deflatable apparatus further including a passage between the interior of the inflatable/deflatable apparatus housing and the exterior of the inflatable/deflatable apparatus housing, the inflatable/deflatable apparatus passage forming an opening on the exterior of the inflatable/deflatable apparatus housing, the passage of the inflatable/deflatable apparatus further including a center, the second end of the tube operably coupled to the inflatable/deflatable apparatus coincident with the opening of the exterior of the inflatable/deflatable apparatus.
[0011] In yet a further aspect, a device includes an inflation bulb, and an inflatable bladder joined to the inflation bulb,
[0012] In still yet a further aspect, a method of cleaning a toilet bowl includes repeatedly squeezing an inflation bulb to inflate an inflatable bladder until the inflatable bladder conforms to an interior of a drain of a toilet bowl, introducing a cleaning solution into the toilet bowl, and deflating the inflatable bladder by opening the release valve.
[0013] A method of using the device and apparatus described herein includes holding the device by the inflation bulb and inserting the inflatable bladder into the toilet bowl drain. Then, with the release valve on the inflation bulb closed, inflate the inflation bladder until the toilet drain is adequately clogged. Waiting until the toilet drain is clogged allows for the toilet bowl to be filled with a stain removing soaking solution to the level desired, and/or other solutions or substances. After allowing some time for solution to work, the release valve on inflation bulb is opened to deflate the inflatable bladder and remove device. The toilet can then be flushed as normal. In order to construct the present device from its essential three subassemblies, insert the hollow, semi rigid tube into the inflation end of the inflation bulb. If using hose clamps, slide both hose clamps onto the tube. Use one to secure the inflation bulb to the tube. Insert the other end of tube into the inflatable bladder and secure using the other hose clamp. If using nylon tie straps, insert tube into the inflation bulb and secure with the nylon tie strap. Insert other end into inflatable bladder and secure with another nylon tie strap. If using bonding materials, such as glue or epoxy, coat both ends of tube and insert into inflation bulb on one end and inflatable bladder on the other. Allow to set and dry.
[0014] Apparatus, systems, and methods of varying scope are described herein. In addition to the aspects and advantages described in this summary, further aspects and advantages will become apparent by reference to the drawings and by reading the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is block diagram of an overview of a system to expand and prevent flow of liquid through a pipe;
[0016] FIG. 2 is a diagram of a drain-blocking apparatus, according to an implementation;
[0017] FIG. 3 is a diagram of a pressuring apparatus, according to an implementation;
[0018] FIG. 4 is a diagram of a tube, according to an implementation;
[0019] FIG. 5 is a diagram of an inflatable bladder, according to an implementation;
[0020] FIG. 6 is a cross section block diagram of a three-way ball valve in an open position, according to an implementation;
[0021] FIG. 7 is a cross section block diagram of a three-way ball valve in a release position, according to an implementation;
[0022] FIG. 8 is a cross section block diagram of a quick-release valve having a spring internal to the apparatus, in a release position, according to an implementation;
[0023] FIG. 9 is a cross section block diagram of a quick-release valve having a spring internal to the valve, in a closed position, according to an implementation;
[0024] FIG. 10 is a flowchart of a method according to an implementation.
DETAILED DESCRIPTION
[0025] In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific implementations which may be practiced. These implementations are described in sufficient detail to enable those skilled in the art to practice the implementations, and it is to be understood that other implementations may be utilized and that logical, mechanical, electrical and other changes may be made without departing from the scope of the implementations. The following detailed description is, therefore, not to be taken in a limiting sense.
[0026] The detailed description is divided into four sections. In the first section, a system level overview is described. In the second section, apparatus of implementations are described. In the third section, implementations of methods are described. Finally, in the fourth section, a conclusion of the detailed description is provided.
System Level Overview
[0027] A system level overview of the operation of an implementation is described in this section of the detailed description.
[0028] FIG. 1 is block diagram of an overview of a system 100 to expand and prevent flow of liquid through a pipe. System 100 provides blockage to a drain pipe.
[0029] System 100 includes a pressuring apparatus 102 . The pressuring apparatus 102 inflates and provides outward pressure on the external environment.
[0030] System 100 also includes a tube 104 that includes a passage 106 . The passage 106 of the tube 104 is coupled to the interior of the pressuring apparatus 102 so that exchange of liquids and gases can occur between the passage 106 of the tube 104 and the interior of the pressuring apparatus 102 when pressure differences exist between the passage 106 of the tube 104 and the interior of the pressuring apparatus 102 .
[0031] System 100 also includes an inflatable/deflatable apparatus 108 . The inflatable/deflatable apparatus 108 can be expanded by application of higher pressure liquids and/or gases into the interior of the inflatable/deflatable apparatus 108 , thus creating a larger volume of the inflatable/deflatable apparatus 108 . The inflatable/deflatable apparatus 108 can shrink from an expanded state by releasing the liquids and/or gases in the inflatable/deflatable apparatus 108 into an environment having lower pressure than the interior of the inflatable/deflatable apparatus 108 . The passage 106 of the tube 104 is coupled to the interior of the inflatable/deflatable apparatus 108 so that exchange of liquids and gases can occur between the passage 106 of the tube 104 and the interior of the inflatable/deflatable apparatus 108 when pressure differences exist between the passage 106 of the tube 104 and the interior of the inflatable/deflatable apparatus 108 .
[0032] The interior of the inflatable/deflatable apparatus 108 and the interior of the pressuring apparatus 102 are coupled through the passage 106 of the tube 104 . Thus, exchange of liquids and gases can occur between the interior of the pressuring apparatus 102 and the interior of the inflatable/deflatable apparatus 108 when pressure differences exist between the interior of the pressuring apparatus 102 and the interior of the inflatable/deflatable apparatus 108 . The inflatable/deflatable apparatus 108 , pressuring apparatus 102 and the passage 106 of the tube 104 are joined to form a continuous enclosure.
[0033] When the inflatable/deflatable apparatus 108 is placed in a drain pipe (not shown), and the pressuring apparatus 102 creates a higher pressure than the pressure in the passage 106 of the tube 104 and the inflatable/deflatable apparatus 108 , gases and/or liquids in the pressuring apparatus 102 and the passage 106 of the tube 104 will move towards and into the inflatable/deflatable apparatus 108 , thus creating a higher internal pressure in the inflatable/deflatable apparatus 108 and causing the inflatable/deflatable apparatus 108 to expand. Upon application of sufficient pressure from the pressuring apparatus 102 , the inflatable/deflatable apparatus 108 can expand and conform to the dimension/circumference of the drain pipe, thus preventing movement of matter through the drain pipe and blocking passage of matter through the drain pipe.
[0034] The blockage of the drain pipe is helpful in the cleaning and disinfecting of toilet bowls. In situations where system 100 is implemented to block a drain pipe of a toilet bowl, after the toilet bowl drain pipe is blocked, water, cleaning and/or disinfecting solutions can be added to the toilet bowl in order to cause the water, cleaning and/or disinfecting solutions to dwell in the toilet bowl. If the system 100 remains in the toilet bowl with the inflatable/deflatable apparatus 108 expanded to the interior dimension/circumference of the drain pipe for a long enough time and with sufficient concentration of cleaning and disinfecting solution in the toilet bowl, the toilet bowl will be cleaned and disinfected to as high a level as the water, cleaning and/or disinfecting solution reside within the toilet bowl. If the level of the water, cleaning and/or disinfecting solution is up to or close to the rim of the toilet bowl, the toilet bowl will be cleaned and disinfected up to or close to the rim of the toilet bowl. In particular, if the cleaning solution includes a decalcification agent, such as CLR™ manufactured by Jelmar of Skokie, Ill. which includes gluconic acid, citric acid, lactic acid, surfactants, glycolic acid and sulfamic acid (gluconic acid dissolves mineral deposits including calcium deposits, glycolic acid penetrates surfaces to remove deep stains and sulfamic acid cleans metal and removes rust), calcium deposits in the toilet bowl can be removed up to or close to the rim of toilet bowl. Other suitable cleaning solutions include chlorine, shock, Chlorox®, limeaway, CLR, and/or boric acid.
[0035] While the system 100 is not limited to any particular pressuring apparatus 102 , tube 104 , passage 106 and inflatable/deflatable apparatus 108 , for sake of clarity a simplified pressuring apparatus 102 , tube 104 , passage 106 and inflatable/deflatable apparatus 108 are described.
Apparatus Implementations
[0036] In the previous section, a system level overview of the operation of an implementation was described. In this section, the particular apparatus of such an implementation are described by reference to a series of diagrams.
[0037] FIG. 2 is a diagram of a drain-blocking apparatus 200 , according to an implementation. Apparatus 200 is one implementation of system 100 in FIG. 1 . Apparatus 200 can block a drain pipe for application of a cleaning and/or disinfecting solution on portions of the interior of the toilet bowl that are higher than the normal unassisted water level in the toilet bowl.
[0038] Apparatus 200 includes an inflation bulb 202 . The inflation bulb 202 provides air pressure. The inflation bulb 202 is operated manually. When the inflation bulb 202 is compressed by external mechanical force, air is squeezed out of the bulb through an exit (not shown). Depending upon the structure of other items in apparatus 200 , the exit is located at various points in portion 204 . Portion 204 of the inflation bulb 202 is often referred to as a collar. When the inflation bulb is released, a mechanism of the inflation bulb 202 provides mechanical force to expand the inflation bulb to the original volume and thus air returns into the inflation bulb 202 through an entry (not shown). Thus, repeated cycles of compression and expansion of the inflation bulb 202 will provide air pressure through the exit. In some implementations the inflation bulb is easily malleable by an ordinary human of at least 5 years old. In some implementations, the inflation bulb is similar to the inflation bulb of a sphygmomanometer. The inflation bulb 202 is one example or implementation of the pressuring apparatus 102 in FIG. 1 .
[0039] In some implementations, the flow of air into and out of the inflation bulb is controlled by one-way check-valves. In some implementations, both the entry and the exit of the inflation bulb 202 include a one-way check valve. The exit one-way check valve allows air to flow out of inflation bulb 202 , but prevents air from entering the inflation bulb 202 . The entry one-way check valve allows air to flow in the inflation bulb 202 , but prevents air from enter in the inflation bulb 202 . The exit one-way check valve can be located either at the exit of the inflation bulb 202 , or the exit one-way check valve can be located in other apparatus that is coupled to the exit of the inflation bulb 202 . In some implementations, at least one of the one-way check valve(s) includes a hinged flap. In some implementations, at least one of the one-way check valve(s) consists of a flap, a hinge and a housing.
[0040] In some implementations of apparatus 202 includes an inflatable bladder 206 or other malleable apparatus having rounded contours. The inflatable bladder 206 is not an inflatable bladder included as the cuff in a sphygmomanometer. In some implementations, the inflatable bladder 206 has rounded edges or corners along a longitudinal axis of the inflatable bladder 206 . In some implementations, the inflatable bladder 206 has a spherical, nearly spherical or elongated spherical geometry. The spherical or rounded inflatable bladder easily and readily conforms to the interior of the dimensions of a conventional toilet drain. In some implementations, the inflatable bladder 206 is sturdy reusable ballooning device. The inflatable bladder 206 is one implementation of the inflateable/deflateable apparatus 108 in FIG. 1 .
[0041] Some implementations of apparatus 200 include a tube 208 . In some implementations, the tube 208 is a hollow semi-rigid tube joining the inflation bulb 202 and the inflatable bladder 206 . In other implementations not shown, the inflation bulb 202 and the inflatable bladder 206 are joined directly together without the tube 208 between the inflation bulb 202 and the inflatable bladder 206 . The tube 208 is one implementation of the tube 104 in FIG. 1 . The hollow aspect of tube 208 is one implementation of the passage 106 in FIG. 1 .
[0042] Some implementations of apparatus 200 include a release valve 210 . In some implementations, the release valve 210 is located on the collar 204 of the inflation bulb. In some implementations, the release valve 210 is located on a portion of the inflation bulb 202 other than the collar 204 of the inflation bulb. In some implementations of apparatus 204 that include a tube 208 , the release valve is located on the tube 208 (not shown). Some implementations of the release valve 210 are described in FIG. 6-8 , such as an implementation of the release valve 210 that includes a three-way ball valve and an implementation of the release value 210 that consists of a three-way ball valve, such as implementation of the release valve 210 includes a plug or flap.
[0043] In some implementations of apparatus 204 that include a tube 208 , the tube 208 is joined or coupled to the inflation bulb 202 and the inflatable bladder 206 , via ring fasteners 212 and 214 , respectively.
[0044] When the inflatable bladder 206 is placed in a drain pipe (not shown), and the inflation bulb 202 is squeezed to create a higher pressure than the pressure in the tube 208 and in the inflatable bladder 206 , then the gases and/or liquids in the inflation bulb 202 and the tube 208 will move towards and into the inflatable bladder 206 , thus creating a higher internal pressure in the inflatable bladder 206 and causing the inflatable bladder 206 to expand. Upon application of sufficient pressure from the inflation bulb 202 , the inflatable bladder 206 can expand to the interior dimension/circumference of the drain pipe, thus preventing movement of matter through the drain pipe and blocking passage of matter through the drain pipe.
[0045] The blockage of the drain pipe is helpful in the cleaning and disinfecting of toilet bowls. In situations where apparatus 200 is implemented to block a drain pipe of a toilet bowl, after the toilet bowl drain pipe is blocked, water, cleaning and/or disinfecting solutions can be added to the toilet bowl in order to cause the water, cleaning and/or disinfecting solutions to dwell in the toilet bowl. If the apparatus 200 remains in the toilet bowl with the inflatable bladder 206 expanded to the size of interior dimension/circumference of the drain pipe for a long enough time and with sufficient concentration of cleaning and disinfecting solution in the toilet bowl, the toilet bowl will be cleaned and disinfected to as high a level that the water, cleaning and/or disinfecting solution reside within the toilet bowl. If the level of the water, cleaning and/or disinfecting solution is up to or close to the rim of the toilet bowl, the toilet bowl will be cleaned and disinfected up to or close to the rim of the toilet bowl.
[0046] In some implementations, the apparatus 200 includes a pressure-dependent automatic leak valve that releases contents of the apparatus when the interior pressure of the contents exceeds a threshold pressure. In some implementations, the pressure-dependent automatic leak valve remains open and releases contents of the apparatus until pressure in the interior is equal to the exterior pressure. In some implementations, the pressure-dependent automatic leak valve remains open and releases contents of the apparatus until pressure in the interior falls equal or below the threshold pressure.
[0047] Apparatus 200 can be manufactured in disposable implementations or reusable implementations. The apparatus 200 can also be incorporated into common bathroom products, including but not limited to, a toilet brush or a toilet plunger.
[0048] Apparatus 200 includes an inflatable or malleable (conformable) form-fitting device to conform to dimensions of toilet drain (drain trap) on the end of a tube.
[0049] FIG. 3 is a diagram of a pressuring apparatus 300 , according to an implementation. Pressuring apparatus 300 is one example of pressuring apparatus 102 in FIG. 1 and inflation bulb 202 in FIG. 2 .
[0050] Pressuring apparatus 300 includes a housing 302 . The housing 302 has an exterior and an interior (not labeled). The housing 302 of the pressuring apparatus 300 has a passage 304 between the interior of the pressuring apparatus housing and the exterior of the pressuring apparatus housing. The pressuring apparatus passage 302 forms an opening 306 on the exterior of the pressuring apparatus housing 302 . The passage 306 of the pressuring apparatus has a center 308 .
[0051] In some embodiments, the pressuring apparatus 300 is a handheld device which contains a certain volume of air. The pressuring apparatus 300 can be made of elastic and semi-elastic materials such as rubber, plastic or polymer blends. One end of the pressuring apparatus 300 houses a single direction check-valve 310 to allow outside air capture, while the other side consists of a narrow neck or collar. The collar is surrounded by at least one air release valve and possibly at least one gauge.
[0052] FIG. 4 is a diagram of a tube 400 , according to an implementation. Tube 400 is one example of tube 104 in FIG. 1 and tube 208 in FIG. 2 .
[0053] The tube 400 has a first end 402 and a second end 404 . The tube 400 has a passage 406 through the longitudinal axis 408 of the tube 400 from the first end 402 to the second end 404 .
[0054] In some implementations, the first end 402 is operably coupled to the pressuring apparatus 102 or inflation bulb 202 coincident with the opening (e.g. 306 in FIG. 3 ) of the exterior of the pressuring apparatus 102 or the inflation bulb 202 . The coincident location of the passage 406 of the tube 400 and the opening 306 of the exterior of the pressuring apparatus 102 or the inflation bulb 202 provides clear passage of liquids and gases between the tube 104 and the inflation bulb 202 . In some implementations, the first end 402 of the tube 400 is coupled to the pressuring apparatus 102 over the opening 306 of the exterior 302 of the pressuring apparatus 300 such that the longitudinal axis 408 of the tube 400 is positioned about on the center 308 of the opening of the pressuring apparatus 300 .
[0055] In some implementations, the tube 400 is a hollow, ¼-½ inch diameter semi-rigid tube and is approximately 2-3 feet in length. The tube 400 is rigid enough to support the weight of the device when held horizontally or inserted with moderate force against the walls of a toilet bowl. The tube 400 connects on the proximal end to the inflation bulb 202 in FIG. 2 and on the distal end to an inflatable bladder 500 in FIG. 5 .
[0056] FIG. 5 is a diagram of an inflatable bladder 500 , according to an implementation. Inflatable bladder 500 is one example of the inflatable/deflatable apparatus 108 in FIG. 1 and the inflatable bladder 206 in FIG. 2 .
[0057] The inflatable bladder 500 has a housing 502 . The housing 502 of the inflatable bladder 500 has an exterior 504 and an interior 506 . The housing 502 of the inflatable bladder 500 has a passage 508 between the interior 506 of the inflatable bladder 500 housing and the exterior 504 of the inflatable bladder 500 housing. The passage 508 of the inflatable bladder 500 forms an opening 510 on the exterior 504 of the housing 502 of the inflatable bladder 500 . The passage 508 of the inflatable bladder 500 has a center 512 . In some implementations, the exterior 504 has relief, such as ridges, which allow the inflatable bladder 500 to more readily and easily grip and tract to the toilet bowl drain when inflated.
[0058] The inflatable bladder 500 can be coupled to the second end 404 of the tube 400 in FIG. 4 coincident with the opening 510 of the exterior of the inflatable bladder 500 . The coincident location of the passage 406 of the tube 400 and the opening 510 of the exterior 504 of the inflatable bladder 500 provides clear passage of liquids and gases between the tube 104 and the inflatable bladder 500 . In some implementations, the second end 404 of the tube 400 is operably coupled to the inflatable bladder 500 over the opening 510 of the exterior 504 of the inflatable bladder 500 such that the longitudinal axis 408 of the tube 400 is positioned about on the center 512 of the opening 510 of the inflatable bladder 500 .
[0059] In some implementations, the inflatable bladder 500 is of sufficient dimensions to easily insert into a toilet bowl drain when not inflated. The inflatable bladder 500 is able to fit all size toilets and drainage pipes when inflated. In some implementations, the inflatable bladder 500 has an inflated diameter of approximately four inches. The inflatable bladder 500 will inflate and deflate in order to substantially plug and unplug the toilet bowl drain. Similar to the inflation bulb 202 , the inflatable bladder 500 can be permanently or removably attached to the tube 400 with clamps, nylon tie straps or other bonding devices.
[0060] FIG. 6 is a cross section block diagram of a three-way ball valve 600 in an open position, according to an implementation. The three-way ball valve is one implementation of the release valve 210 in FIG. 2 .
[0061] The three-way ball valve 600 includes a housing 602 and a three-way rotatable passage 604 . The three-way rotatable passage 604 rotates about center point 606 , the center point being 606 in the center of the housing 602 . The three-way rotatable passage 604 includes three arms, 608 , 610 and 612 . Arms 608 and 610 are on opposite sides of the three-way rotatable passage 604 and arm 612 is positioned at a right angle to the other arms 608 and 610 . The three-way ball valve includes three openings 614 , 616 and 618 . Opening 618 is often referred to as an exhaust opening. Openings 614 and 616 are on opposite sides of the housing 602 and opening 618 is positioned at a right angle to the other openings 614 and 616 . When the three-way rotatable passage 604 is positioned or rotated into a position where the opposite-positioned arms 608 and 610 are aligned with the opposite positioned openings 614 and 616 as shown in FIG. 6 , the three-way ball valve 600 is in the open position that provides passage between the openings 614 and 616 and through arms 608 and 610 . In some implementations shown as shown in FIG. 6 where one of the opposite openings is coupled to a pressuring apparatus 102 or an inflation bulb 202 and the other opposite opening is coupled to an inflatable/deflatable apparatus 108 or an inflatable bladder 206 , the three-way rotatable ball valve provide passage of matter between the pressuring apparatus 102 or an inflation bulb 202 and the inflatable/deflatable apparatus 108 or an inflatable bladder 206 .
[0062] FIG. 7 is a cross section block diagram of a three-way ball valve 600 in a release position, according to an implementation. The three-way ball valve is one implementation of the release valve 210 in FIG. 2 .
[0063] When the three-way rotatable passage 604 is positioned or rotated into a position where one of the opposite-positioned arms 608 and 610 is aligned with release opening 618 as shown in FIG. 7 , the three-way ball valve 600 is in a release position that provides passage of matter between the openings 618 and 616 and through arms 612 and 610 . In some implementations shown as shown in FIG. 7 where one of the opposite openings is coupled to a pressuring apparatus 102 or an inflation bulb 202 and the other opposite opening is coupled to an inflatable/deflatable apparatus 108 or an inflatable bladder 206 , the three-way rotatable ball valve provides release of matter from the inflatable/deflatable apparatus 108 or an inflatable bladder 206 .
[0064] FIG. 8 is a cross section block diagram of a quick-release valve 800 having a spring internal to the apparatus, in a release position, according to an implementation. The quick-release valve 800 is one implementation of the release valve 210 in FIG. 2 .
[0065] Quick-release valve 800 includes a valve 802 that fits into seat 804 . When the valve 802 is seated into seat 804 (not shown), no matter passes between the interior 806 of enclosure 808 and the exterior 810 . When the valve 802 is not seated into seat 804 (as shown), matter can pass between the interior 806 of enclosure 808 and the exterior 810 . In some implementations, the valve 802 is has a conical geometry, as shown in valve 902 in FIG. 9 .
[0066] A spring 812 or other force displacement mechanism presses upon the valve, urging the valve 802 into a closed state. When the valve 802 is forced inward and away from the seat 804 by pressing on a button 814 attached to the valve 802 , the quick-release valve 800 is in the release position and matter can pass between the interior 806 of enclosure 808 and the exterior 810 . In the implementation shown in FIG. 8 , the spring 812 is located in the apparatus, inflation bulb 202 or tube 208 .
[0067] FIG. 9 is a cross section block diagram of a quick-release valve 900 having a spring internal to the valve, in a closed position, according to an implementation. The quick-release valve 900 is one implementation of the release valve 210 in FIG. 2 .
[0068] Quick-release valve 900 includes a valve 902 that fits into seat 904 . When the valve 902 is seated into seat 904 (as shown), no matter passes between the interior 906 of enclosure 808 and the exterior 810 . When the valve 902 is not seated into seat 904 (not shown), matter can pass between the interior 906 of enclosure 808 and the exterior 810 . In some implementations, the valve 902 is has a conical geometry, as shown in valve 802 in FIG. 8 .
[0069] A spring 912 or other force displacement mechanism presses the seat 904 and a button 914 apart, urging the valve 902 into a closed state against the seat 904 . When the valve 902 is forced inward and away from the seat 904 by pressing on the button 914 attached to the valve 902 , the quick-release valve 900 is in the release position and matter can pass between the interior 906 of enclosure 908 and the exterior 910 . In the implementation shown in FIG. 9 , the spring 914 is located outside the apparatus, inflation bulb 202 or tube 208 .
[0070] In regards to the materials of system 100 and apparatus 200 - 800 , material of nearly or about pure latex are disfavored because latex hardens in exposure to chlorine; chlorine being one of the possible cleaning solutions that can be employed by system 100 and apparatus 200 - 800 . Therefore, materials being either a latex compound or rubber can be implemented in the major components, such the inflation bulb 202 , the tube 208 , rings 212 and 214 and/or the inflatable bladder 206 . In particular, the portions of the apparatus that are most likely to be exposed to chlorine during immersion in the toilet bowl such as the tube 208 , ring 214 and/or the inflatable bladder 206 are particularly most beneficial to exclude a pure or about pure latex material. The relative dimensions and geometries of the items in apparatus 200 are purely instructive and are not limiting.
Method Implementations
[0071] In the previous section, apparatus was described. In this section, the particular methods performed by system 100 and apparatus 200 - 800 are described by reference to a flowchart.
[0072] FIG. 10 is a flowchart of a method 1000 according to an implementation. Method 1000 is a process of cleaning a toilet bowl using system 100 or apparatus 200 - 800 .
[0073] Some implementations of method 1000 include inserting an inflatable bladder or other malleable apparatus into a drain of a toilet bowl, at block 1002 .
[0074] Method 1000 also includes repeatedly squeezing the inflation bulb to inflate the inflatable bladder until the inflatable bladder conforms to the interior of a drain of a toilet bowl, at block 1004 .
[0075] Some implementations of method 1000 include introducing liquid into the toilet bowl until the top level of the liquid is about at the top of the toilet bowl, at block 1006 . In some implementations, the liquid includes water.
[0076] Some implementations of method 1000 include introducing a cleaning solution into the toilet bowl, at block 1008 . The actions at blocks 1006 and 1006 can be performed in parallel with each other (as shown), serially to each other (not shown) other in some implementations, one of the actions of 1006 and 1008 can be omitted (not shown).
[0077] Method 1000 also includes deflating the inflatable bladder, such as by opening the release valve, at block 1010 .
[0078] Some implementations of method 1000 include filling or adding 1012 water to the toilet bowl to a level that is sufficiently high level to cause the toilet to automatically flush. Some implementations of method 1000 include removing the inflatable bladder from the toilet bowl, at block 1014 .
Conclusion
[0079] A toilet bowl cleaning apparatus is described. Although specific implementations are illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purpose may be substituted for the specific implementations shown. This application is intended to cover any adaptations or variations. One of ordinary skill in the art will appreciate that implementations can be made in other ways that provide the required function.
[0080] In particular, one of skill in the art will readily appreciate that the names of the methods and apparatus are not intended to limit implementations. Furthermore, additional methods and apparatus can be added to the components, functions can be rearranged among the components, and new components to correspond to future enhancements and physical devices used in implementations can be introduced without departing from the scope of implementations. One of skill in the art will readily recognize that implementations are applicable to future cleaning and disinfecting compounds, different toilet drains, and new inflation bulbs and inflatable bladders.
[0081] The terminology used in this disclosure is meant to include all environments and alternate technologies which provide the same functionality as described herein
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The presently disclosed device and method uses a rubber bulb, tubing and an inflatable bladder to temporarily plug a toilet bowl or drain. The plugged drain for a toilet bowl to be thoroughly cleaned by allowing a solution, filled to the rim or other level of the toilet bowl, to soak away stains and disinfect the toilet bowl. The device can be disposable or reusable. The device can also be incorporated into common bathroom products, including but not limited to a toilet brush or plunger.
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BACKGROUND
[0001] The present invention generally relates to nosepieces for use with tools for installing blind bolts, and more specifically relates to a high performance nosepiece for use in such an application.
[0002] Blind bolts are popular fasteners, for example, in the aircraft industry. They are a good alternative to threaded fasteners, providing comparable joint preloads, with a better ability to resist vibration and the benefit of one side installation. A conventional blind bolt 10 is shown in FIG. 1 and includes a stein 12 , a locking collar 14 and a sleeve 16 . The stem 12 has a head 18 at one end 20 and a serrated portion 22 proximate an opposite end 24 . As shown, the stem 12 extends through the sleeve 16 such that the head 18 of the stem 12 contacts an end 26 of the sleeve 16 .
[0003] While FIGS. 5-8 relate to the present invention, reference can be made to these Figures with regard to explaining the manner in which a conventional blind bolt is installed. As shown in FIG. 5 , to install such a blind bolt, the sleeve 16 of the blind bolt 10 is inserted into an aperture 28 in a workpiece 30 (which consists of two or more structures 30 a , 30 b ), and the jaws 32 of a riveter 40 are used to grip and pull on a serrated stem 12 of the blind bolt. This causes a bulb 42 to form in the blind area 44 of the workpiece 30 , as shown in FIG. 6 , thereby providing a clamp up load to the workpiece structures 30 a , 30 b . While the jaws 32 of the riveter 40 pull on the stem 12 , an installation load from the riveter 40 to the fastener 10 is transferred to the locking collar 14 of the blind bolt. This installation load is applied to a very small bearing area, which results in extremely high operating stresses. The high stress applied to the locking collar 14 is desirable, and is part of the installation process of the blind bolt 10 . During installation, the high stresses developed in the locking collar 14 cause deformation of the locking collar 14 into a groove 46 on the stem, as shown in FIG. 7 , which provides vibration resistance. Upon further pulling on the stem 12 by the riveter 40 , the stern breaks as shown in FIG. 8 (at the notch 48 shown in FIGS. 5-7 ), completing the installation of the blind bolt 10 .
[0004] Due to the locking collar 14 , blind bolts such as shown in FIG. 1 are designed for minimal FOD (foreign object debris), a very desirable feature in the aircraft industry, for example. Other blind bolt designs also include a “shift washer” which is integral with the fastener and which provides the correct interface and installation for the locking collar. Upon installation, the shift washer falls. As such, the shift washer only has to withstand the stresses associated with a single installation. However, in the case of installing a blind bolt 10 such as is shown in FIGS. 1 and 5 - 8 , the nosepiece of the riveter 40 has to provide the correct interface, set the locking collar 14 reliably and have a decent life and reliability. Furthermore, the nosepiece has to resist tremendous operating stresses, and retain its shape accurately so it can install correctly all fasteners within its lifespan.
[0005] Two nosepiece designs 50 , 80 which are currently available in the industry are shown in FIGS. 2 and 3 . As shown, both designs provide a long, slender, conical active area 52 , 82 to interface with the locking collar 14 . The fact that the active areas 52 , 82 are conical provides that the active area 52 , 82 interferes with an end surface 54 (identified in FIG. 5 ) of the sleeve 16 of the blind bolt 10 . As a result, low nosepiece reliability and life are associated with both of these designs, and these issues are well known. In fact, the industry has tried over the years to eliminate these shortcomings, without success. The most significant improvement was the use of some exotic materials (like Vasco 350). However, the tool life improvement was incremental and reliability did not improve significantly.
[0006] Reliability of the designs shown in FIGS. 2 and 3 is low because at high levels of stress and not enough support of the active area 52 , 82 , any minor deviation or material, surface or heat treat flaw can cause part failure. As a result, the manufacturing tolerances surfaces and heat treat requirements are very tight, thereby making manufacturing very costly and causing high rejection rates.
[0007] Furthermore, the life of one of the nosepieces 50 , 80 shown in FIGS. 2 and 3 can vary from a few installations (i.e., under ten) to a few hundred installations, and virtually identical nosepieces can have very different life expectancies, making the product very unreliable.
[0008] Finally, the designs shown in FIGS. 2 and 3 provide inconsistent and poor dimensional stability; they can also have several forms of failure that become very difficult to detect during operation. Therefore, if the nosepieces are not inspected carefully prior to being re-used, while the nosepiece appears to be in good condition, the dimensional changes may cause faulty fastener installation, a very undesirable outcome.
OBJECTS AND SUMMARY
[0009] An object of an embodiment of the present invention is to provide an improved nosepiece for use with a riveter for installing blind bolts.
[0010] Another object of an embodiment of the present invention is to provide a nosepiece which provides a dramatically improved tool life, better reliability and better dimensional stability.
[0011] Yet another object of an embodiment of the present invention is to provide a nosepiece which provides a positive visual indication of structural failure.
[0012] Briefly, and in accordance with at least one of the foregoing objects, an embodiment of the present invention provides a nosepiece which has an active area which is annular and effectively matched to the dimensions of the locking collar of a blind bolt which the nosepiece is configured to install. The active area is configured to provide that no tapered surface interferes with the sleeve during installation of the blind bolt. Instead, the active area includes a protrusion which intersects a support area at a ninety degree angle. The transition from the protrusion to the support area surface may provide a fillet. Providing a minimum or no transition fillet radius from the active area to the support area allows for a minimum length of the active area, providing maximum reinforcement to the active area. It also concentrates the operating stresses this area, dispersing them from the critical, working surface of the active area, providing an expected failure mode. In other words, by providing a minimum or no transition fillet radius from the active area to the support area, the operating stresses are concentrated in this area. As such, when there is structure failure, such failure tends to occur at this location, causing the part to chip, thereby providing a positive, very easy visual indication of the working condition of the nosepiece. Preferably, an external surface of the nosepiece is threaded such that the nosepiece can be threaded into a riveter. Also, preferably a rear surface of the nosepiece is tapered and is configured to engage and spread open the jaws of a riveter, such that the stem of a blind bolt can be readily inserted into the riveter through a bore in the nosepiece, without the jaws interfering.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The organization and manner of the structure and operation of the invention, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in connection with the accompanying drawings, wherein like reference numerals identify like elements in which:
[0014] FIG. 1 illustrates a conventional blind bolt;
[0015] FIGS. 2 and 3 illustrate prior art nosepiece designs;
[0016] FIG. 4 illustrates a nosepiece which is in accordance with an embodiment of the present invention;
[0017] FIGS. 5-8 provide a sequence of cross-sectional views, showing the nosepiece of FIG. 4 being used in association with a riveter to install a blind bolt such as is shown in FIG. 1 ;
[0018] FIG. 9 illustrates a two component nosepiece configuration which is in accordance with an alternative embodiment (for dramatically improved performance) of the present invention;
[0019] FIG. 10 illustrates the nosepiece of FIG. 9 , after significant use; and
[0020] FIGS. 11-13 illustrate the same body being used with three different inserts to install different size blind bolts.
DESCRIPTION
[0021] While the present invention may be susceptible to embodiment in different forms, there is shown in the drawings, and herein will be described in detail, an embodiment thereof with the understanding that the present description is to be considered an exemplification of the principles of the invention and is not intended to limit the invention to that as illustrated and described herein.
[0022] FIG. 4 illustrates a nosepiece 100 which is in accordance with an embodiment of the present invention. As shown, the nosepiece 100 has an active area 102 which includes an annular protrusion 104 . The protrusion 104 is effectively matched to the dimensions of the locking collar 14 of a blind bolt 10 which the nosepiece 100 is configured to install. The active area 102 is configured to provide that, unlike the designs shown in FIGS. 2 and 3 , no tapered surface interferes with surface 54 of the sleeve 16 of the blind bolt 10 during installation. Instead, the active area 102 includes a protrusion 104 which intersects a support area 106 at generally a ninety degree angle. The transition from the protrusion 104 to the intersecting, support area 106 may provide a fillet, and the support area 106 has an outer edge 108 which may also be rounded. An external surface 110 of the nosepiece 100 is threaded such that the nosepiece 100 can be threaded into a riveter 40 , and more specifically into a pulling head which is engaged with a riveter 40 . Specifically, the nosepiece 100 can be engaged with, for example, the following pulling heads: H955 pulling head, H9055 pulling head or a right angle pulling head such as the H866-3, 4, 5 or 6 pulling head, each of which is commercially available from Cherry Aerospace®. Also, the following riveters, for example, can be used: the G746a power riveter, the G747 power riveter, the G704B riveter, the G30 hand riveter or the G750A hand riveter, each of which is commercially available from Cherry Aerospace®. The riveter, pulling head and nosepiece can also be used to install, for example, Cherrylock® A Code fasteners, which are also commercially available from Cherry Aerospace®.
[0023] FIGS. 5-8 provide a sequence of cross-sectional views, showing the nosepiece 100 of FIG. 4 being used in association with a riveter 40 to install a blind bolt 100 such as is shown in FIG. 1 . As shown, the nosepiece 100 has a throughbore 112 for receiving a stem 12 of the blind bolt 10 , and the surface 106 which intersects with the annular protrusion 102 has an outside diameter (dimension 120 in FIG. 5 ) which is larger than both the inside diameter (dimension 122 in FIG. 6 ) and outside diameter (dimension 124 in FIG. 8 ) of the protrusion 102 . Also, as shown in FIG. 5 , preferably a rear surface 130 of the nosepiece 100 is tapered and is configured to engage and spread open the jaws 32 of the riveter 40 , such that the stem 12 of the blind bolt 10 can be readily inserted into the riveter 40 , through the bore 112 in the nosepiece 100 , without the jaws 32 interfering.
[0024] To install the blind bolt 10 , the sleeve 16 of the blind bolt 10 is inserted into an aperture 28 in a workpiece 30 , as shown in FIG. 5 , and the stem 12 of the fastener 10 is inserted into the nosepiece 100 , such that the annular protrusion 102 contacts the locking collar 14 of the fastener 10 . Then the riveter 40 is actuated, causing the jaws 32 of the riveter 40 to grip and pull on the serrated stein 12 of the blind bolt 10 . This causes a bulb 42 to form in the blind area 44 of the workpiece 30 , as shown in FIG. 6 , thereby providing a clamp up load to the workpiece structures 30 a , 30 b . While the jaws 32 of the riveter 40 pull on the stem 32 , an installation load from the riveter 40 to the fastener is transferred by the nosepiece 100 to the locking collar 14 of the blind bolt 10 . This installation load is applied to a very small bearing area, which results in extremely high operating stresses. The high stress applied to the locking collar 14 is desirable, and is part of the installation process of the blind bolt 10 . During installation, the high stresses developed in the locking collar 14 cause deformation of the locking collar 14 into a groove 46 on the stem 12 , as shown in FIG. 7 , which provides vibration resistance. Upon further pulling on the stein 12 by the riveter 40 , the stein 12 breaks as shown in FIG. 8 , completing the installation of the blind bolt 10 .
[0025] As shown in FIGS. 5-8 , the active area 104 is annular, short and stubby, with a minimum fillet radius at the transition to the support area 106 . Since the fillet radius would interfere with the setting of the locking collar to the full depth, this portion has to be compensated by increasing the length of the protrusion 102 (i.e., the extent to which the protrusion 104 extends from the support area 106 ). By keeping this to a minimum, the feature is as stubby as necessary. The dimensions of the protrusion 102 (i.e, the inside diameter (dimension 122 in FIG. 5 ) and the outside diameter (dimension 124 in FIG. 8 ) closely match the fastener dimensions, providing maximum bearing surface for the active area. The protrusion length (i.e., the extent to which the protrusion 104 extends from the support area 106 ) of the annular active area 104 closely matches the maximum standard requirement for setting the locking collar 14 . As such, during installation, the fastener 100 is precisely guided and centered during installation and by keeping corner breaks of the work surface to an absolute minimum.
[0026] Providing a minimum or no transition fillet radius from the active area 104 to the support area 106 allows for a minimum length of the active area, providing maximum reinforcement to the active area. It also concentrates the operating stresses in this area, dispersing them from the critical, working surface of the active area, providing an expected failure mode. In other words, by providing a minimum or no transition fillet radius from the active area 104 to the support area 106 , the operating stresses are concentrated in this area. As such, when there is structure failure, such failure tends to occur at this location, causing the part to chip, thereby providing a positive, very easy visual indication of the working condition of the nosepiece. Furthermore, the two piece embodiment displaces most of the stress from this area to an area inside of the softer body, acting as a shock absorber, increasing the life of this design dramatically.
[0027] The short, stubby design provides excellent support to the stress area, keeping the active area rigid. Buckling and radial plastic deformation of the annular area are not possible. The only failure mode allowed by the current design is compressive (axial), and that can be controlled very well by the mechanical properties of the material used, and by using a two piece design to further reduce the stresses in the active area.
[0028] The nosepiece area 106 behind the active annular feature 104 is quite sizeable by comparison, able to absorb considerable shock and provide the much needed hoop (radial) strength. Corner breaks at the outside diameter/inside diameter of the annular active area are minimal, to keep the load bearing area as large as possible.
[0029] The nosepiece 100 shown in FIGS. 4-8 provides dramatically improved tool life (such as 600 to 1200 installations), good reliability (in extensive tests, all nosepieces such as is shown in FIGS. 4-8 had similar life expectancy, within reasonable margins) and dimensional stability (the design is very rigid, with very little or no dimensional changes being possible over the life of the nosepiece).
[0030] Furthermore, the nosepiece 100 shown in FIGS. 4-8 is configured to provide a positive visual indication of structural failure. This is because, in operation, the stress is concentrated in a known area, away from the working surface, and that is precisely where failure occurs. When that happens, the material in the stressed area chips away, providing an excellent visual indication of the failure. By comparison, the designs 50 , 80 illustrated in FIGS. 2 and 3 do not behave consistently, progressively deforming over the life of the nosepiece. As such, if the nosepieces are not inspected carefully prior to being re-used, and a nosepiece has suffered dimensional changes, there could be faulty fastener installation.
[0031] In an alternative embodiment, significantly improving the life and reliability of this design, the annular area 104 can be a separate component made out of a different material and to higher precision requirements, pressed or otherwise mounted into the body of the nosepiece. This option is represented by the dotted line 140 in FIG. 8 .
[0032] FIG. 9 illustrates a nosepiece 200 which is in accordance with an alternative embodiment of the present invention. The nosepiece 200 consists of two separate components—a body 202 and an insert 204 which is pressed into the body 202 . An external surface 206 of the body 202 includes threads 208 so that the nosepiece 200 can be threaded into a pulling head used with a riveter, such as the pulling head 40 shown in FIGS. 5-8 , much like nosepiece 100 . The body may also be made press fit into the pulling head. The body 202 preferably includes a hex-shaped portion 210 for engagement with a tool, and includes a stepped central throughbore 212 in which the insert 204 is pressed. The throughbore 212 in the body 202 preferably includes an increased diameter portion 214 which receives an increased diameter portion 216 of the insert 204 . The insert 204 also includes a central throughbore 218 , and includes a front end surface profile 220 which provides an active area 222 that intersects a support area 224 at generally a ninety degree angle, much like nosepiece 100 . Preferably, like nosepiece 100 , a rear surface 226 of the insert 204 of the nosepiece 200 is tapered or conical and is configured to engage and spread open the jaws 32 of the riveter 40 , such that the stem 12 of a blind bolt 10 can be readily inserted into the riveter 40 , through the bore 218 in the insert 204 , without the jaws 32 interfering.
[0033] While the insert 204 is made out of a very hard and tough material, such as Maraging 350, to resist the tremendous installation loads and shocks developed during tool operation, the body 202 is made out of a much softer, ductile material, such as a low alloy steel, acting as a shock absorber to the insert 204 which is pressed into the body 202 .
[0034] During use, the fact that the body 202 is softer than the insert 204 provides that the body 202 allows the insert 204 to embed into the body 202 slightly with each cycle, transferring most of the shock load away from the active area 222 of the insert 204 . The unavoidable failure is therefore transferred to the softer body 202 , to an area that will not impede the proper performance of the nosepiece 200 , improving significantly the life of the nosepiece 200 by deflecting shocks away from the active area 222 . As an example, as shown in FIG. 9 , the insert 204 may initially protrude from the body 202 by 0.064 inches (dimension 230 in FIG. 9 ). However, as an example, as shown in FIG. 10 , after significant use the insert 204 may embed into the body 202 by as much as 0.010 inches, causing the insert 204 to only end up protruding from the body 202 by 0.054 inches (dimension 230 in FIG. 10 ), and a deformation bulb 232 may end up forming in the body.
[0035] A shoulder 234 is provided on the insert 204 , and the shoulder 234 provides a visual indication of the status of the nosepiece 200 . For example, the nosepiece 200 may be used as long as the shoulder 234 is above or flush with a front surface 236 of the body, and the active area 222 is in good condition (i.e., has no fractures or deformations).
[0036] As discussed above, a rear surface 226 of the insert 204 is tapered or conical and is configured to engage and spread open the jaws of a riveter. Since the jaws of a conventional riveter are very hard with sharp edges, and the body 202 is made of soft material, the back end of the body 202 cannot be used to open the jaws because this would result in premature wear. To avoid this issue, the rear surface 226 of the harder insert 204 is configured to engage and open the jaws instead.
[0037] Preferably, the nosepiece 200 is configured such that it is designed modular so that one body 202 can take multiple size inserts. For example, FIGS. 10, 11 and 12 show the same body 202 receiving three different sized inserts—an insert 204 for accommodating a—8 blind bolt (see FIG. 10 ), an insert 204 a for accommodating a—6 blind bolt (see FIG. 11 ), and an insert 204 b for accommodating a—5 blind bolt (see FIG. 12 ). This keeps production cost down and simplifies product structure. Additionally, due to this feature the insert could be pressed directly into the body of a pulling head when space constraint is a big issue.
[0038] While embodiments of the present invention are shown and described, it is envisioned that those skilled in the art may devise various modifications of the present invention without departing from the spirit and scope of the disclosure.
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A nosepiece for use with a pulling head and a riveter for installing blind bolts, primarily the “Unimatic” or “U” type. The nosepiece is preferably made out of two different components (a hard and tough one acting as the interface to the fastener, and a soft, ductile one acting as a shock absorber) and has an active area which is annular and effectively matched to the dimensions of the locking collar of the blind bolt. No tapered surface interferes with the sleeve during installation of the blind bolt. Instead, the active area includes a protrusion which intersects a support surface generally at a ninety degree angle. Providing a minimum or no transition fillet radius from the active area to the support area allows for a minimum length of the active area, providing maximum reinforcement to the active area. It also concentrates the operating stresses in a known area, dispersing them from the critical, working surface of the active area, providing an expected failure mode. A two piece design dissipates the operating stresses away from the active area, moving the unavoidable failures to an internal area of the nosepiece that cannot affect installation of the fastener. This “stress and shock absorption” together with the design features described above leads to superior reliability and dramatic endurance improvements.
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FIELD OF THE INVENTION
The present invention is directed towards flash memory, and more particularly, to a flash memory cell using gate induced drain leakage (GIDL) current.
BACKGROUND OF THE INVENTION
Toward the end of the 1980s, the semiconductor industry developed the electrically erasable PROM (EEPROM). The result was a new generation of memories targeted at the low-cost, high-density memory market. The term "flash" historically had been used to describe a mode of erasing an entire memory array in a short duration of time, such as one second. Typically, flash memory is programmed by hot electron injection at the drain edge and erased by Fowler-Nordheim tunneling from the source.
Flash memory is classified as nonvolatile memory because a memory cell in the flash memory can retain the data stored in the memory cell without periodic refreshing. Most prior art flash memory can store a single bit in a memory cell. In other words, the memory cell can either store a "1" or a "0."
A prior art flash memory cell is shown in FIG. 1. The memory cell includes a double stack of polysilicon forming a floating gate 101 and a control gate 103. The source side is biased to a voltage V s and is doubly implanted with an n+ structure formed within an n- base. Typically, the n+ structure on the source side is implanted with arsenic at a dose of 10 16 /cm 2 . The n- base on the source side is doped with phosphorous at a dose of 10 14 /cm 2 . The drain side n+ structure is biased to a voltage V d and is doped with arsenic to a dose of 10 16 /cm 2 . Typically, the drain side does not have a lightly doped drain structure, which will tend to reduce the electrical field near the drain side and degrade the generation of hot electrons during programming. A tunnel oxide is placed between the substrate and the floating gate 101. The tunnel oxide is typically 80-120 angstroms thick.
Programming of the prior art flash memory cell of FIG. 1 is performed by channel hot electron injection. During the programming operation, the drain voltage V d is typically biased to 7 volts, the control gate voltage V cg is biased to 9-12 volts, and the source voltage V s is grounded. Hot electrons are injected toward the floating gate 101 during programming. One drawback of channel hot electron injection programming is low injection efficiency and the relatively large power consumption during programming. Note also that large voltage biases are necessary to achieve programming.
During the erase operation, Fowler-Nordheim tunneling is used through the source side. The bias during the erase function is typically 0 volts for the drain voltage V d , 9-12 volts for the source voltage V s , and the control gate voltage V cg varies between -9 volts to 0 volts. Thus, a large electric field can be established across the tunnel oxide between the floating gate 101 and the source overlap area of the n- base. Electrons on the floating gate 101 will tunnel into the source n+ structure and be removed.
However, as noted above, the prior art flash memory cell requires relatively high voltage biasing on the terminals of the memory cell which results in relatively high power consumption. Therefore, what is needed is a flash memory cell that can operate with low voltage and low power consumption.
SUMMARY OF THE INVENTION
A flash memory cell formed on a semiconductor substrate is disclosed. The cell comprises: a p-well formed in said substrate; a gate structure formed atop said p-well, said gate structure including a control gate and a floating gate, said floating gate electrically isolated from said control gate and said semiconductor substrate by a thin dielectric layer; an n- base formed adjacent to a first edge of said gate structure and extending underneath said gate structure; a p+ structure formed within said n- base and adjacent to said first edge of said gate structure; and a n+ structure adjacent a second edge of said gate structure. With such a structure, it is possible to program the cell by band-to-band tunneling enhanced hot electrons generated at the p+ surface. The erase is performed by Fowler-Nordheim tunneling through the n- base region.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a cross-sectional view of a prior art flash memory cell;
FIG. 2 is a cross-sectional view of a semiconductor substrate illustrating a flash memory cell formed in accordance with the present invention;
FIG. 3 is a cross-section view of the flash memory cell of FIG. 2 illustrating the programming method;
FIG. 4 is a cross-section view of the flash memory cell of FIG. 2 illustrating the erase operation; and
FIG. 5 is a cross-section view of the flash memory cell of FIG. 2 illustrating the read operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As seen in FIG. 2, the preferred embodiment of the present invention is shown comprising an n-channel flash memory cell 201. The flash memory cell 201 includes a control gate 203 and a floating gate 205 formed atop a semiconductor substrate. The floating gate 205 is surrounded by an insulating dielectric, commonly silicon dioxide. The floating gate 205 is separated from the substrate surface by a thin gate oxide on the order of between 50 to 100 angstroms thick. The formation of the floating gate 205 and the control gate 203 is substantially similar to the prior art shown in FIG. 1 and will not be further described in detail.
For the n-channel flash memory cell 201 of the present invention, in the preferred embodiment, a deep n-well is formed within a p-type semiconductor substrate. The deep n-well is formed using conventional diffusion or ion implantation techniques. The deep n-well preferably has a depth of 3 microns and has a dopant concentration of 10 15 /cm 3 .
Formed within the deep n-well is a p-well. The p-well is formed using conventional diffusion or ion implantation techniques. The p-well preferably has a depth of 1.5 microns and a dopant concentration of 10 16 /cm 3 . As can be seen, the control gate 203 and the floating gate 205 rest atop the p-well.
On the source side of the floating gate 205 and control gate 203 is an n+ structure. Preferably, the n+ structure is self-aligned to the source side edge of the floating gate 205 and control gate 203. The n+ structure is preferably formed using ion implantation to a depth of 0.3 microns and having a dopant concentration (preferably arsenic ions) of about 10 20 /cm 3 .
Also formed within the p-well is an n- base structure that is formed on the drain side of the floating gate 205 and control gate 203. The n- base extends underneath the floating gate 205. Preferably, this can be accomplished using self-aligned ion implantation followed by thermal diffusion of the n-type dopants (typically phosphorous) such that the n-type dopant laterally diffuses underneath the floating gate 205. Further, preferably using the same mask as used to form the n- base, a p+ structure is formed within the n- base and self-aligned to the drain side of the control gate 203 and floating gate 205. Preferably, the p+ structure has a depth of 0.3 microns and a dopant concentration (for example boron ions) of 10 20 /cm 3 . Further, preferably, the n- base structure has a depth of 0.7 microns and a dopant concentration of 10 17 /cm 3 .
Metal interconnections are then made to the various structures of the flash memory cell 201 using conventional techniques. Specifically, a source connection is made to the n+ structure, a drain connection is made to the p+ structure, and a control gate connection is made to the control gate 203. In that way, a voltage V s can be applied to the n+ structure, a voltage V d can be applied to the p+ structure, and a voltage V cg can be applied to the control gate 203.
From FIG. 2, it can be seen that a vertical bipolar structure (i.e., p+/n- base/p-well bipolar) is formed at the drain side. The n- base region is a key element of the flash cell 201. First, the n- base serves as the drain for the n-channel flash cell 201 during read operation. Second, the n- base serves as an isolation region so that hot electrons generated from GIDL current during programming can be redirected by the favored electrical field toward the floating gate which results in fast programming. Third, the n- base also serves as an erase area with a small coupling ratio to the floating gate so that fast erase operation can result. The GIDL current on the surface of the n- base is negligible due to its lower doping level than the n+ structure.
The operation of the flash memory cell 201 is seen in FIGS. 3-5. Turning to FIG. 3, the voltages applied to the various connections and structures of the flash memory cell 201 for the programming operation is shown. The programming method is based upon band-to-band tunneling enhanced hot electron generation (BBHE) as well as Fowler-Nordheim tunneling. The preferred bias during programming is: V d is biased to between -V cc and -2V cc ; n- base is floating; V cg biased to between V cc and 2V cc ; V s is floating; V pw is biased to between 0 and V cc ; deep n-well biased to V cc ; and the p-type substrate biased to ground. Preferably, V cc is approximately 2.5 or 3.3 volts.
Under these biasing conditions, electrons are generated on the surface of the p+ structure underneath the floating gate 205 by band-to-band tunneling. These band-to-band tunneling generated electrons may tunnel through the tunnel oxide toward the floating gate 205 by Fowler-Nordheim tunneling if the electrical field across the tunneling oxide is sufficiently large (approximately 10 MV/cm). These band-to-band tunneling generated electrons may also flow into the n- base region and generate hot electrons by gaining energy through the junction electric field and/or impact ionization. The hot electrons can overcome the barrier and be injected towards the floating gate 205 with the aid of the positive bias on the control gate 203. In summary, the programming current is generated by two mechanisms: (1) Fowler-Nordheim tunneling directly from the p+ structure into the floating gate 205 and (2) hot electron injection from the p+ structure through the n- base into the floating gate 205. The mechanism that generates most of the current to the floating gate 205 depends upon the bias applied to the control gate, the p-well, and the p+ structure.
Note that the n- base is forward biased with respect to the p-well during programming by the band-to-band tunneling electron current. The n- base potential is clamped to the same voltage as the p-well by a one diode voltage drop. The reverse bias p+/n- base structure provides a large electric field for generation of band-to-band tunneling hot electrons by impact ionization. The bipolar action of the p-well/n-base/p+ structure is negligible, since the p-well injection efficiency is small due to its lower doping level than the n- base doping level.
Moreover, note that the band-to-band hot electron mechanism can be implemented only on a p-channel cell. In the preferred embodiment, with an n- base at the drain side, it is therefore possible to apply band-to-band hot electron current for programming of n-channel cells.
Turning next to FIG. 4, the erase operation of the flash memory cell 201 is illustrated. The preferred bias for the erase operation is as follows: V s and the n- base are floating; V cg is biased to between -V cc and -2V cc ; V d is biased to between V cc and 2V cc ; the p-well is biased to 0 volts; the deep n-well is biased to V cc ; and the p-type substrate is biased to ground. The potential of the n- base is clamped to the p+ structure by the forward biased p+/n- base junction. Since the coupling ratio from the p+ structure and the n- base to the floating gate is very small, there is a large electrical field established across the tunnel oxide between the floating gate 205 and the p+/n- base region to trigger Fowler-Nordheim tunneling. The electrons on the floating gate 205 will be tunneling into the p+/n- base region and removed away.
Note that the p+/n- base/p-well bipolar transistor at the drain side may be turned on during erase operation and may result in undesirable current transients at the drain. The bipolar action can be eliminated by designing the doping of the n- base low enough, so that the entire n- base can be depleted by the bias between the p+ drain and the p-well. Certainly if the n- base is shorted to the p+ structure during erase, the bipolar action is eliminated.
The read operation of the flash memory cell 201 is shown in FIG. 5. The preferred bias for the read operation is: V d approximately 1.5 volts; V cg approximately to V cc ; V s approximately to 0 volts; p-well to 0 volts; n- base floating; deep n-well to V cc ; and p-type substrate to ground. The n- base potential is one diode voltage drop (typically approximately 0.5 volts) below V d during the read operation. The channel may be inverted or not (depending on the absence or presence of net electron charge on the floating gate) so that the magnitude of the read current i r denotes the digital information stored in the flash cell 201. Note that with the floating n- base, the p+/n- base/p-well bipolar transistor may be turned on during read and may result in undesirable leakage current. One way to eliminate the turn-on of the bipolar transistor is to short the n- base to the p+ structure during read operation.
There are several advantages of the flash memory cell 201 of the present invention. First, programming by band-to-band hot electron and Fowler-Nordheim tunneling is faster than channel hot electron injection. The band-to-band hot electron injection efficiency is known to be larger than conventional channel hot electron injection. Further, the band-to-band hot electron injection does not need large channel current during programming. Thus, not only is the speed of the programming enhanced, the power consumption during programming is reduced significantly.
Second, erasing by Fowler-Nordheim tunneling through the p+ structure n- base at the drain side is effective and low power consumption is similar to the conventional source side Fowler-Nordheim erase. The n- base doping is lower than conventional n+ junction, and thus there is a negligible band-to-band tunneling induced leakage current during erase. It is known that GIDL current at the source side in conventional flash memory cells would degrade the oxide and may present a limit for future scaled cells. The flash memory cell 201 of the present invention eliminates GIDL degradation and can be scaled for future advanced cell structures.
Note also that the flash memory cell 201 of the present invention cannot form a p-channel flash cell by inverting the polarities of the conduction types and voltage biases. This is because hole injection through the tunnel oxide not only will degrade tunnel oxide but is also very ineffective due to the larger energy barrier for holes at the oxide interface. Therefore, a corresponding p-channel cell is not useful.
While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
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A flash memory cell formed on a semiconductor substrate is disclosed. The cell comprises: a p-well formed in the substrate; a gate structure formed atop the p-well, the gate structure including a control gate and a floating gate, the floating gate electrically isolated from the control gate and the semiconductor substrate by a thin dielectric layer; an n- base formed adjacent to a first edge of the gate structure and extending underneath the gate structure; a p+ structure formed within the n- base and adjacent to the first edge of the gate structure; and a n+ structure adjacent a second edge of the gate structure. With such a structure, it is possible to program the cell by band-to-band tunneling enhanced hot electrons generated at the p+ surface. The erase is performed by Fowler-Nordheim tunneling through the n- base region.
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FIELD OF THE INVENTION
The invention relates to amphoteric vinyl monomers that have surfactant properties. These vinyl monomers are the condensation product of a tertiary amine substituted acrylamide, an alkylene oxide and a succinic anhydride compound.
PRIOR ART
Amphoteric compounds are those which contain both an anionic and a cationic hydrophilic group, and a hydrocarbon hydrophobic group. Typically the cationic portion is a quaternary ammonium derivative while the anionic portion can be a carboxylate, a sulfonate or a sulfate group.
Latex is produced by emulsion polymerization in aqueous solution. Latex product is typically kept in aqueous solution until final use, but these solutions are metastable and tend to coagulate or separate, an undesirable property. These metastable solutions suffer destabilization by such varying stimuli as contact with electrolyte or organic solvent, mechanical effects and thermal effects such as freezing.
In the past, emulsion phase stabilizers have been developed that are designed to neutralize thermodynamic unstability in such solutions. Such phase stabilizers are typically highly polar monomers which form synthetic lattices which dissipate disruptive stimuli and hence prevent the untoward effects associated therewith.
U.S. Pat. No. 3,959,355 discloses quaternary ammonium salts, used for latex stabilization, of the formula: ##STR1## wherein V is: ##STR2## These compounds are distinguished from those of the present invention in two ways. First, the unsaturated group V is much less reactive in free radical polymerization than monomers of the present invention. That is, the unsaturated group V lacks resource activity in free radical polymerization compared with the alpha, beta unsaturated carbonyl group in monomers of the present invention. When V is an allyl or beta-methyl allyl ester, monomers of the prior art polymerize with difficulty and give products of low molecular weight. It is also known that the presence of such allyl monomers often tend to retard both the rate and degree of polymerization in reactions in which other comonomers are involved. (R. H. Yocum and E. B. Nyquist, Functional Monomer, Vol. 1, page 384 Marcel Dekker, Inc., N.Y. 1973 and R. C. Laible, Chem. Rev. 58 807 (1958)).
Second, these compounds are salts, such as halide or sulfate salts, whereas compounds of the present invention are inner salts wherein the charge on the quaternary nitrogen is neutralized by the covalently bonded carboxy anion and not by a halide or sulfate anion.
U.S. Pat. No. 4,212,820 discloses cationic, surface active monomers. Harry Distler, Mechanism of Reactions of Sulfur Compounds, Vol. 4, 1969 pages 11-12 mentions a reaction of a tertiary amine substituted monomer, tetrahydrophthalic anhydride and ethylene oxide.
SUMMARY OF THE INVENTION
The present invention is a composition of matter which is the condensation product of:
(a) a tertiary amine substituted acrylamide of the general formula: ##STR3## wherein R 1 is hydrogen or methyl,
R 2 and R 3 are independently alkyls of from 1 to 3 carbon atoms and
A is a linear alkyl of from 2 to 3 carbon atoms;
(b) an alkylene oxide; and
(c) a succinic anhydride compound.
These amphoteric monomers are useful as surfactants in reducing surface and interfacial tension in aqueous solutions over a wide pH range.
The monomers are particularly useful for the preparation of water soluble copolymers that have surface active properties.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In one aspect the present invention is a composition of matter of the formula: ##STR4## wherein R 1 is selected from the group consisting of hydrogen and methyl,
R 2 is an alkyl of from 1 to 3 carbon atoms,
R 3 is an alkyl of from 1 to 3 carbon atoms,
R 4 is selected from the group consisting of hydrogen and methyl,
R 5 is an alkyl or alkenyl of from 9 to 21 carbon atoms, and,
A is a linear alkyl of from 2 to 3 carbon atoms.
Amphoteric surface active monomers of this configuration are conveniently produced by a simple synthesis. Typically a tertiary amine substituted acrylamide monomer is reacted with ethylene oxide or propylene oxide and an alkenyl succinic anhydride in aprotic polar solvent such as acetone, ethyl acetate, tetrahydroforan, dimethylformamide, acetonitrile, etc. at temperatures of about 40° C. to about 90° C. and pressures sufficient to keep all components in the liquid phase. The reaction proceeds to completion without catalyst. Optionally a trace of water or other protic solvent can be employed as an initiator. Reaction is typified by the sequence: ##STR5##
This new composition of matter is an inner salt wherein the charge on the quaternary nitrogen is neutralized by the covalently attached carboxy anion. It has been found that surfactants of this configuration are useful in reducing surface and interfacial tension in aqueous media over a wide pH range.
The present invention also relates to aqueous solutions comprising water and from about 0.01 wt % to 20 wt % or more of a monomer characterized by the general formula: ##STR6## wherein R 1 is selected from the group consisting of hydrogen and methyl,
R 2 is an alkyl of from 1 to 3 carbon atoms,
R 3 is an alkyl of from 1 to 3 carbon atoms,
R 4 is selected from the group consisting of hydrogen and methyl,
R 5 is an alkyl or alkenyl of from 9 to 21 carbon atoms, and
A is a linear alkyl of from 2 to 3 carbon atoms.
These aqueous solutions display surface and interfacial surface activity as demonstrated in Example 2. These solutions may comprise latex and optionally pigmentation for paint applications. Alternately these aqueous solutions may comprise brine for such applications such as secondary oil recovery or detergent adjuvants for cleaning purposes.
These amphoteric monomers exhibit surfactant properties in aqueous solution in concentrations ranging from 0.01 wt% and higher depending upon the mode of application. The minimal concentration of these products employed in commercial use is about 0.01 wt% to about 0.1 wt% while the upper concentration, which is limited almost entirely by cost, for all but special purposes seldom exceeds 20 wt%. Solutions of 0.01 wt% to 1 wt% are demonstrated in Example 2.
In another aspect, the present invention is a composition of matter of the general formula: ##STR7## wherein R 1 is selected from the group consisting of hydrogen and methyl,
R 2 is an alkyl of from 1 to 3 carbon atoms,
R 3 is an alkyl of from 1 to 3 carbon atoms,
R 6 is a linear or branched alkyl of from 7 to 20 carbon atoms, and
A is a linear alkyl of from 2 to 3 carbon atoms.
Amphoteric monomers of this configuration are conveniently synthesized. In Step 1, a tertiary amine substituted acrylamide monomer is reacted with an alkylene oxide, specifically a glycidyl alkyl ether, and succinnic anhydride. The reaction is carried out in aprotic polar solvent such as acetone, ethyl acetate, tetrahydrofuran, dimethyl formamide, acetonitile, dimethyl sulfoxide, etc. at temperatures of 40° C. to 90° C. and pressures sufficient to maintain all constituents in the liquid phase. No catalyst is required in most cases, however a trace of water or other protic solvent such as ethylene glycol, ethanol, methanol, etc. may be used to initiate reaction.
The reaction may be graphically demonstrated: ##STR8##
A typical synthesis of these compounds is demonstrated in Example 3.
In another embodiment, this invention relates to solutions. These solutions comprise water and from about 0.01 wt % to about 20 wt % of a monomer characterized by the general formula: ##STR9## wherein R 1 is selected from the group consisting of hydrogen and methyl,
R 2 is an alkyl of from 1 to 3 carbon atoms,
R 3 is an alkyl of from 1 to 3 carbon atoms,
R 6 is a linear or branched alkyl of from 7 to 20 carbon atoms, and
A is a linear alkyl of from 2 to 3 carbon atoms.
These aqueous solutions display surface and interfacial activity. Example 4 demonstrates solutions in the range of 0.01 wt% to 1 wt% monomer.
These solutions may comprise latex and optionally pigmentation for paint applications. These solutions may alternately comprise brine for applications such as secondary oil recovery and/or detergent adjuvants as described below.
Latex is synthesized by emulsion polymerization carried out in aqueous solution. As seen in Example 6, polymerization can be carried out in solutions of the present invention to produce stable latex emulsions in aqueous media. Such pigments as titanium dioxide, iron oxide, chromium oxide, phthalocyanine blue, Hansa yellow, etc. may also be incorporated into the stable latex containing solutions without loss of stability to produce paints.
Latex containing solutions of the present invention contain typically about 0.01 wt% to about 20 wt% monomer and preferably, about 1 wt% to about 15 wt% with the exact amount determined by the desired composition of the latex copolymer of typically acrylate esters, vinyl acetate and styrene monomers. The use of monomers of the present invention to produce latex in aqueous solution produces internally stabilized polymer emulsions which are inherently superior to those established by added surfactant. This inherent superiority in latex paint formulations is evidenced by mechanical stability of latex lattices, and superior particle size control and film properties. Latex containing solutions of the present invention are stable to electrolyte, organic solvent, mechanical effects and temperatures down to about 4° C.
For detergent purposes, usually the range of concentration is between about 1 wt% to 15 wt% with the residuum being detergent adjuvants described below. In all instances the lower or minimal concentration (0.01% by weight to 0.1% by weight) is referred to as an "effective amount" of surfactant. When these stabilized products are employed as detergents they ordinarily are present in at least the minimal concentrations disclosed accompanied by one or more of the following classes of materials which are generically referred to as detergent adjuvants.
1. Inorganic salts, acids and bases. These are usually referred to as "builders." These salts usually comprise alkalies, phosphates and silicates of the alkali metals as well as their neutral soluble salts. These materials constitute from about 40 to 80 weight percent of the composition in which they are employed.
2. Organic builders or additives--These are substances which contribute to characteristics such as detergency, foaming power, emulsifying power or soil suspending effect. Typical organic builders include sodium carboxymethyl cellulose, sequestering agents such as ethylenediaminetetraacetic acid and the fatty monoethanolamides, etc.
3. Special purpose additives--These include solubilizing additives such as lower alcohols, glycols and glycol ethers, bleaches or brighteners of various structures which share in common that they are dyestuffs and they do not absorb or reflect light in the visible range of the spectrum.
Typical formulations are herein described.
______________________________________DETERGENT FORMULATIONSParts by wt. Components______________________________________A. Dry cleaning composition10 Potassium Oleate13 Product Example 1 or 350 1,1,2-Trichloroethane24 Water 3 n-ButanolB. Washing Machine Composition13 Product Example 1 or 335 Sodium Tripolyphosphate30 Sodium Silicate20 Sodium Carbonate 2 Sodium Carboxymethyl CelluloseC. Automatic Dishwasher Composition 5 Product Example 1 or 334 Sodium Silicate61 Sodium TripolyphosphateD. Disinfectant and Detergent Composition6.3 Product Example 1 or 345 Sodium Tripolyphosphate45 Sodium Carbonate3.7 Oleyl dimethyl ethyl ammonium bromide______________________________________
The present invention includes a class of monomers with surface active properties over a range of pH values.
The products of the present invention are useful in household detergent products as well as in an enhanced oil recovery process surfactant formulation. The present invention is most useful as a chemical intermediate that is copolymerized with water soluble monomers such as acrylamide. Monomers of the present invention impart surface active properties to the copolymer product.
The following examples illustrate preparation of typical compounds falling within the scope of the invention. It is understood that these examples are merely illustrative and that the scope of the invention is described in the claims.
EXAMPLE 1
In a 500 ml four neck round bottom flask equipped with mechanical stirrer, dry ice condenser, thermometer and addition funnel, a mixture of dimethylaminopropyl methacrylamide (34 g), 2-dodecen-1-ylsuccinic anhydride (53.3 g) and acetone (150 g) was heated to 50° C. A solution of propylene oxide (14.6 g) in acetone (50 g) was added through the addition funnel over a period of one hour. The reaction mixture was digested at 50° C. over a period of five hours. The completion of the reaction was indicated by a clear solution obtained instantaneously when one drop of reaction mixture was admixed with three milliliters of water. The excess propylene oxide and a small portion of acetone solvent were removed by distillation. The desired product in the form of a solution in acetone was obtained as a bottoms product by a non aqueous titration method (toluene sulfonic acid in acetic acid solvent) found 0.69 meq/g of titratable base (theory 0.70 meq/g). Infra red spectra of the product after stripped off acetone solvent showed carbonyl bands at 5.8 micron typical of ester function and 6-6.6 micron typical of a methacrylamide. These results strongly supported that the expected product was obtained: ##STR10##
EXAMPLE 2
The surface tension and interfacial tension (water/light mineral oil) of aqueous solution prepared from a sample of solvent free monomer made in Example 1 were measured and results are summarized below.
______________________________________ Surface tension Interfacial tensionAmphoteric Monomer dyne/cm dyne/cm______________________________________ 1 wt % 28.4 0.9 0.1 wt % 28.3 0.60.01 wt % 29.8 1.5______________________________________
EXAMPLE 3
In a 500 ml 3-neck round bottom flask equipped with mechanical stirrer, thermometer and addition funnel a mixture of dimethylaminopropyl methacrylamide (34 grams), succinic anhydride (20 grams) and acetone (150 grams) was brought to 50° C. A solution of linear alkyl glycidyl ether (57 grams, equivalent weight 286, Procter and Gamble, Epoxide 8) in acetone (50 grams) was added through the addition funnel over a period of one hour. The reaction mixture was digested at 50° C. for one hour. Analysis of the resulting solution by a non aqueous titration method (toluene sulfonic acid in acetic acid solvent) formed 0.65 meq/g titratable base (theory 0.66 meq/g). Infra red spectra of the product after stripped off acetone solvent showed three types of carbonyl band; ester 5.75 micron, secondary amide 6.0 and 6.5 micron and carboxylate 6.3 micron. These and the remaining bands are consistent with that of the expected product: ##STR11##
EXAMPLE 4
The surface tension and interfacial tension (water/light mineral oil) of aqueous solution prepared from a sample of solvent free surface active amphoteric monomer made in Example 3 were measured and results are summarized below.
______________________________________ Surface tension Interfacial tensionAmphoteric Monomer dyne/cm dyne/cm______________________________________1.0 wt % 29.4 3.60.1 wt % 29.0 3.90.01 wt % 32.1 5.5______________________________________
EXAMPLE 5
In a field in which the primary production has already been exhausted, an injection well is completed in the hydrocarbon-bearing formation and perforations are formed between the interval of 6890-6910 feet. A production well is drilled approximately 415 feet distance from the injection well, and perforations are similarly made in the same hydrocarbon-bearing formation at 6895-6915 feet.
The hydrocarbon-bearing formation in both the injection well and the production well is hydraulically fractured using conventional techniques, and a gravel-sand mixture is injected into the fracture to hold it open and prevent healing of the fracture.
In the next step oil field brine of 1000 ppm hardness at a temperature of 75° F. containing dissolved therein 1% by weight of the product of Example 1 is injected via the injection well into the formation at a pressure of about 1300 psig and at the rate of 1.05 barrels per minute. Injection of the drive fluid continues at the rate of 1.05 barrels per minute and at the end of 87 days a substantial production of petroleum is achieved.
EXAMPLE 6
A commercially available latex base paint is to be reformulated using monomer of Example 3 to stabilize the latex emulsion. The new paint formulation is as follows:
______________________________________Product of Example 3 1.9 wt %Ethyl Acrylate 32.5 wt %Methyl Methacrylate 16.2 wt %Methacrylic Acid 0.6 wt %Sodium Persulfate 1.9 wt %Water 46.9 wt % 100.0 wt %______________________________________
Water and monomer of Example 3 are charged to a nitrogen blanketed, steam jacketed reaction vessel #1 and heated to 80° C. Ethyl acrylate, methyl methacrylate and methacrylic acid are charged to vessel #2 and thoroughly mixed. Sodium persulfate catalyst is added to vessel #1 along with 3 to 4% of the contents of vessel #2. Vessel #1 is maintained at 80° C. for 10 to 15 minutes with stirring as latex polymerization is initiated. Contents of vessel #2 are pumped into vessel #1 with a metering pump at such a rate that entire addition is completed in 2 to 21/2 hours. Temperature is maintained at about 80° C. to 83° C. Once addition is complete, vessel #1 is maintained at 80° C. to 85° C. for an additional 1/2 hour with stirring. Vessel #1 contents are cooled, pH is corrected with ammonia and pigment is added.
A stable latex emulsion is thereby produced.
EXAMPLE 7
It is desired to treat clay containing bayou water for use in the industrial water system of a petrochemical plant. One thousand gallons per minute of water is introduced into a mixer-settler along with the product of Example 3 monomer in a concentration of 0.01 wt% to 0.1 wt%. The monomer flocculates the clay and thereby causes it to settle. Resulting water is then passed to a clarifier where more flocculated clay settles. A clear, industrial grade water is thereby produced.
The principle of the invention and the best mode contemplated for applying that principle have been described. It is to be understood that the foregoing is illustrative only and that other means and techniques can be employed without departing from the true scope of the invention defined in the following claims.
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Amphoteric surface active monomers and monomer solutions are revealed.
The monomers are synthesized by reacting a tertiary amine substituted acrylamide, an alkylene oxide and a succinic anhydride compound in aprotic polar solvent.
These compositions are useful for their surface activity and their ability to copolymerize with water soluble vinyl monomers and impart surface activity to the resulting copolymer. The monomers and copolymers thereof may be used as flocculants or for stabilizing polymeric latex.
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This application is a Rule 1.60 divisional application of application Ser. No. 07/492,573, filed March 13, 1990, now U.S. Pat. No. 5,031,780.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a flat panel display device, and more particularly to an improvement of the joining portion of the envelope thereof.
2. Description of the Prior Art
A vacuum envelope of a conventional flat panel display device is shown in FIG. 1, in which a face glass plate 1 of a flat shape and a metal container of a round dome shape are joined together by joining the flange portion of the metal container 2 to the face glass plate 1 by a frit glass 3.
It is noted that throughout the attached drawings, like parts are designated by like reference numerals.
FIG. 2 shows an improved structure of the conventional vacuum envelope shown in FIG. 1, in which a heat bonding material 4 made of a Pb wire is disposed between the glass plate 1 and the metal container 2 and they are clamped by a channel member 5, in addition, the assembled members are heated at 300° C. and the PB wire mode molten to accomplish a hermetic seal. This technique is described in SID 82 DIGEST, page 208.
In the arrangement shown in FIG. 1, upon increasing the thickness of the metal plate of the metal container 2 in order to enhance the pressure resistance of the metal container 2, there may occur cracking in the glass plate at the joint of the metal container 2 and the glass plate 1 due to increasing rigidness of the metal container 2. On the other hand, the container shown in FIG. 2, which is the improvement of that shown in FIG. 1, must be baked in order to enhance the vacuum of the envelope. The baking is required to be performed at 300° C. to 350° C. However, since the melting point of the Pb wire is 300° C., such baking cannot be done.
Moreover, there is another problem that in the arrangement of clamping the flange portion of the glass plate 1 and the metal container 2 by the channel member 5, a tight seal can not be assured unless a sufficient clamping pressure is applied to the channel member 5.
SUMMARY OF THE INVENTION
An essential object of the present invention is to provide an improved flat panel display device which is capable of eliminating various problems described above, and manufactured simply.
In order to accomplish the above object of the present invention, there is provided a flat panel display device which comprises a face glass plate, a metal container assembled to the face glass plate through a frit glass for providing an envelope for accommodating electron beam generating means and electron beam control means, the metal container including an outer container made of a thin metal plate and an inner container separably assembled to the inside of the outer container for acting as a pressure resistive container for supporting the envelope against air pressure. Only the outer container is joined to the face glass plate.
BRIEF EXPLANATION OF THE DRAWINGS
FIGS. 1 and 2 are respectively cross sectional views of conventional envelopes of a flat panel display device,
FIG. 3 is a cross sectional view of a first embodiment of an envelope of a flat panel display device according to the present invention,
FIG. 4 is a partial cross sectional view of an essential part of the envelope shown in FIG. 3,
FIG. 5 is a cross sectional view of an essential portion of a second embodiments of the envelope according to the present invention,
FIG. 6 is a cross sectional view of a third embodiment of the envelope according to the present invention,
FIG. 7 is a cross sectional view of a 4th embodiment of the envelope according to the present invention,
FIG. 8 is a cross sectional view of a 5th embodiment of the envelope according to the present invention,
FIG. 9 is a cross sectional view of a 6th embodiment of the envelope according to the present invention,
FIG. 10 is a cross sectional view of a 7th embodiment of the envelope according to the present invention,
FIG. 11 is a cross sectional view of a 8th embodiment of the envelope according to the present invention,
FIG. 12 is an exploded view of a 9th embodiment of the envelope according to the present invention,
FIG. 13 is a cross sectional view of a 9th embodiment of the envelope according to the present invention,
FIG. 14 is a cross sectional view of an essential portion of the 9th embodiment of the envelope according to the present invention,
FIG. 15 is a cross sectional view of an essential portion of a modification of the 9th embodiment of the envelope according to the present invention,
FIG. 16 is a cross sectional view of an essential portion of a 10th embodiment of the envelope according to the present invention,
FIG. 17 is a cross sectional view of an essential portion of a 11th embodiment of the envelope according to the present invention, and
FIG. 18 is a cross sectional view of an essential portion of a 12th embodiment of the envelope according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 3, showing a cross sectional view of a preferred first embodiment of a flat panel display device according to the present invention, there is provided a transparent face glass plate 10 of a flat plate shape, having its inner surface coated with a fluorescent layer 11 for displaying picture by receiving electrons from an electrode in a known manner. The face glass plate 10 is made of soda float glass. Reference numeral 12 denotes a linear cathode, 13 a back face electrode, 14 a control electrode. A plurality of sets of these members 12, 13 and 14 are provided in an envelope 8 in a similar manner to a conventional flat panel display device. 15 denotes an outer container made of a thin metal plate in a form of a generally semi spherical dome shape, having its outer peripheral flange 15a affixed to the peripheral edge portion of the face glass plate 10 through a frit glass 16 to seal the envelope 8. The enlarged sealed portion is shown in FIG. 4. 17 denotes a pressure tight container made of a thick metal plate and provided for supporting against air pressure acting on the envelope 8 when the envelope 8 is evacuated to form a vacuum. The outer shape of the pressure tight container 17 is generally the same shape as the outer container 15 so that the inner surface of outer container 15 tightly contacts with the outer surface of the pressure tight container 17. It is noted that the flange portion 17a of the pressure tight container 17 is merely clamped between the flange portion 15a of the outer container 15 and the glass plate 10. When the interior of the envelope 8 is evacuated, the vacuum is maintained by the joint formed by the frit glass 16 between the outer container 15 and the face glass plate 10. In the embodiment, there is used frit glass having a melting point of 450° C. Accordingly, it is possible to bake the display device sufficiently at 350° C. When the interior of the envelope 8 is evacuated to form vacuum, the outer container 15 is subjected to the air pressure, the outer container is prevented from the breaking since the air pressure is supported by the pressure tight container 17. Since the outer container 15 is made of a thin metal plate, cracking of the glass plate 10 at the joint between the glass plate 10 and the outer container 15 can be prevented even when they are joined. In addition, since the pressure tight container 17 is not bonded to the face glass plate 10, there does not occur a problem of a difference of the expansion coefficient between the glass and the metal. This makes it possible to use material with a large expansion coefficient which is inexpensive, whereby the cost of the display device can be reduced. In order to increase the mechanical strength of the pressure tight container 17, there may be provided one or more ribs on the surface of the pressure tight container which opposes the face glass plate 10.
It is noted that the joining arrangement shown in the drawings is provided in a similar manner all around the periphery of the envelope 8.
FIG. 5 shows a second embodiment of affixing the outer container 15 to the glass plate 10. In this embodiment, a spacer 18 having an expansion coefficient near the expansion coefficient of the face glass plate 10 is disposed between the face glass plate 10 and the flange portion 15a of the outer container 15 and the two members 10 and 15 are bonded through bonding materials 18a so that the outer peripheral edge portion of the envelope 8 all around is hermetically sealed. In this embodiment, it is possible to increase the expansion coefficient of the material of the outer container 15.
The operation of the display device constructed as above will be explained. By heating the cathode 12, an electron beam is released from the cathode 12. The electron beam can pass the control electrode 14 and impinges the fluorescent layer 11, which emits light.
FIG. 6 shows a third embodiment of the present invention in which there is used a metal plate 19 made of metal such as, for example 42-6 an alloy which is alloy of 42% Ni, 6% Cr and remainder Fe, having an expansion coefficient near the expansion coefficient of the face glass plate 10. The outmost edge of the metal plate 19 is larger than the outmost edges of the outer container 15 and the face glass plate 10 so that the outer portion of the metal plate 19 is projected outwardly from the flange of the outer container 15 and the metal plate 19 is joined to the flange portion of the face glass plate 10 by fritting 16 and further the metal plate 19 is joined to the flange portion of the outer container 15 at the portion 20 by way of laser welding to provide an envelope 8. In this embodiment, one advantage is that it is unnecessary to increase the temperature for the sealing of the envelope and sealing can be completed in a short time. A further advantage is that since the outer container is not fritting joined, the expansion coefficient of the metal of the outer container can be selected as desired and it is possible to use an inexpensive metal.
As mentioned above, in the respective embodiments, of the flat panel display device according to the present invention, the metal container or the outer container can be affixed to the glass plate in a stable condition without causing any cracking, the display device can be manufactured at a low cost and the characteristic of the display device can be made stable. In addition, the various members of the display members can be sealed stably in a vacuum, so that the characteristics of the display device ca be stabilized.
FIG. 7 shows a 4th embodiment of the flat panel display device according to the present invention in which the outer container 22 made of a thin metal has its flange portion 22a affixed to the peripheral portion of the face glass plate 10 through a frit glass 24 The pressure tight container 23 is merely placed on the glass plate 10 without joining to the face glass plate. A blocking member 25 is disposed between the flange portion 22a of the outer container 22 and the face glass plate 10 at a position between the frit glass 24 and the lower portion of the peripheral wall 23a of the pressure tight container 23 so as to prevent the molten frit glass 24 from reaching the contact portion of the lower end of the wall 23a of the pressure tight container 23 and the face glass plate 10 at the time of sealing the outer container 22 and the flat glass plate 10. The blocking member 25 is made of for example the same kind of glass as the face glass plate 10. With the same glass as the glass of the face glass plate 10, when the frit glass 24 situated between the outer container 22 and the face glass plate 10 is molten due to a high temperature of 350° C. to 450° C. in the production process of the vacuum envelope and a part of the molten frit glass 24 reaches the contact surface of the blocking member 25 and the face glass plate 10 and both parts 25 and 10 are joined by the frit glass 24, it is possible to eliminate a problem of the thermal stress caused by joining of the face glass plate 10 and the blocking member 25 since the flat glass plate 10 and the blocking member 25 have the same thermal expansion coefficient.
The blocking member 25 may be affixed to the face glass plate 10 by fritting in advance before joining of the face glass plate 10 and the outer container 22.
In a fifth embodiment shown in FIG. 8, a rib 22b is formed on the contact surface of the flange 22a of the outer container 22 in a position between the frit glass 24 and the peripheral wall 23a of the pressure tight container 23 so that the rib 22b contacts with the top surface of the face glass plate and acts as the blocking member 25.
FIG. 9 shows a 6th embodiment which is suitable in a case in which the difference of the thermal expansion coefficients of the face glass plate 10 and the outer container 22 is large and it is necessary to provide a buffer member 26 for joining the flat glass plate 10 and the outer container 22. In the embodiment shown, there are sandwiched the upper frit glass layer 24, the buffer member 26 and the lower frit glass layer 24 between the face glass plate 10 and the outer container 22. The buffer member 26 is bent to form a projection 26a at a position between the flange portion 22a of the outer container 22 and the peripheral wall 23a of the pressure tight container 23 and further bent to form an inner wall 26b projected upward.
In case the buffer member 26 is placed as described above, when the device is heated in the production process of the vacuum envelope, the frit glass flows from both of the upper portion and the lower portion of the buffer member 26. The flow of the frit glass can be stopped by the projection 26a and inner wall 26b which act as the blocking members. Therefore, in this embodiment, it is not necessary to provide a separate blocking member as shown in the embodiment shown in FIG. 7.
FIG. 10 shows a 7th embodiment which is used in case the difference of the thermal coefficients of the face glass plate 10 and outer container 22 is large and the buffer member 26 is used. In the arrangement shown in FIG. 10, the buffer member 26 is formed in a step shape with the upper portion 26d placed on the face glass plate 10 through the frit glass 24a and the lower portion 26e projects outwardly from the periphery of the face glass plate 10 so that the joining face 26c of the buffer member 26 joined to the flange portion of the outer container 22 is situated on a level lower than the upper surface of the face glass plate 10. Accordingly, even when the frit glass 24b situated on the joining face 26c on which the buffer member 26 and the outer container 22 are joined and the frit glass 24a situated on the joining face on which the buffer member 26 and the flat glass plate 10 are joined flow, both of the flown frit glass never reach the contact point of the pressure tight container 23 and the buffer member 26. Therefore, there does not occur a problem of the thermal stress due to joining of the pressure tight container 23 and the buffer member 26. In this embodiment, it is not necessary to join the outer container 22 and the buffer member 26 by the frit glass4 but there may be used any other way of joint such as the laser welding which can assure the hermetic seal.
FIG. 11 shows an 8th embodiment in which the frit glass 24 is placed at the portion 10a of the face glass plate 10 which is downwardly stepped from the top face of the flat glass plate 10 so that flow of the molten frit glass can be prevented.
As described in the embodiments shown in FIGS. 7 to 11, the frit glass does not reach inner part of the flat glass plate, even when the frit glass is molten at the joining portion between the outer container and the flat glass plate in the production process of the vacuum envelope, the flat glass plate and the pressure tight member are not bonded, whereby the thermal stress is kept minimal and assuring to produce the flat panel display device can be produced with high reliability.
FIGS. 12 to 15 show a 9th embodiment of the present invention.
In FIGS. 12 to 15, 10 is the face glass plate which is made of transparent soda float glass and is the same glass plate used in the various embodiments, 32 denotes frit glass or glass particles of low melting temperature for sealing, 33 a weldable member made of 42-6 alloy, (specifically, Ni 42%, Cr 6% and remainder Fe) having a thermal expansion coefficient which is the same as the thermal expansion coefficient of the glass, 34 an outer container or a back plate made of metal and opposing to the face glass plate 10 and 35 a metal member or particles having a melting temperature lower than the melting temperature of the back plate 34 and which is wettable for both the back plate 34 and the weldable member 33.
The envelope 8 of the flat panel display device in the 9th embodiment is produced in such a manner as described hereinafter. As shown in FIG. 13, the frit glass 32 is coated between the face glass plate 10 and the weldable member 33 and the envelope is heated in an electric furnace at about 450° C., whereby the flat glass plate 10 and the weldable member are joined. Thereafter, the back plate 34 is tightly contacted with the weldable member 33, then the peripheral edges of the above arrangement are welded by a high density welding such as CO 2 laser welding to seal the envelope tightly. However, since there are deformations such as crinkles in the peripheral portions of the back plate 34 caused by pressing work, it may occur that the amount of the deformation exceeds the allowance of the gap between the works of the laser welding.
In this embodiment, as shown in FIG. 14, a metal member 35a which is wettable to the back plate 34 and the weldable member 33 and has a melting point lower than that of the back plate 34 is placed between the welding portion of the back plate 34 and the weldable member 33 and they are tightly contacted and the peripheral edges of the envelope 8 are sealed in an air tight seal by CO 2 laser welding so that the gap is filled by the welding material.
When the gap is large or the deformation is complicated it may occur that the gap is not filled by the welding material. In this case, in place of the metal member 35a, particles 35bare used. The particles 35b are wettable to the to the back plate 34 and the weldable member 33 and has a melting temperature lower than the melting temperature of the back plate 34.
One example of the way of filling the particles 35b is explained hereinafter with reference to FIG. 15. The particles 35b are mixed with the organic binder and the mixture is coated on the welding portion of the flange of the back plate 34 relatively thick. Then the back plate 34 coated by the mixture is heated up to 300° C. to 350° C. so as to release the inorganic material and being simultaneously pressed so as to increase the density of the particle layer 35b and causing the weldable member 33 to be tightly contacted to the particle layer 35b. By this way, the gap between the welding portion of the back plate 34 and the welding portion of the weldable member 33 are filled by the particles of a high density, whereby the particle layer 35b can act as a meting layer and further act as a joining layer.
According to the 9th embodiment, it is possible to make the joining portion of the envelope simple without requiring a highly accurate joining and to provide the envelopes of the display devices with a good air tight sealing and a high reliability.
FIG. 16 shows a 10th embodiment in which 10 denotes the face glass plate, 42 an outer container made of thin metal, 43 a pressure tight container, 44 a joining member having a thermal expansion coefficient substantially the same as that of the face glass plate 10, 45 frit glass of a low melting temperature for sealing, 46 an air tight seal portion made by laser welding and 47 a buffer member which is inserted between the lower end portion of the peripheral wall of the pressure tight container 43 and the flat glass plate 10 or joining member 44.
In the arrangement described above, when the envelope is evacuated and air impinges from outside, the pressure by the pressure tight container 43 is applied to the face glass plate 10 through the buffer member 47, so that the stress in the face glass plate 10 can be relieved. When the pressure is applied to the frit glass 45 through the joining member 44, such pressure is applied to the frit glass through the buffer member 47, whereby the stress occurs in the frit glass 45 and face glass plate 10 can be relieved. As the buffer member 47, it is effective to use a spreading metal or soft metal such as aluminum. As the buffer member 47, there may be used rubber or plastic resin.
In a high temperature processing of 350° C. to 450° C., in the production of the envelope, there occurs a thermal stress due to the difference of the thermal expansion coefficient between the joining member 44 and the flat glass plate 10. The effect of the difference of the thermal coefficient is particularly great when the enclosure is bulky. In order to decrease the thermal stress, it is necessary to make the outer container 42 and the joining member 44 of a thin material. However, when the flat glass plate 10 and thin joining member 44 are joined by the frit glass 45, the joining strength becomes small.
FIGS. 17 and 18 show 11th and 12th embodiment for increasing the joining strength.
Referring to FIG. 17, 48 denotes a reinforcing member made of preferably a glass member which is the same as the glass of the flat glass plate. As the reinforcing member 48, there may be used a metal member such as 42-6 alloy having the same or close thermal expansion coefficient to that of the face glass plate 10. The joining member 44 is provided with a through hole 44a and the reinforcing member 48 is joined to the flat glass plate 10 by the frit glass 45 through the joining member 44. In case the reinforcing member 48 is made of 42-6 alloy, it is desired that the reinforcing member be as thin as possible for decreasing the thermal stress which occurs when they are joined by the frit glass.
A buffer member 47a is disposed between the pressure tight container 43 and the reinforcing member 48 so as to decrease the pressure applied to the reinforcing member 48 from the pressure tight container 43 by the buffer member 47a, whereby it is possible to decrease the stress concentration on the reinforcing member 48, the frit glass 45 and the face glass plate 10.
FIG. 18 shows a 12th embodiment in which the buffer member 47b is shaped in a form of an inverted U in cross sectional view and is situated on the joining member 44 so as to surround the reinforcing member 48. The pressure tight container 43 is placed on the buffer member 47b. There is provided a predetermined gap 49 between the inner top surface 47c of the buffer member 47b and the top surface 48a of the reinforcing member 48. By providing the gap 49 between the buffer member 47b and the reinforcing member 48, when the envelope 8 is evacuated and put in air, the pressure of the air does not act on the reinforcing member 48 but acts only on the buffer member 47b made of soft metal such as aluminum, which can be deformed, thereby decreasing the stress acting on the frit glass 45 and the face glass plate 10. Accordingly, even if the reinforcing member 48 is made of glass which is brittle, the reinforcing member is prevented from breaking, therefore, the safety of the envelope can be increased. Since the envelope is safe as mentioned above, it is possible to make the outer container and pressure tight container by a material of relatively large thermal expansion coefficient, whereby the manufacturing cost of the flat panel display devices can be decreased.
It is an advantage that the stress acting on the pressure tight container and the flat glass plate due to the air pressure acting on the envelope which is evacuated can be decreased so that the safety of the envelope in terms of the vacuum pressure strength can be increased.
Another advantage of the embodiments is to increase the joining strength even if the joining member is made of a thin member and the stress concentration can be decreased without reducing the effective picture size ratio.
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A flat panel display device which comprises a face glass plate, a metal container assembled to the face glass plate through a frit glass for providing an envelope for accommodating electron beam generating means and electron beam control means, the metal container including an outer container made of a thin metal plate and an inner container separately assembled to the inside of the outer container for acting as a pressure resistive container for supporting air pressure. Only the outer container is joined to the face glass plate.
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BACKGROUND OF INVENTION
1. Field of the Invention
The present invention provides a light-emitting element, and more particularly, an organic adhesive light-emitting device with an ohmic metal bulge.
2. Description of the Prior Art
The applications of light-emitting diodes (LED) are extensive and include such applications as optical display devices, traffic signals, data storing devices, communications devices, illumination devices, and medical apparatuses. An important issue is how to lower the manufacturing cost of LEDs.
A light-emitting diode and its related method of manufacture are disclosed in U.S. Pat. No. 6,682,950, in which a light-emitting diode layer is bonded to a transparent substrate by means of a transparent adhesive layer. Nevertheless, the prior art method, due to the non-conductivity of the transparent adhesive layer, while being suitable for use in diodes of which two electrodes are located at the same side, is not suitable for use in diodes of which electrodes are respectively located at the upper surface and lower surface of the diode. In addition, part of the diode stack layer needs to be removed by means of an etching process to produce two electrodes at the same side. In doing so, not only is material wasted, but also the complexity of the processes is increased.
SUMMARY OF INVENTION
It is therefore an object of the claimed invention to develop a light emitting diode having an organic adhesive layer with an ohmic metal bulge for sticking a conductive substrate and a light-emitting stack layer together, which forms ohmic contacts, so as to conduct current, and to simplify manufacturing processes and to reduce the cost of the diode.
Briefly described, the claimed invention discloses an organic adhesive light-emitting device with an ohmic metal bulge. The organic adhesive light-emitting device comprises a conductive substrate, a light-emitting stack layer, a metal layer formed over the conductive substrate, a reflective layer formed over the light-emitting stack layer, an organic adhesive layer with an ohmic metal bulge. The metal layer comprises an ohmic metal bulge for forming an ohmic contact between the metal layer and the reflective layer, and an adhesive material around the ohmic metal bulge for bonding the metal layer and the reflective layer together.
According to the claimed invention, the conductive substrate comprises at least one material selected from a material group consisting of GaP, GaAsP, AlGaAs, Si, Ge, and SiC, or other substitute materials. The adhesive material comprises at least one material selected from a material group consisting of PI, BCB, and PFCB, or other substitute materials. The ohmic metal bulge comprises at least one material selected from a material group consisting of In, Sn, Al, Au, Pt, Zn, Ge, Ag, Ti, Pb, Pd, Cu, AuBe, AuGe, Ni, PbSn, and AuZn, or other substitute materials. The reflective layer comprises at least one material selected from a material group consisting of In, Sn, Al, Au, Pt, Zn, Ge, Ag, Ti, Pb, Pd, Cu, AuBe, AuGe, Ni, Cr, PbSn, AuZn, and indium tin oxide, or other substitute materials. The metal layer comprises at least one material selected from a material group consisting of In, Sn, Al, Au, Pt, Zn, Ge, Ag, Ti, Pb, Pd, Cu, AuBe, AuGe, Ni, Cr, PbSn, and AuZn, or other substitute materials. The light-emitting layer comprises at least one material selected from a material group consisting of AlGaInP, GaN, InGaN, and AlInGaN, or other substitute materials.
These and other objects of the claimed invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates a schematic diagram of a present invention light-emitting diode having an organic adhesive layer with an ohmic metal bulge.
FIG. 2 illustrates a schematic diagram of a present invention light-emitting diode having an organic adhesive layer with an ohmic metal bulge.
FIG. 3 illustrates a schematic diagram of a present invention light-emitting diode having an organic adhesive layer with an ohmic metal bulge.
DETAILED DESCRIPTION
Please refer to FIG. 1 , which illustrates an organic adhesive light-emitting device 1 . The organic adhesive light-emitting device 1 includes a first electrode 20 , a conductive substrate 10 formed over the first electrode 20 , a metal layer 11 formed over the conductive substrate 10 , and an organic adhesive layer 12 formed over the metal layer 11 . The organic adhesive layer 12 includes an ohmic metal bulge 121 and an adhesive material 122 around the ohmic metal bulge 121 . The adhesive material 122 adheres to a portion of the metal layer 11 , while the ohmic metal bulge 121 adheres to another portion of the metal layer 11 for forming an ohmic contact and a reflective layer 13 on the organic adhesive layer 12 . Furthermore, the adhesive material 122 adheres to a portion of the reflective layer 13 , while the ohmic metal bulge 121 adheres to: another portion of the reflective layer 13 for forming an ohmic contact, a transparent conductive layer 14 on the reflective layer 13 , a first contact layer 15 on the transparent conductive layer 14 , a first cladding layer 16 on the first contact layer 15 , a light-emitting layer 17 on the first cladding layer 16 , a second cladding layer 18 on the light-emitting layer 17 , a second contact layer 19 on the second cladding layer 18 , and a second electrode 21 on the second contact layer 19 . The reflective layer 13 can be eliminated because it is included solely to increase brightness. If the reflective layer 13 is eliminated, the metal layer 11 can be replaced with a metal reflective layer for reflecting.
Please refer to FIG. 2 , which illustrates an organic adhesive light-emitting device 2 . The organic adhesive light-emitting device 2 includes a first electrode 220 , a conductive substrate 210 formed over the first electrode 220 , and an organic adhesive layer 211 formed over the conductive substrate 210 . The organic adhesive layer 211 includes an ohmic metal bulge 2111 and an adhesive material 2112 around the ohmic metal bulge 2111 . The adhesive material 2112 adheres to a portion of the conductive substrate 210 , while the ohmic metal bulge 2111 adheres to another portion of the conductive substrate 210 for forming an ohmic contact and a reflective layer 212 on the organic adhesive layer 211 . Furthermore, the adhesive material 2112 adheres to a portion of the reflective layer 212 , while the ohmic metal bulge 2111 adheres to: another portion of the reflective layer 212 for forming an ohmic contact, a transparent conductive layer 213 on the reflective layer 212 , a first contact layer 214 on the transparent conductive layer 213 , a first cladding layer 215 on the first contact layer 214 , a light-emitting layer 216 on the first cladding layer 215 , a second cladding layer 217 on the light-emitting layer 216 , a second contact layer 218 on the second cladding layer 217 , and a second electrode 221 on the second contact layer 218 . The reflective layer 212 can be replaced with a metal layer for forming an ohmic contact with the ohmic metal bulge 2111 .
Please refer to FIG. 3 , which illustrates an organic adhesive light-emitting device 3 . The organic adhesive light-emitting device 3 includes a metal substrate 310 , and an organic adhesive layer 311 formed over the metal substrate 310 . The organic adhesive layer 311 includes an ohmic metal bulge 3111 and an adhesive material 3112 around the ohmic metal bulge 3111 . The adhesive material 3112 adheres to a portion of the metal substrate 310 , while the ohmic metal bulge 3111 adheres to another portion of the metal substrate 310 for forming an ohmic contact and a reflective layer 312 on the organic adhesive layer 311 . Furthermore, the adhesive material 3112 adheres to a portion of the reflective layer 312 , while the ohmic metal bulge 3111 adheres to: another portion of the reflective layer 312 for forming an ohmic contact, a transparent conductive layer 313 on the reflective layer 312 , a first contact layer 314 on the transparent conductive layer 313 , a first cladding layer 315 on the first contact layer 314 , a light-emitting layer 316 on the first cladding layer 315 , a second cladding layer 317 on the light-emitting layer 316 , a second contact layer 318 on the second cladding layer 317 , and a first electrode 319 on the second contact layer 318 .
In the above, the conductive substrate includes at least one material selected from a material group consisting of GaP, GaAsP, AlGaAs, Si, Ge, and SiC, or other substitute materials. The metal substrate includes at least one material selected from a material group consisting of Cu, Al, Mo, and MMC (metal matrix composite) carrier, or other substitute materials. The MMC carrier is a carrier with holes having been injected with a proper metal, so as to provide an adjustable heat conductive coefficient or a heat expansive coefficient. The adhesive material includes at least one material selected from a material group consisting of PI, BCB, and PFCB, or other substitute materials. The ohmic metal bulge includes at least one material selected from a material group consisting of In, Sn, Al, Au, Pt, Zn, Ge, Ag, Ti, Pb, Pd, Cu, AuBe, AuGe, Ni, PbSn, and AuZn, or other substitute materials. The reflective layer includes at least one material selected from a material group consisting of In, Sn, Al, Au, Pt, Zn, Ge, Ag, Ti, Pb, Pd, Cu, AuBe, AuGe, Ni, Cr, PbSn, AuZn, and indium tin oxide, or other substitute materials. The metal layer includes at least one material selected from a material group consisting of In, Sn, Al, Au, Pt, Zn, Ge, Ag, Ti, Pb, Pd, Cu, AuBe, AuGe, Ni, Cr, PbSn, and AuZn, or other substitute materials. The transparent conductive layer includes at least one material selected from a material group consisting of indium tin oxide, cadmium tin oxide, antimony tin oxide, zinc oxide, and zinc tin oxide, or other substitute materials. The first cladding layer includes at least one material selected from a material group consisting of AlGaInP, AlInP, AlN, GaN, AlGaN, InGaN, and AllnGaN, or other substitute materials. The light-emitting layer includes at least one material selected from a material group consisting of AlGaInP, GaN, InGaN, and AlInGaN, or other substitute materials. The second cladding layer includes at least one material selected from a material group consisting of AlGaInP, AlInP, AlN, GaN, AlGaN, InGaN, and AlInGaN, or other substitute materials. The second contact layer includes at least one material selected from a material group consisting of GaP, GaAs, GaAsP, InGaP, AlGaInP, AlGaAs, GaN, InGaN, and AlGaN, or other substitute materials. The first contact layer includes at least one material selected from a material group consisting of GaP, GaAs, GaAsP, InGaP, AlGaInP, AlGaAs, GaN, InGaN, and AlGaN, or other substitute materials.
Those skilled in the art will readily observe that numerous modifications and alterations of the device may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.
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Organic adhesive light-emitting device with ohmic metal bulge. The organic adhesive light-emitting device includes a conductive substrate, a light-emitting stack layer, a metal layer formed over the conductive substrate, a reflective layer formed over the light-emitting stack layer, and an organic adhesive layer having an ohmic metal bulge and an adhesive material around the ohmic metal bulge. The adhesive material bonds the metal layer and the reflective layer together, while the ohmic metal bulge forms ohmic contacts with the metal layer and the reflective layer. The configuration can simplify a light-emitting diode.
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FIELD
[0001] The present invention relates to a self compensated, adjustable fluid emitter, particularly intended to be used in irrigation systems, which emitter comprises:
[0002] a casing externally delimiting a volume which is divided into a first chamber and into a second chamber by a membrane that can be elastically deformed;
[0003] an inlet that can be connected to a fluid supplying source and communicating with said first chamber;
[0004] an outlet communicating with said second chamber;
[0005] said first and said second chamber being in communication one with the other by means of at least a communicating duct; and
[0006] means for retaining in a fixed position said membrane dividing the first chamber from the second chamber and allowing said membrane to be elastically deformed when said membrane is subjected to a fluid pressure difference between said first chamber and said second chamber,
[0007] said membrane being deformed such that at least a portion thereof changes its position with respect to said outlet, modifying the flow rate of the fluid through said outlet depending on the pressure difference and, accordingly, on the deformation of the membrane that moves closer and/or farther away from the outlet, so the flow rate of the fluid through said outlet is controlled and kept constant by said membrane despite variations in the fluid pressure at least at the inlet or outlet.
[0008] More particularly, the flow rate or the flow amount through said outlet is reduced when the membrane is deformed moving closer to the outlet, while the flow rate of the fluid increases when the membrane is deformed moving farther away from said outlet. Therefore, the flow rate of the fluid through said outlet is controlled and kept constant by means of said membrane despite fluid pressure variations at least at the inlet or outlet.
BACKGROUND
[0009] Fluid emitting devices, particularly for irrigation systems are known. For example U.S. Pat. No. 4,428,397 describes a device of this type.
[0010] However, the above mentioned devices have some drawbacks. The adjustment of the flow rate in relation to the pressure difference between the two chambers divided by the membrane is solely obtained by means of structural and elasticity properties of the membrane. Therefore, the membrane is the only functional member determining the adjustment for a very large range of pressure differences.
[0011] Besides a saturation effect, i.e. a non-response effect when the fluid pressure difference in the two chambers divided by the membrane is over a certain maximum limit value and when it is lower than a certain minimum value, the continuous elastic stress of the material composing the membrane can cause the ageing of the material with regard to elastic characteristics and it may not be possible to adjust pressure difference values close to extreme values of the pressure difference range, within which the elastic behavior of the membrane would guarantee the flow rate to be adjusted. For example, when the membrane has to operate for a long time under high pressure difference conditions, the material can be inelastically deformed or stretched and so the elastic recovery to the original configuration cannot occur, rendering impossible the adjustment upon a low pressure difference.
[0012] Moreover, in order to guarantee a lasting and optimal elastic behavior, the membrane has to be composed of a material with high elastic qualities and so quite expensive. This has a considerable effect as regards total costs of irrigation systems having a large number of said emitters.
[0013] In FR 1.299.719, a flow regulating device is disclosed that includes two chambers separated by a membrane. One of the two chambers communicates with an inlet duct for a pressure fluid and the other one communicates with a duct delivering said pressure fluid, with the fluid passing from a chamber to the other one via a through aperture provided in said membrane. An outlet spout cooperates with the membrane for defining a predetermined pressure in the corresponding chamber of the device that communicates with the delivering duct, which outlet spout can be adjusted with reference to its relative position with respect to the membrane.
[0014] In such device, the distance between the membrane and the outlet spout acts for allowing a pressure to be adjusted on the corresponding side of the membrane, but it does not allow a range of the flow rate to be adjusted. Moreover the membrane has to be perforated thus making it highly sensitive to wear and so it is subjected to breaking or to functionality loss.
[0015] In all known devices, the flow rate is adjusted by limiting and controlling the pressure. After all known devices do not act independently of the flow rate and pressure. The two magnitudes can be really correlated one with the other. However there is the need of independently adjusting the two magnitudes, at least as regards a certain range of pressures and/or flow rates.
SUMMARY
[0016] The field of use to which the invention refers is the filed of drop emitters. In this field, it is advantageous to have available emitters that can change the flow rate of delivered irrigation water as a function of the seeding, growing, and harvesting cycles. It is advantageous to change the delivery of nutritious substances by increasing or decreasing them in the different evolution stages of these cycles according to needs and requirements of plants when the plants are growing and developing. All this, without shocking or abusing plants and saving tools and workforce when replacing emitters.
[0017] The invention aims at providing an emitter of the type described hereinbefore, wherein, by means of simple and inexpensive arrangements, the above described drawbacks of known emitters regarding the automatic control of the flow rate under different fluid supplying conditions may be overcome.
[0018] The invention achieves the above aims by providing a self compensated adjustable emitter, particularly intended for use in irrigation systems, which emitter includes the above described features, and wherein means for changing the position of the membrane with respect to the outlet, i.e. for mechanically and firmly changing the distance of said membrane from the outlet and/or means for mechanically and firmly changing the elastic behavior of the membrane and/or for generating a firm deformation of said membrane are further provided.
[0019] According to an advantageous embodiment, said means are provided in combination with means for reducing the pressure acting simultaneously and independently of the compensating membrane.
[0020] Said means for mechanically and firmly changing the elastic behavior of the membrane and/or for generating a firm deformation of the membrane can be operated already in the idle condition thereof, i.e. when there is no fluid pressure difference in the two chambers divided by said membrane.
[0021] These means can be also operated when the membrane is in its operating condition and i.e. when there is a fluid pressure difference in the two chambers divided by said membrane.
[0022] Means for changing the position of the membrane with respect to the outlet can also be operated when the membrane is not urged and/or deformed, i.e. in its idle condition, or when there is no fluid pressure difference in the two chambers divided by said membrane.
[0023] According to the first embodiment, the membrane is supported by an intermediate flange of the inner space of the casing between two opposite walls, one of which has the fluid inlet port and the other one of which has the outlet port, said two opposite walls being each one a part of a cup-like half-shell, and the two cup-like half-shells being tightly coupled together and being movable so that they can move closer and/or farther away one with respect to the other, including said opposite walls, while only one of the two half-shells, particularly the half-shell having the wall wherein the inlet port is provided, bears the flange fastening the membrane.
[0024] A preferred embodiment provides the casing to have a substantially cylindrical shape, the two half-shells being made of two opposing cup-like members and the two opposite walls having the inlet port and the outlet port respectively composed of top and bottom walls of the cylindrical casing, while the membrane is supported by an inner perimetric annular flange provided in the cup-like member, whose wall has the inlet port said flange being arranged parallel to said wall bearing the inlet port.
[0025] A variant embodiment provides the casing to be made of a cup-like member and of a wall closing the open side of said cup-like member to be slidably mounted inside said cup-like member, moving closer and farther away from an opposite bottom wall of said cup-like member.
[0026] In particular, the wall closing the cup-like member is composed of the surface of a closing cylinder having a certain axial extension.
[0027] Even in this case the cup-like member bears the membrane, while the closing wall can be moved with respect to said membrane.
[0028] The cup-like member has a cylindrical shape and the bottom side thereof is circular and bears the inlet port, the closing wall being also composed of a circular shaped wall that is substantially parallel to the bottom wall of the cup-like member and to the flange supporting the membrane as well as to the membrane in its non-deformed configuration.
[0029] In all above mentioned variants, ducts or passageways for the fluid from the first chamber provided on the side of the membrane faced toward the inlet port to the second chamber provided on the side of the membrane faced toward the outlet port are provided in the flange supporting the membrane and/or in the shell perimetric wall of one or both the cuplike members.
[0030] Moreover, that ducts and/or passageways have sections that not change in relation to fluid supplying and/or delivering conditions.
[0031] A second alternative provides the membrane to be supported by means having a predetermined fixed position with respect to the outlet port, while spring means are provided that can be loaded in an adjustable way in order to obtain a variable deformation of the membrane already when there is no pressure difference in the two chambers divided by it.
[0032] Particularly, an embodiment provides the membrane to be retained by a perimetric flange provided at an intermediate position between two opposite walls delimiting the casing, one of which wall bears the inlet port and the other one bears the outlet port, while on the membrane side faced towards the wall bearing the outlet port there is provided a spring member interposed between said side of said membrane and a fixed abutment member, there being provided means for mechanically deforming said spring means and for elastically loading them.
[0033] An embodiment provides said spring loading means to be composed of means compressing the spring member between said side of the membrane and said abutment member.
[0034] Particularly, the abutment wall or the abutment member can be moved and constitute means compressing the spring member.
[0035] The preferred embodiment provides the abutment wall of said spring means interposed between said abutment wall and the membrane to be composed of the wall of the casing wherein the inlet port is provided, which wall can be tightly moved closer and farther away from the membrane, while the membrane is supported by means having a fixed position with respect to the outlet port.
[0036] The casing may be manufactured similarly to the casing previously described with reference to the first alternative.
[0037] When the casing is made of two opposing cup-like members that can be tightly engaged and can be moved closer or farther away one with respect to the other, so the bottom side of one of the two cup-like member is the wall bearing the inlet port and acting as a abutment part that can be moved loading the spring member, the second cup-like member has a bottom side with the outlet port and an inner perimetric flange supporting or fastening the perimetric edges of the membrane, which flange has a fixed position with respect to the bottom wall bearing the outlet port. A spring member is provided between the bottom wall of the cup-like member bearing the inlet port and the membrane when the two opposing cup-like members are tightly mounted.
[0038] A variant embodiment provides only a cup-like member, whose bottom wall has the inlet port and a wall closing the cup-like member has an annular perimetric flange supporting the peripheral edges of the membrane, which flange is provided at a certain distance from the inner side of the closing wall.
[0039] As already described in the previous embodiment with reference to the first alternative, also in this case the casing may have cylindrically shaped cup-like members constructed as a cylindrical half-shell and end walls of the cylindrical casing, which are provided one with the inlet port and the other one with an outlet port, while the membrane is borne by an inner, annular peripheral flange that is integral with the cup-like member or the closing wall may bear the outlet port.
[0040] Advantageously, the spring member is composed of a coil spring.
[0041] The membrane is supported along an annular perimetric band that is continuous or discontinuous or provided with passageways for the fluid or passage ducts for the fluid, while it freely extends for the remaining part of the surface thereof, the membrane being al least rested on supporting abutment parts and particularly on an annular perimetric flange on the side thereof opposite to the chamber communicating with the fluid outlet port.
[0042] As regards means for reducing the pressure, said means are integrated in the emitter and may consist of a labyrinth or a duct having an intricate path.
[0043] Advantageously, said labyrinth or intricate path duct is interposed between the inlet and the outlet of the communication duct connecting the two chambers separated by the membrane or said labyrinth or intricate duct may form at least partially the communication duct between said two chambers.
[0044] With reference to embodiments wherein the casing is composed of two parts tightly slidably connected according to a direction perpendicular to the membrane, and wherein a part has a shell wall tightly overlapping the shell wall of the other part, the intricate duct or labyrinth are provided along a perimetric band of one of said two overlapped and slidable perimetric walls and is formed of a perimetric groove extending for an angle size smaller than 360° or is like an annular groove or helicoidal groove extending along various coils, while one of the end of said annular groove leads to a chamber and the other end leads into the other chamber of the two chambers separated by the membrane.
[0045] Said duct can be provided in combination with any one of the above arrangements for the casing, and particularly it can be made like an annular or helicoidal perimetric groove provided on the outer side of the perimetric wall of one of the two half-shells or of the cylindrical member slidably and tightly entering inside the perimetric wall of the other half-shell member of the two half-shells or of the two parts composing the casing according to one or more of the embodiments described above.
[0046] According to another embodiment of the emitter according to the present invention, instead of an elastic member deforming the membrane on the side thereof faced towards the inlet, there are provided rigid members deforming the membrane which are provided at a predetermined distance from the membrane, and in such a position of the membrane intermediate between the two chambers, causing the membrane to merely rest against said deforming means without being deformed by them, while in a position moved towards the chamber where the inlet leads, i.e. a position reducing the size of said chamber, the membrane is deformed by the rigid deforming means toward the chamber wherein the outlet leads, and in a modified position that increases the volume of the chamber wherein the inlet leads when the membrane is moved away from said rigid deforming means. Said rigid deforming means are composed of a spout extending the inlet towards the membrane and projecting at a predetermined extent toward the membrane, which has an inner supply duct leading at the end side of the extending spout and intended to contact the membrane, and which further has a radial or side port for supplying the fluid in the peripheral wall.
[0047] By means of the features of the present invention, it is possible to pre-set a certain distance of the membrane from the outlet port both by bringing closer or farther away the outlet port from the membrane that is in its idle condition, i.e. without fluid pressure differences in the two chambers divided by the membrane or without a deformation, and causing a deformation of the membrane by elastically and mechanically pre-loading the membrane, leading to a greater or lower deformation when there is no pressure difference between the two chambers divided by the membrane. That allows calibrating emitters such that they can always operate in a restricted adjustment range as regards the adjustment caused only by the elastic deformation of the membrane due only to the intrinsic elasticity characteristics thereof. That allows having emitters with a longer lasting automatic adjustment of the flow rate, but also using less noble and less expensive materials for membranes without compromising the system functionalities while drastically decreasing manufacturing costs.
[0048] By means of the above features, the emitter according to the present invention allows the flow rate of the delivered fluid to be adjusted and the pressure to be adjusted. Both functions are independent one from the other. Moreover, the fact of adjusting the flow rate and the pressure allows self compensating functions for the delivered flow rate to be provided in different ranges of the flow rate or for different values of the flow rate that are pre-set by moving and/or preloading the membrane.
[0049] The diagram of FIG. 11 shows the trend of the flow rate as a function of the pressure for three different emitter adjustments. In this case, it can be noted that for three different values of the flow rate, the emitter performs a self compensation as the pressure increases, while keeping the flow rate constant at the predetermined value.
[0050] Therefore, by acting on the relative position of the two half-shells and so on the distance between the membrane and the mouth of the outlet duct, it is possible to set a value of the flow rate that is kept independently of the change in the pressure value in a particularly high range, and in the example of FIG. 11 such value is from 1 to 4 atmospheres.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] Features of the invention and advantages deriving therefrom will be clearer from the following description of some embodiments shown as not limitative example in annexed drawings.
[0052] FIG. 1 is a first embodiment of the present invention, wherein the preventive adjustment of the operating range of the adjusting membrane is obtained by modifying the distance of the adjusting membrane in its idle condition from the outlet port, i.e. without pressure differences on the two sides of the membrane or under the not-deformed condition of the membrane.
[0053] FIGS. 2 and 3 are the embodiment of FIG. 1 , but with the distance of the membrane from the outlet of the emitter set in two different ways and with the membrane deformed by a pressure difference.
[0054] FIG. 4 is a variant embodiment, wherein the membrane is subjected to a previous deformation that can be adjusted by spring preloading means in combination with a movement of the bottom wall bearing the membrane with respect to the inlet port in this example the membrane being not preloaded.
[0055] FIGS. 5 and 6 are two further operating adjusting conditions of the emitter according to FIG. 5 , wherein the membrane is considerably deformed.
[0056] FIG. 7 is a variant embodiment of the example according to FIGS. 4 to 6 , which variant provides the provision of means for reducing the pressure in the form of an intricate duct or a labyrinth interposed between the two chambers of the emitter in the communication duct.
[0057] FIG. 8 is the variant of FIG. 7 applied to the embodiment of FIGS. 1 to 3 .
[0058] FIGS. 9 and 10 are a third variant embodiment of the device according to the present invention, wherein rigid pressing or supporting means act on the side of the fluid inlet chamber instead of an elastic member against the membrane.
[0059] FIG. 11 is a diagram of the emitter behavior according to the present invention with reference to the change in the flow rate of the delivered fluid as a function of the fluid pressure and for three different values of the flow rate set in the emitter.
DETAILED DESCRIPTION
[0060] With reference to FIG. 1 , there is shown a fluid emitter, particularly an irrigation dripping device that includes a casing 1 , inside which there is defined a space for storing the fluid to be delivered; an inlet mouth 2 intended to be connected to a fluid source; and an outlet, particularly an outlet duct 3 for delivering the fluid drop by drop. In the shown embodiment, the duct composed of the inlet port and the outlet duct are coaxially arranged, and each of them is provided at one of two opposite upper or lower end walls 101 and 201 of the emitter casing 1 .
[0061] The inner delimited space of the casing 1 is divided in two chambers C 1 and C 2 by a membrane 4 supported in an intermediate position between the two walls 101 and 201 by an inner peripheral flange 5 extending along the inner side of the shell wall 301 of the casing 1 .
[0062] The membrane 4 is made of an elastic material and tightly divides the two chambers C 1 and C 2 , which are in communication by means of one or more ducts and/or one or more passageways made in the flange 4 and/or inside the thickness of the shell walls 301 of the casing 1 (not shown in the annexed figures but known in the prior art).
[0063] Therefore, as it results from the figure and from the previous disclosure, the membrane 4 is a barrier that can be elastically deformed with the fluid freely flowing between the two chambers and from the inlet mouth 2 to the outlet duct 3 . The membrane 4 is supported and held only along a band of the peripheral edge, while the remaining inner portion of its extension is free to be deformed, since it extends like a bridge on the open central region of the peripheral annular flange 5 .
[0064] Ducts and passageways between the chamber C 1 and the chamber C 2 , respectively on the side of the membrane faced towards the inlet port 2 and towards the outlet duct 3 , are such that under certain pressure conditions of the fluid inside the chamber C 1 and inside the chamber C 2 two different pressures are generated. In particular, when the inlet fluid pressure is very high, such that it is not possible to have the dripping action or the amount of the delivered fluid is exceeds the desired amount, a pressure difference between the fluid in the chamber C 1 and the fluid in the chamber C 2 is generated in favor of the pressure inside the chamber C 1 . As shown in following figures, the higher pressure in the chamber C 1 causes the membrane to be elastically deformed bending into the chamber C 2 towards the wall bearing the outlet duct 3 . In this case, the membrane moves closer the entrance of the outlet duct 3 in the chamber C 2 and causes a reduction of the flow rate that depends on the higher pressure inside the chamber C 1 , achieving an automatic adjustment of the flow rate within desired ranges of the flow rate for delivering the fluid by dripping action.
[0065] Therefore, the fact that the outlet duct 3 and the inlet mouth 2 are coaxially arranged is particularly advantageous since it maximizes and centers the deforming action with the position of the outlet duct 3 . Moreover, the rotational geometry is concentric with the axes of the two ducts, of the membrane 4 and of the flange 5 , optimizing the desired effect, this design cannot be considered as limitative. This is also true if the casing is manufactured with a cylindrical shape with the two walls 101 and 201 composed of the end walls of the cylindrical casing 1 , the shell wall 301 composed of the cylindrical shell wall 301 , the flange 5 extending in a plane parallel to the two end walls 101 and 201 , therefore as the membrane 4 , and with the inlet mouth 2 and the outlet duct 3 that are coaxial with respect to the end walls 101 and 201 and to the axis of the cylindrical casing.
[0066] The inner surface of the wall 201 delimiting the chamber C 2 on the side of the membrane faced towards the outlet duct 3 advantageously has a shape that is not flat and has an axial annular projection 401 about the outlet duct 3 , extending it towards the membrane 4 . This annular, axial projection 401 can be advantageously provided with one or more radial grooves constituting a passageway for the fluid when the membrane is deformed to the greatest extent. In fact, if the fluid supplying pressure in the chamber C 1 increases too much, the membrane could be deformed such that the entrance of the outlet duct 2 in the wall 201 can be completely closed, causing the delivering flow to be stopped and so the irrigation fluid to be not present with the danger of damaging the crops. By providing the annular, axial projection 401 with radial grooves or through apertures (not shown in the figures), the membrane cannot completely prevent the output flow even when it completely adheres against the most projecting surface of the axial projection 401 constituting the entrance of the outlet duct 3 . For example, in this case the radial grooves would be closed only at the open side and the fluid would be able to pass from the chamber C 2 towards the outlet duct 3 through them with a minimum flow rate guaranteed even in the case of fluid supplying pressures overcoming a maximum limit within, which the membrane can automatically and progressively (i.e. depending on the supplying fluid pressure) adjust the flow rate.
[0067] According to a first embodiment shown in FIGS. 1 to 3 , the flow rate of the delivering flow depends on the pressure of the fluid supplied to the dripping unit and is adjusted not only automatically solely by means of the intrinsic elasticity of the membrane 4 , but also by a manual mechanical action presetting a certain operating condition of the membrane and adapting it to changing conditions of the delivering pressure that are present in the system or in the fluid supplying source to which the emitter is connected or has to be connected.
[0068] As shown in FIGS. 1 to 3 , this is achieved through the distance between the mouth of the outlet duct 2 , i.e. the inner surface of the wall delimiting the chamber C 2 about the outlet duct 2 , and in the present example, the end surface of the axial projection 401 and the faced surface of the membrane 4 cooperate with the mouth of the outlet duct 3 , i.e. with said surfaces is made, making such distance adjustable and pre-set, in order to reduce the passage opening according to the pressure difference between the two chambers C 1 and C 2 , so to modify the flow rate.
[0069] In the embodiment of FIGS. 1 to 3 , the position of the wall 201 , in which the outlet duct 3 is provided, is modified with respect to the membrane 4 , i.e. to the flange 5 fastening it.
[0070] Different specific arrangements are possible. The wall 201 , in which the outlet duct is provided, can be made to be tightly mounted and moved, as well as to be locked in place inside and along perimetric or shell walls 401 of a cup-like member that is integrally formed by the end wall 101 bearing the inlet port 2 , by the shell or perimetric wall 301 with the inner flange 5 fastening the membrane 4 . In the shown embodiment, this is achieved by providing the wall 201 wherein the outlet duct 2 is made as an axially elongated body that can be axially tightly moved inside the perimetric shell wall 301 in the direction coaxial to the outlet duct 2 and/or to the inlet duct 3 and/or in the direction perpendicular to the membrane 4 . The coupling of the wall 201 or of the body 201 can be of any type and particularly the above mentioned cylindrical realization is advantageous since it allows a screw type coupling the body 201 , making the movable wall composed of cylindrical member provided with an external thread, while the shell wall 301 has a corresponding inner thread in the axial portion between the flange 5 and the free end edge opposite to the wall 101 . The tight effect can be guaranteed, for example, by one or more O-rings interposed between the external shell wall of the cylindrical body forming the movable wall 201 and the inner side of the shell wall 301 of the cup-like member.
[0071] Other structural variants are possible, for example the movable wall 201 bearing the outlet duct 3 can be also a part of a cup-like member opposing the cup-like member associated to the end wall 101 provided with the inlet duct 2 . In this case, the outlet duct 3 can be made by a mouthpiece integral with the end wall 201 of the second cup-like member, while shell walls of the two cup-like members have such diameters that the inner diameter of the first cup-like member associated to the inlet mouthpiece 1 is greater or substantially equal to the outer diameter of the shell wall of the second cuplike member bearing the outlet mouthpiece. In substance, the body 201 of the FIG. 1 and of the following figures is not solid but it is made hollow like a cup for a certain axial length, while for the remaining axial length it would have the diameter reduced such to make the outlet mouthpiece.
[0072] The two cup-like members can be also substantially symmetrical one with respect to each other, the only differences being the annular axial projection of the outlet duct 3 on the second cup-like member and the presence of the inner flange 5 on the first cup-like member associated to the inlet mouthpiece 2 .
[0073] The two variants have not to be intended as limitative, as well as references made to the rotational or cylindrical symmetry shape that are simpler from the a construction and description point of view, but they are not the only possible shapes, because the casing may be made with any shape and the fluid inlet and outlet ducts 2 , 3 of the membrane 4 may have different orientations. The only essential feature is the distance between the entrance of the outlet duct 3 in the chamber C 2 and the membrane surface faced toward it that can be varied and locked at the selected value. The arrow F 1 in the figures generally denotes the possibility to move the wall 201 in order to achieve this functionality in examples of FIGS. 1 to 3 .
[0074] FIGS. 5 and 6 show a variant of the present invention, in which the initial distance is not adjusted, i.e. the distance of the membrane from the entrance of the outlet duct 3 when it is in its idle condition, or when there is no deformation or where there is no pressure difference in chambers C 1 and C 2 divided by the membrane, but an initial predetermined deformation of the membrane is given by mechanical and preferably spring means when there is no fluid pressure difference in the two chambers C 1 and C 2 . In this case, the initial distance of the membrane 4 from the entrance of the outlet duct 3 , i.e. the distance of said membrane from the entrance of the outlet duct 3 when there is no a substantial pressure difference between the fluid pressure in the two adjacent chambers C 1 and C 2 divided by the membrane 4 , is modified by acting on the membrane moving closer and/or farther away from said entrance of the outlet duct 3 on the basis of a deformation caused by mechanical means, which is adjustable.
[0075] Different embodiments are possible providing a pressing member that is rigid or elastically pliable and that can be pushed with a different force against the membrane on the side thereof faced towards the chamber C 1 , wherein the fluid inlet duct comes out directly connected to the supplying source.
[0076] Means for adjusting said pressing force can be provided in different configurations, to be all considered within the reach of the person skilled in the art, and also in different constructional choices.
[0077] A preferred and advantageous embodiment that is shown in FIGS. 5 to 6 provides a construction similar to the one of the previous embodiment, but in this embodiment the wall 201 is made like a cup or at least with an end face faced towards the membrane that is made hollow like a cup, and the shell peripheral wall 501 forms a step-like enlargement supporting the outer peripheral band of the membrane. The step-like enlargement 601 is the same as the flange 5 in the previous embodiment, while like the embodiment of FIGS. 1 to 3 , the end wall member 201 can be axially moved towards the inlet duct, i.e. towards the end wall 101 of the cup-like member delimiting the chamber C 1 that is associated to the inlet mouth 2 .
[0078] A spring member, for example a coil spring 6 is interposed between the wall 101 and the cup-like member, i.e. the end wall 101 associated to the inlet mouth 2 and the faced side of the membrane 4 , that is, the side thereof faced towards the end wall 101 bearing the inlet mouth 2 .
[0079] The member 201 can be moved with respect to the cup-like member according to one of the modes described with reference to the previous example, for example by tightly screwing and/or unscrewing it inside the shell wall 301 of the cup-like member delimiting the chamber C 1 , particularly when the pieces have a cylindrical shape or a rotational or cylindrical symmetry shape defined above in more details. In this case, it is to be noted that the membrane 4 , that is the flange supporting it, is integrated in the body 201 and so it moves together with the surface of the extension axial projection 401 of the outlet duct 3 , therefore the movement of the body 201 does not lead to a change of the distance between the mouth of the outlet duct 3 and the flange supporting the membrane as in the previous example, but causes only the membrane 4 to go closer or farther away from the end surface 101 bearing the inlet mouth 2 , and so it causes the coil spring 6 to be pressed at a greater or lower extent determining a deformation of the membrane 4 that can change depending on the compression of the spring 6 . Therefore, when there is no fluid pressure difference in the two chambers C 1 and C 2 , it is possible to previously set a deformation of the membrane 4 corresponding to a different distance between it and the entrance of the outlet duct 3 and consequently a different flow rate.
[0080] Like in the previous example, the casing 11 can have also other configurations different from the shown configurations, that however involve some functional and constructional advantages such as, for example, the screw coupling between the member 201 and the shell perimetric wall 301 of the cup-like member, and also the fact that the membrane spring member inlet mouth 2 and outlet duct 3 are coaxial one with respect to the other, which is achieved by means of the cylindrical shape or of the cylindrical symmetry.
[0081] From the functional point of view, in both the variant embodiments it is possible to previously and manually or mechanically adjust the distance between the membrane and the entrance of the outlet duct when there is no pressure difference between the fluid pressure in the two chambers divided by the membrane, in order to define an operating point of the emitter corresponding to a predetermined flow rate where there is no such pressure difference. Therefore, that allows adapting the operating point of the emitter to average conditions of the supplying pressure such that it is not necessary always to act in extreme conditions of the possible adjusting range. In the first case, the idle distance of the membrane from the entrance of the outlet duct is changed by moving the entrance of the outlet duct from the membrane without changing the membrane configuration, i.e. without a deformation thereof or without the fluid pressure difference in the two chambers. On the contrary, in the second case in said condition without a pressure difference between the fluid pressure in one chamber C 1 and the fluid pressure in the other chamber C 2 the membrane is subjected to a deformation modifying the distance between it and the entrance of the outlet duct. In both cases, when there is no pressure difference between the fluid pressure in one chamber C 1 and the fluid pressure in the other chamber C 2 the flow rate of the emitter is modified.
[0082] With reference to FIG. 7 , the emitter shown in this figure is the one of FIGS. 4 to 6 so like structural parts use like reference numbers. The emitter of FIG. 7 is different from the one of FIGS. 4 to 6 in that along the perimetric shell wall of the cylindrical body 201 closing the open side of the cup-like member being tightly inserted in the cylindrical perimetric wall 301 of such cup-like member there is provided a groove 10 opened towards said shell wall 301 of the cup-like member and making a labyrinth or intricate duct one of the end thereof leading in the chamber C 1 by an axial duct 11 and the other end thereof leading in the chamber C 2 by a terminal duct 12 . Ducts 11 , 12 and the groove 10 together make the communication duct between the two chambers and at the same time they are a means for reducing the pressure. The groove 10 can be an annular one, or it can extend less than a round angle or it can extend for various coils having a helicoidal shape (not shown).
[0083] By way of example, in FIG. 7 there is also shown the seal 13 between the cup-like member and the cylindrical body, and in this example it is housed in a corresponding annular outer groove 14 of the cylindrical body and is interposed between the groove and the inner surface of the shell wall 301 of the cup-like member.
[0084] The example of FIG. 8 show the application of variants provided in FIG. 7 to the embodiment of FIGS. 1 to 3 in combination with the embodiments of FIGS. 4 to 6 .
[0085] With reference to FIGS. 9 and 10 , there is shown a further variant embodiment that is different from the preceding variants in that it provides means cooperating with the membrane, which are stationary means pressing thereon when the two casing parts are brought one closer the other for more than a certain extent, so that the membrane gets closer to the inlet of the chamber C 1 for more than a certain minimum extent.
[0086] In the examples of FIGS. 9 and 10 , like reference numbers are used for like structural parts or parts having the same function.
[0087] In the chamber C 1 , the inlet 2 extends towards the membrane 4 with an extension spout 20 extending for a certain length. In an intermediate relative position condition between the two casing parts of the emitter, that is, with the membrane in an intermediate position spaced from the inlet 3 ( FIG. 9 ) the extension spout 20 abuts against the membrane 4 , so the axial outlet port of said spout becomes closed. In such condition a radial or side port 21 provided in the shell perimetric wall of the extension spout 20 guarantees the supply of the fluid in the chamber C 1 . With the membrane 4 moving closer to the inlet 3 , the extension spout 20 acts as a member deforming the membrane 4 ( FIG. 10 ), so the latter becomes bent toward the outlet 3 . By moving the membrane farther away with respect to the position of FIG. 1 , the membrane 4 moves farther away from the extension spout 20 , opening the axial supply duct and so increasing the supply flow in the chamber C 1 .
[0088] As it can be seen from FIGS. 9 and 10 , even in such embodiment there can be provided a pressure reducing device such as in the exemplary embodiments of FIGS. 7 and 8 .
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A self-compensated, adjustable fluid emitter includes a casing externally delimiting a volume, which is divided into a first chamber and into a second chamber by a fixed membrane that can be elastically deformed. An inlet communicates with the first chamber and an outlet communicating with the second chamber, causing the first and the second chambers to be in communication one with the other through a communicating duct. In operation, the membrane becomes deformed such that at least a portion thereof changes its position with respect to the outlet, modifying the flow rate of the fluid through the outlet depending on the pressure difference. Therefore, the flow rate of the fluid through the outlet is controlled and kept constant by the membrane in spite of changes in fluid pressure at least at the inlet or the outlet.
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CROSS-REFERENCE TO OTHER APPLICATION
[0001] This application claims priority from No. 60/269,999 filed Feb. 20, 2001, which is hereby incorporated by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates to tools for cutting hard, non-metallic materials including abrasive wood and wood-based composites. More specifically, tools of interest include circular saws, milling cutters, routers, panel cutters and similar tools whose cutting edges can be fabricated from blanks of ultrahard polycrystalline cubic boron nitride (CBN) or the like.
[0003] Background: Woodworking Tools
[0004] Tooling for woodworking-type applications has some significant differences from the requirements of metalworking. (Many of the materials which are cut in woodworking-type applications are not merely wood, and sometimes not wood at all: particleboard and oriented-strand fiberboard, as well as non-wood polymers such as Melamine™ or other inorganic-loaded durable composites, may be encountered.) Common features of woodworking-type applications include air cooling (and associated high tooth speeds), workpiece materials with shear strengths much lower than ferrous metals, high shock loading (in many cases), and high abrasion. (Even among pure wood materials, many include microparticles of silicon dioxide, and composite materials may contain very abrasive filler components.)
[0005] Background: Carbide-Toothed Circular Saws
[0006] Cutting tools (especially woodworking tools) often use inserted teeth of a material which is harder than the hardest of steels. The most common material used for this is a “cemented carbide,” which typically includes small grains of tungsten carbide bonded into a matrix with a metal (typically cobalt). (Because the strength and hardness of the matrix are derived from the grains of tungsten carbide, such cemented carbides are often referred to simply as “carbide.”) Such “carbide” saw tips have a hardness of about 92 (Rockwell A).
[0007] Some firms manufacture only the steel bodies of circular saws, which are hardened, tempered and finished in every way except for tipping, and are then sold to other saw manufactures who specialize in carbide tipping. Other firms manufacture the complete saws including both the steel bodies and the installed tips. In either case, the same standard carbide tips are used in the fabrication of the blades. The steel bodies are normally made of high-carbon alloy tool steel, then a pocket is ground into the periphery of the saw body to accommodate the carbide tips. The tips may be ¼ to ⅜ inches long, 0.062 to 0.093 inches thick and from 0.10 to 0.375 inches wide, depending on the width of the finished saw blade.
[0008] In the woodworking industry, carbide tipped saws are typically 8 to 20 inches in diameter. Depending on their function, the 8 inch blades may have between 24 and 48 teeth, and the larger saws 60 to 100 teeth. For cutting non-ferrous metals, the number of teeth is typically between 24 and 80 for saws ranging from 8 to 18 inches in diameter. However, saws with greater tooth density (i.e. more teeth per inch) would be required to produce superior finishes and to cut thin materials.
[0009] Background: Ultrahard Cutting Tool Materials
[0010] Carbides were invented in the 1920s, and the search for better cutting materials continues to this day. In general, the ideal cutting tool surface should combine abrasion-resistance (hardness) with shock-resistance (toughness). (Of course there are many other relevant properties, including yield strength, rigidity, temperature limits, corrosion resistance in some applications, etc.) Materials which are harder than carbides are particularly interesting for woodworking applications, as well as many other applications.
[0011] In early 1970s, General Electric Company introduced a variety of Polycrystalline Diamond (PCD) cutting tool materials consisting of a layer of micron-sized diamonds integrally bonded with a carbide substrate. These man-made ultrahard crystalline and polycrystalline compounds have become readily available from commercial sources in a variety of grades, making possible tremendous advances in cutting tool design.
[0012] In practice, thin layers of PCD or CBN are bonded to a disk of tungsten carbide substrate ranging from 60 to 100 mm in diameter. The process requirements are extreme, e.g. 1300° C. and tens of thousands of atmospheres of pressure. These bonded disks, or wafers, generally have a combined thickness of around 3 to 4 mm with PCD or PCBN forming a single-sided layer 0.1 to 0.3 mm thick. The substrate face of tungsten carbide is ground flat and overall thickness is further reduced by grinding to one of several industry standard dimensions.
[0013] Then, using sophisticated computer controlled wire electrical discharge machine tools, the wafers are sliced into squares, rectangle, and round shapes dimensionally similar to standard carbide blanks and inserts. Ultimately, these “preforms” are ground into final dimensions for lathe tools or otherwise incorporated onto tool steel bodies in the same manner as carbide tips and inserts, and are sharpened by various special techniques.
[0014] The diamond layer's abrasion resistance, coupled with the carbide's strength, produced a cutting tool material that achieved a tremendous increase in machining performance over other available materials, tungsten carbide, for example. PCD is primarily used in non-ferrous metalworking applications such as copper and aluminum or to machine plastics, rubber, synthetics, and laminates. It had also found widespread use in sawing and shaping medium-density fiberboard and chipboard in the furniture industry. Unfortunately, notwithstanding is superb properties, it reacts chemically with iron and steel and cannot be used to machine any steel alloy.
[0015] Polycrystalline Cubic Boron Nitride (PCBN) is used for machining ferrous materials such as gray cast iron. PCBN is manufactured like PCD, except that a layer of cubic boron nitride crystals replace the diamond. Excellent machining results are obtained with PCBN-based tools in finish-turning work on nickel-based alloys. Because of its great hardness and wear resistance, PCBN cutting tools can be used at high cutting speeds and temperatures. In addition to higher available cutting speeds and excellent wear behavior, PCBN cutting materials achieve longer tool lives, allowing parts to be finished in a single cut, reliably attaining high accuracy over a long machining time.
[0016] Both PCD and PCBN provide major improvements over conventional carbide cermets, and it is now possible to machine substances that have previously been extremely difficult to fabricate. The most common ultrahard materials used in modern tools are polycrystalline diamond (PCD), which is 3.6 times harder than tungsten carbide, and cubic boron nitride (CBN), which is 2.8 times harder than carbide. However, the very properties of hardness and abrasion resistance that make polycrystalline tools superior cutting devices also make these tools extremely difficult to grind and finish.
[0017] Background: Cost Considerations for Ultrahard Materials
[0018] Despite their extraordinary performance, the application of these ultrahard materials is frequently limited by their high cost, which is at least ten times that of tungsten carbide. In addition, because of their extreme hardness, they can only be shaped with varying degrees of difficulty. PCD can only be ground by special diamond grinding wheels that are no harder than the PCD, and therefore, have a short service life. Other means of shaping PCD include electrodischarge machining (EDM) by either wire or shaped carbon electrode methods. Both of these methods require expensive, specialized computer controlled equipment that further adds to the cost of the tools in which they are incorporated.
[0019] The cost of polycrystalline diamond (PCD) and cubic boron nitride (CBN) are approximately the same. One might think, therefore, that absent diamond's inability to machine ferrous materials, there would be no practical use for PCBN which is less hard and less resistant to abrasion than PCB. Presumably because of the technical superiority of PCD over PCBN, no manufacturer recommends PCBN for wood, wood—composite products or plastics. Further, no toolmaker supplies tools for these applications.
[0020] Background: Grit-Surfaced (Non-Toothed) “Saws”
[0021] A common type of cutting tool is a circular blade which does not have shaped teeth at its edge, but which is simply coated with a diamond grit. Such cutting tools are commonly referred to as diamond “saws,” but in fact they do not perform the same type of material-removal action as is performed by a saw with shaped teeth. A saw with shaped teeth, when it is operating correctly, will carve off chips of material. By contrast, a grit-coated blade will have more of a scraping or abrasive action. (See generally Jim Effner, Chisels on a wheel (1992); and Peter Koch, Utilization of Hardwoods Growing on Southern Pine Sites (1985); both of which are hereby incorporated by reference.) A cutting action is greatly preferable for many applications, to produce a cleaner cut, lower temperature, and lower power requirements.
[0022] Polycrystalline Cubic Boron Nitride (PCBN) Woodworking Tools and Methods
[0023] The present inventors have discovered that PCBN cutting tips can be accurately ground with the same equipment commonly used to fabricate high quality tungsten carbide tools, with substantially the same geometries, and with only slight modifications of technique. Thus it turns out that, for woodworking applications, PCBN tooling is much more nearly analogous to carbide than to diamond. This is quite contrary to common belief in the industry, and radically changes the economics of PCBN tooling.
[0024] There are severe restrictions on tooth geometry of PCD tools, particularly the hook angle: the use of positive hook angles (as is usual with circular saws for woodworking) can cause PCD tools to chatter or to suffer fracture. (Hook angle is the angle of the leading face of the tooth: if the tooth is angled to pull workpiece material back toward the center of the blade, it is said to have a positive hook angle.) Thus use of very small or negative hook angles is necessary with PCD tools. The geometry of PCBN cutters however, can be made to very closely approximate those of proven carbide tools, i.e. positive hook angles can be used for faster and cooler cutting.
[0025] A profound advantage of PCBN over PCD in all but the largest operations, is that PCBN tools can be maintained using modified $20,000 grinding machines where PCD requires an electrodischarge machine costing ten times as much. This makes on-site or near site service feasible, reduces tool repair costs, turnaround time, and the inventory cost of spares.
BRIEF DESCRIPTION OF THE DRAWING
[0026] The disclosed inventions will be described with reference to the accompanying drawings, which show important sample embodiments of the invention and which are incorporated in the specification hereof by reference, wherein:
[0027] [0027]FIG. 1 shows a circular saw blade using the novel cutting tips of the present application.
[0028] [0028]FIG. 2A shows a section of a conventional circular saw blade like that of FIG. 1, with diamond-tipped teeth set with a negative hook angle.
[0029] [0029]FIG. 2B shows a section of a circular saw blade like that of FIG. 1, with teeth having a zero negative hook angle.
[0030] [0030]FIG. 2C shows a section of the circular saw blade of FIG. 1, with cubic-boron-nitride-containing teeth set with a positive hook angle.
[0031] [0031]FIG. 3 shows an example of another cutting tool which can use teeth like those of FIG. 2C, and also shows how hook angle is measured in such tools.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] The numerous innovative teachings of the present application will be described with particular reference to the presently preferred embodiment (by way of example, and not of limitation).
[0033] At first appearance, it would appear that PCBN could not compete with PCD in the areas amenable to PCD applications. PCD is harder than PCBN and tests on certain materials show that it is less resistant wear. However, studies and experiments by the present inventors have indicated that wear due to abrasion is most important, and that wear tests of PCBN conducted on hardened steel at 600° C. are not necessarily applicable to cutting wood products where sharpness and edge retention are paramount. At this juncture we have not proved that wear characteristics of PCBN woodworking tools are inferior to PCD at all (although this is suspected from physical properties).
[0034] It turns out that most carbide tools compete with other carbide tools and not with PCD. If PCBN tools can be produced at five times the cost of carbide tools (a realistic expectation, especially if using the novel tooth configuration of Ser. No. 09/469,673, which is hereby incorporated by reference) and PCBN outlasts carbide by 20 fold, it is quite feasible to economically use PCBN tools in wood-product applications.
[0035] It has been discovered, through experimentation and field test that rotating tools (e.g. saws, shapers, and routers) tipped with Polycrystalline Cubic Boron Nitride (PCBN) cutting elements, perform extremely well in the shaping of medium-density fiberboard and chipboard material. These tools were made in the laboratory of Sheffield Saw and Tool using readily available preforms from two of the major suppliers of PCBN.
[0036] In a sample embodiment, the cutting tips are commercial carbide-backed BZN boron nitride (from GE), supplied in widths about 0.040″ over that required. The cutting tip blanks were brazed into place using a standard low-melting-point high-Ag silver solder (Handy and Harmon Eazy-Flow-3, in a sample embodiment).
[0037] Top grinding was done with a Vollmer CHC 020 machine, and side grinding was done with a Vollmer FS2A dual side-grinder. (These are machines which are normally used for grinding carbide teeth, and are NOT suitable for grinding diamond teeth.) Triple-chip tooth geometry was used in a sample embodiment, but other geometries can be used, including alternate top bevel (ATB), conical ATB, ATB/chamfer, flat, conical-flat, and trapezoidal, for example.
[0038] Both single- and dual-grit diamond wheels have been used successfully.
[0039] In a sample embodiment, diamond grit sizes from 200 to 800 grit have been used, i.e. closely comparable to those which would be used for sharpening a carbide-toothed blade.
[0040] However, a notable difference is that the feed rate must be less for grinding boron nitride-tipped cutters than for conventional carbide-tipped ones. In a sample embodiment, the feed rate was reduced to 50% of that which would be used for grinding conventional saw tooth carbides.
[0041] The hook angles of the PCBN teeth were typically set at about 5 degrees less than would be used for a positive-hook carbide tooth application. Thus for a rough ripping application, where a carbide tooth might be set at 20° or more, a PCBN tooth would be given a hook angle of e.g. 15°. (However, PCBN teeth are believed to be less economical for such applications, due to the high density of foreign objects encountered.) The key point is the PCBN teeth can be given a hook angle which is less positive than that of carbide teeth, but significantly more positive than would be possible with diamond teeth.
[0042] Performance comparison against carbide shows that the PCBN tools outperform carbide by at least a factor of 50. An accurate performance index is difficult to compute, because the lifetimes of the PCBN tools are so extremely long.
[0043] A test was also run to compare an experimental PCBN saw with a conventional PCD saw. The operator who was using a PCD saw on a trial basis complained that the force required to push the saw through the material was excessive compared to a carbide blade. No problem was experienced with a PCBN blade, probably because the hook angle was comparable to that on a carbide blade.
[0044] [0044]FIG. 1 shows a circular saw blade 110 using the novel cutting tips of the present application. As described above, the body 102 will typically be a steel plate, typically with appropriate tensioning for flatness under load. Radius R, reproduced in the following figures, will be used to show how the tooth geometry relates to the central hole 104 .
[0045] [0045]FIG. 2C shows a section of the circular saw blade of FIG. 1, with cubic-boron-nitride-containing teeth 103 A/ 103 B set with a positive hook angle. Note that the blade's radii do NOT lie in the face plane of each tooth. Preferable these teeth, as described above, include a PCBN layer 103 B on a tungsten carbide layer 103 A. The positive hook angle shown in this Figure has been slightly exaggerated for clarity, but is preferably more positive than would be used with diamond-coated teeth. Hook angles differ with different application, but, for any given application, the hook angle preferably used with the teeth of the presently preferred embodiment is more positive than that which would be used with diamond, and preferably is closer to the angle which would be used (for that application) with a carbide tooth rather than a diamond tooth.
[0046] [0046]FIG. 2A shows a section of a conventional circular saw blade, with diamond-tipped teeth set with a negative hook angle. In this example two instances of the radius R are shown, to show how the tooth face plane relates to the blade radius: note how each tooth is leaning slightly backwards (opposite to the geometry of FIG. 2C).
[0047] For clarity, FIG. 2B shows a section of a conventional circular saw blade 110 ″ in which the teeth are set with a zero negative hook angle.
[0048] [0048]FIG. 3 shows an example of another cutting tool which can use teeth like those of FIG. 2C, and also shows how hook angle is measured in such tools. The solid line is normal (perpendicular) to the cutting tooth circle (which in this example has infinite radius, i.e. is a straight line), and the dotted line shows the face plane of a tooth. In this example the teeth are set with a slight “scooping” angle, i.e. have positive rake.
[0049] Definitions:
[0050] Following are short definitions of the usual meanings of some of the technical terms which are used in the present application. (However, those of ordinary skill will recognize whether the context requires a different meaning.) Additional definitions can be found in the standard technical dictionaries and journals.
[0051] Braze: to solder with brass or other hard alloy.
[0052] Carrier Blade: a blade, typically made of steel, to which a cutting tip is attached.
[0053] Carbide: a material more commonly referred to as cemented carbide which typically includes small grains of tungsten carbide bonded into a matrix at high temperatures and pressure by another metal which is typically cobalt. The name cemented carbide comes from the fact the both the strength and hardness of the substance are derived from the compound of tungsten and carbon (WC), and another material (frequently cobalt) serves merely as a binder.
[0054] Chatter: as used herein is vibration or movement of the cutting tool engaged in the cut due to exterior forces applied against an inadequately supported cutting tip.
[0055] Cutting Tip: a material that is usually harder than steel that is attached to the tips of a carrier blade to provide a harder cutting surface. (See FIGS. 1, 2, and 3 for an illustration).
[0056] Solder: to make a tight junction of metallic sheets, piping, and the like, by the application of a molten alloy.
[0057] Tungsten Carbide: (WC), a cemented carbide which is harder than steel.
[0058] Pocket: an indention in a carrier blade shaped to receive a cutting tip. (See FIGS. 1, 2, and 3 for an illustration).
[0059] Superhard Material: any material harder than steel.
[0060] Ultrahard Materials: any material harder than tungsten carbide, including but not limited to polycrystalline diamond (PCD) and cubic boron nitride (CBN).
[0061] Modifications and Variations
[0062] As will be recognized by those skilled in the art, the innovative concepts described in the present application can be modified and varied over a tremendous range of applications, and accordingly the scope of patented subject matter is not limited by any of the specific exemplary teachings given.
[0063] For example, the described methods and geometries are not solely applicable to woodworking-type applications, but can also be applied advantageously to other applications where abrasion resistance is a high concern (such as precision machining of uncured or partially-cured ceramic structures).
[0064] It should also be noted that the disclosed inventions are applicable to manual-feed as well as to automatic grinding machines.
[0065] Note also that, although woodworking applications are preferred, boron nitride teeth can also cut ferrous materials (unlike diamond teeth).
[0066] None of the description in the present application should be read as implying that any particular element, step, or function is an essential element which must be included in the claim scope: THE SCOPE OF PATENTED SUBJECT MATTER IS DEFINED ONLY BY THE ALLOWED CLAIMS. Moreover, none of these claims are intended to invoke paragraph six of 35 USC section 112 unless the exact words “means for” are followed by a participle.
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Cubic boron nitride tooling, e.g. for woodworking, is fabricated with the same geometries and machinery as is used for fabricating conventional carbide tooling.
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My invention is directed to uniquely shaped slab elements for covering the ground or other like surfaces. Specifically, my invention is directed to such slab elements which can be combined with other like slab elements in a variety of different orientations to form stable load-carrying surfaces in a multiplicity of different patterns.
Slab elements of differing shapes have been employed in the construction of traffic-carrying surfaces such as roadways, footways, embankments and pool decks. Typically, the slab elements are made of concrete, formed in desired shape in molds, and cured under high pressure where the slab material is compacted and hardened into the desired shape in the mold, and removed from the mold and exposed to ambient air to complete the curing cycle. The method by which such slab elements can be made are well known in the art and form no part of my invention. Hence, methods for making slab elements will not be addressed further except to note that the shape of the molds used to form prior art slab elements must be modified so as to conform to the shape of my slab elements. To construct a surface employing slab elements, the under-surface is prepared in known fashion to provide a smooth flat surface upon which to place the slab elements. The slab elements are placed one at a time such that their vertical or peripheral walls or edge faces come into close contact. The gaps between edge faces may be filled either with mortar, concrete, or other such solidifying spacer element, or, preferably, with sand which is simply poured into the gaps in a known manner. My invention is ideally suited to the latter, less costly method. The traffic load encountered by surfaces constructed in the above manner can vary from as light as pedestrian traffic to as heavy as several ton trucks and forklifts.
Slab elements employed for traffic surfaces have come in a wide variety of shapes from square and rectangular to multi-sided and irregular shaped surfaces, but a slab element's shape is known to affect the ground cover's load carrying capacity and durability. When viewed from the top, such slab elements generally fall into one of three basic categories.
The first category is a slab element which has a known and simple geometric shape, such as a rectangle, a square, a hexagon, or an octagon. This catergory is less desirable than other categories hereinafter discussed because their shapes preclude an interlock joint between adjacent slab elements. Additionally, proper utilization can require greater material and care than other slab elements and are often not satisfactory in use. For example, if such slab elements were placed in the manner expected of my invention, i.e., with sand between them, the surface would not be stable because there is no interlock. Furthermore, because there is no interlock, long, straight channels are more easily formed between the elements thus permitting rain, for example, to wash away the sand further reducing the load carrying stability of the ground cover formed with those elements. Hence, such slab elements would typically require mortar or concrete between elements. Mortar or concrete are typically more expensive than sand and are more difficult to work with.
A second category of slab element is one wherein, from a top plan view, the slab element looks substantially rectangular but the edges are deformed in such a manner as to interlock when laid next to an adjacent, identical stone. Examples of second category slab elements are shown in U.S. Pat. No. 2,919,634 and U.S. Pat. No. 3,494,266. Also included in this category are cetain multi-faced irregularly shaped slab elements such as that disclosed in U.S. Pat. No. Des. 82,970. The slab elements disclosed in the aforementioned patents overcome some of the drawbacks of slab elements discussed in the preceding paragraph because they may be interlocked. However, they are less attractive from an aesthetic standpoint. Moreover, the slab elements in this category generally may not be intermixed with other differently shaped second category slab elements as would be possible with first category slab elements to permit a wide variety of patterns to be created.
A third category of slab element, and the one with which my invention is concerned, overcomes the drawbacks of both first and second category slab elements. A third category slab element is comprised of two or more sections having the shape of first category slab elements which are combined into one integral slab element. An example of such a slab element is disclosed in U.S. Pat. No. 4,128,357. The slab element of that patent has a main section which is of a known octagonal shape, and a tail section which is of a known square shape, with the main and tail sections being formed as one slab element. The primary advantage of such an integral slab element is that it can interlock for durability and stability. A disadvantage, however, is that it is susceptible of only a few different interlocking patterns.
Another example of an interlocking slab element, referred to as a trillium design, is shown in the brochure entitled, "Munich Two Interlocking Paving Stone" from Unilock, Ltd. of Georgetown, Ontario. The trillium design is comprised of three regular hexagonal shaped sections to form a cloverleaf pattern. As already stated with respect to second category slab elements, the currently employed third category slab elements suffer a major disadvantage in that they do not lend themselves to a sufficient number of differing patterns.
An objective of my invention is to provide a slab element which lends itself to forming a large number of different, attractive, interlocking patterns. This objective is accomplished by providing a slab element which has a main hexagonal section and at least one tail section integral therewith which are oriented substantially in one plane. The main section has a first pair of adjoining minor peripheral edges or faces and a second pair of adjoining minor peripheral edges or faces with the first and second pairs of minor peripheral edges or faces being oppositely disposed in spaced-apart relationship. The main section further has a pair of spaced apart, parallel major peripheral edges or faces interconnecting the first and second pairs of minor peripheral faces. The tail section has four minor peripheral faces or edges, with one of the four minor faces of the tail section being substantially coextensive in size and shape and spacially coincident with one of the minor faces of the main section. Finally, each of the major peripheral faces is approximately twice the length of the minor faces. Preferably, in such a slab element, the intersection of each major face with the adjoining minor face defines an angle of approximately 135°, and the minor faces of the tail section define substantially a square.
By means of the foregoing angular and length relationships of that peripheral face, adjacent slab elements can be arranged in a wide variety of orientations relative to each other to provide many different interlocking patterns.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a first preferred embodiment of a slab element of my invention for covering the ground and the like.
FIG. 2 is a front elevational view of the slab element of FIG. 1.
FIG. 3 is a top plan view of the slab element of FIG. 1.
FIG. 4 is a bottom plan view of the slab element of FIG. 1.
FIG. 5 is a rear perspective view of the slab element of FIG. 1.
FIG. 6 is a top plan view of a mirror image of the slab element of FIG. 1 and is another preferred embodiment of a slab element according to my invention.
FIG. 7 is an isometric view of another preferred embodiment of a slab element of my invention.
FIG. 8 is a top plan view of the slab element of FIG. 7.
FIG. 9 is a bottom plan view of the slab element of FIG. 7.
FIG. 10 is a rear elevational view of the slab element of FIG. 7 as seen along line 10--10 of FIG. 8, the front elevational view being a mirror image thereof.
FIG. 11 is a right side elevational view of the slab element of FIG. 7 as seen along line 11--11 of FIG. 8, the left side elevational view being a mirror image thereof.
FIG. 12 is an isometric view of a further preferred embodiment of a slab element according to my invention.
FIG. 13 is a top plan view of the slab element of FIG. 12.
FIG. 14 is a bottom plan view of the slab element of FIG. 12.
FIG. 15 is a right side elevational view of the slab element of FIG. 12 as seen along line 15--15 of FIG. 13, the left side elevational view being a mirror image.
FIG. 16 is a front elevational view of the slab element of FIG. 12 as seen along line 16--16 of FIG. 13.
FIG. 17 is a rear elevational view of the slab element of FIG. 12 as seen along line 17--17 of FIG. 13.
FIG. 18 is a top plan view of a still further preferred embodiment of a slab element according to my invention.
FIG. 19 is a bottom plan view of the slab element of FIG. 18.
FIG. 20 is a front elevational view of the slab element of FIG. 18 as seen along line 20--20 of FIG. 18.
FIG. 21 is a rear elevation view of the slab element of FIG. 18 as seen along line 21--21 of FIG. 19.
FIG. 22 is a right side elevational view of the slab element of FIG. 18 as seen along line 22--22 of FIG. 18.
FIG. 23 is a left side elevational view of the slab element of FIG. 18 as seen along line 23--23 of FIG. 18.
FIG. 24 is a top plan view of a repeating first closed pattern with the slab elements of FIG. 1.
FIG. 25 is a top plan view of a repeating second closed pattern with the slab elements of FIG. 1.
FIG. 26 is a top plan view of a repeating third closed pattern with the slab elements of FIG. 1.
FIG. 27 is a top plan view of a repeating fourth closed pattern with the slab elements of FIG. 1 and FIG. 6.
FIG. 28 is a top plan view of a repeating fifth closed pattern with the slab elements of FIG. 1 and FIG. 6.
FIG. 29 is a top plan view of a sixth closed pattern with the slab elements of FIG. 1 and FIG. 6.
FIG. 30 is a top plan view of a seventh closed pattern with the slab elements of FIG. 1 and FIG. 6.
FIG. 31 is a top plan view of an eighth closed pattern with the slab elements of FIG. 1.
FIG. 32 is a top plan view of a repeating first open pattern with the slab elements of FIG. 1 and FIG. 6.
FIG. 33 is a top plan view of a repeating second open pattern with the slab elements of FIG. 1 and FIG. 6.
FIG. 34 is a top plan view of a repeating third open pattern with the slab elements of FIG. 1.
FIG. 35 is a top plan view of a repeating fourth open pattern with the slab elements of FIG. 1 and FIG. 6.
FIG. 36 is a top plan view of a repeating fifth open pattern with the slab elements of FIG. 1 and FIG. 6.
FIG. 37 is a top plan view of a first edger.
FIG. 38 is a top plan view of a second edger.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With particular reference to FIGS. 1 through 5, there is shown a slab element 1 comprised of a main hexagonal section 2 and an integral square tail section 3. The main hexagonal section 2 is comprised of six lateral faces or edges 4 through 9 around the periphery thereof. Face 4 is referred to as a first major face, and is exposed. First major face 4 adjoins a minor face 5, which is internal, to form an included angle 14 of approximately 135°. First minor face 5 adjoins a second minor face 6, which is exposed, to define an included angle 15 of approximately 90°. Second minor face 6 adjoins a second major face 7, also exposed, to define an included angle 16 of approximately 135°. Second major face 7 adjoins a third exposed minor face 8 to define an included angle 17 of approximately 135°. Third minor face 8 adjoins a fourth exposed minor face 9 to define an included angle 18 of approximately 90°. Fourth minor face 9 adjoins the first major face 4 to define an included angle 19 of approximately 135°. Each of the minor faces 5, 6, 8 and 9 are equal in length and preferably about three inches. Major faces 4 and 7 are equal in length and twice the length of any of the minor faces 5, 6, 8 and 9 and are, thus, preferably approximately six inches in length. The faces 4, 5, 6, 7, 8, and 9 lie in planes which are substantially perpendicular to the planes containing the upper and lower surface 1a and 1b, respectively, of the slab elements.
The tail section 3 is comprised of four adjoining minor lateral faces 10, 11, 12 and 13 around the periphery thereof, each of which is equal in length to the minor faces 5, 6, 8 and 9 of the hexagonal main section 2. The four minor tail faces 10, 11, 12 and 13 preferably define substantially a square when viewed from the top as in FIG. 2. Of faces 10, 11, 12, and 13, only face 10 is internal; the others are exposed.
The tail section 3, which is integral to hexagonal main section 2 to form the slab element 1, adjoins at its minor internal face 10 the hexagonal main section 2 along first minor internal face 5 thereof. Minor face 10 and first minor face 5 are substantially coextensive in size and shape and spatially coincident with each other such that no portion of either of those faces extends beyond the other. The vertical plane along which minor face 10 and first minor face 5 spatially coincide is indicated by reference numeral 21. In my preferred embodiments, the upper edge of each minor and major face of each main and tail section is chamfered as indicated by reference numerals 20, 20. The chamfer is preferably 6 mm. in height and 4 mm. in depth and, as shown in FIG. 2, starts inwardly from the outer wall of the face towards the interior of its respective main or tail section 2 or 3. When the slab element 1 is thus provided with chamfers 20, 20, upper edge 21a of plane 21 may be viewed as a false joint in which case two identifiable polygons of known shape, namely, a hexagon and a square, are clearly discernible in slab element 1 as is especially shown in FIG. 2.
Alternately, slab element 1 need not be provided the chamfers 20, 20 and would then appear as in the bottom plan view of FIG. 3.
In order to provide an even further variety of design from that available with the slab element 1 shown in FIG. 1, an alternative preferred embodiment generally depicted as 1' is provided as shown in top plan view in FIG. 6. Slab element 1' is identical in all respects to slab element 1 except it is a mirror image thereof. Alternatively, slab element 1' could be obtained by providing slab element 1 with chamfers 20, 20 on both the upper edge as shown as well as along the bottom edge (not depicted) and turning slab element 1 over. Providing a slab element 1 having chamfers 20, 20 along the upper edge and the bottom edge eliminates the need for an alternative slab element 1', but is not generally desirable in that false joint 21 will be created on both the top and the bottom of the slab element creating unnecessary stress concentrations and leaving less material to maintain the two sections as one integral element. Such weakening at the false joint is not desired in that the slab element could break more easily at the joint 21a under the stress of a heavy load, thereby losing the interlock feature sought by my invention. Moreover, having chamfers 20, 20 along the bottom edge of slab element provides an opportunity for the sand between the slab elements to slowly fill the crevices left by the chamfers on the bottom, causing the slab elements to come loose or have less stability when they are provided in an overall pattern to cover the ground as contemplated by my invention.
As more fully discussed hereinafter, a ground cover may be made by using any substantially L-shaped slab element comprised of two or more different integral sections of simple geometric shape which meet certain dimensional criteria. When such L-shaped sections are disposed in a common plane, adjacent slab elements are capable of having a wide variety of orientations with respect to each other and can result in a vast number of different interlocking patterns. To satisfy the criteria of my invention, the slab element must meet the following dimensional criteria with respect to included angles and length of faces:
(A) The slab element must be L-shaped and comprised of simple geometric integral sections;
(B) Each included angle must be a multiple of 45°;
(C) The length of each face must be a multiple of a predetermined length X;
(D) The internal spatially coincident faces of adjoining sections must be coextensive in size and shape;
(E) The length of each face must be approximately equal to the predetermined length X;
(F) The following formula must be satisfied for each included angle in each section:
φ=(n/X+Z-2)45°
where
φ=included angle
Z=total number of sections in slab element
n=sum of length of the two faces defining the included angle
X=predetermined length as set forth above.
As an example, referring to FIG. 1, included angle 18 maybe determined as set out above.
Let X =3 in. n=the sum of the length of minor faces 8 and 9, each of which is 3 in. Hence, n=6 in. Z=2 as there is one main section 2 and one tail section 3. Thus, φ for included angle 18=(6 in/3 in+2-2)45°=90°. Similarly, φ for included angle 17=((3 in+6 in)/3 in+2-2)45°=135°. A review of each angle shows that it satisfies the above criteria. Hence, my slab elements 1 and/or 1' are particularly advantageous due to their ability to provide a multiplicity of different patterns which are aesthetically acceptable while employing a generally L-shaped slab element to provide the interlock feature.
FIGS. 24 through 36 show some of the many varied patterns of ground covers which can be obtained by using slab elements 1 and/or 1' of my invention. The chamfers 20, 20 and dummy joints 21a have been omitted to facilitate an understanding of the manner in which the patterns may be created, but it is to be understood that it is preferred that elements with such chamfers and dummy joints be employed. Also shown is FIGS. 37 and 38 are a first edger 115 and second edger 116, respectively, which may be employed in known fashion at the periphery of the patterns formed by the ground cover where necessary to fill out the space sought to be covered. In the edgers 115 and 116, the main section 2 of a slab element 1 has been modified to main section 2a or 2b, respectively. It should be readily apparent that edgers are created by eliminating any part of a section along a line formed between two confronting face intersections. Also, preformed edges are preferable to breaking a complete slab element 1 as that could lead to frayed edges and weakened elements.
Typically, the slab elements of my invention will be employed to form one of two types of patterns which I refer to as closed or open patterns. Examples of closed patterns are shown in FIGS. 24 through 31. I have used the term closed pattern to mean that there is no opening in the center or in any interior region of the pattern. Conversely, I have used the term open pattern to refer to patterns such as are shown in FIGS. 32 through 36, in which there is at least one opening in the interior of the patterns. Furthermore, a pattern is repeating where one or more repeaters, as hereinafter described, repeat in similar orientation. As will be more fully understood by reference to the drawing figures, there are a number of basic "repeaters" which are employed in all of the above patterns whether open or closed. These repeaters consist of two of my slab elements 1 and/or 1' in a particular adjoining relationship. For example, a first repeater is indicated generally at 51 in FIG. 24. First repeater 51 consists of two slab elements 1a and 1b in a common plane wherein minor faces 11a and 11b of tail sections 3a and 3b are located proximate to each other. Similarly, second repeater 52 consists of two slab elements 1a and 1b in a common plane wherein minor faces 9a and 9b of main sections 2a and 2b are located proximate to each other. As can readily be seen in FIG. 24, using a multiplicity of first repeaters 51 and second repeaters 52 results in the repeating first closed pattern 50. Upon further inspection, a third repeater 57 may be seen in FIG. 24. Third repeater 57 consists of two slab elements 1a and 1b in a common plane and in which major face 4a of slab element 1a is located proximate to major face 7b of slab element 1b. Third repeater 57 may be employed as was done in FIG. 24 by making rows of third repeaters 57 which alternate between rightside up and rotated 180°. Similarly, rows of third repeaters 57 may be employed wherein all third repeaters have the same orientation as is shown in FIG. 25 as a repeating second closed pattern 55. Also shown in FIG. 25 is a fourth repeater 56 which consists of two slab elements 1a and 1b in which minor face 9a of main section 2a of slab element 1a is located proximate to minor face 11b of tail section 3b of slab element 1b. A fifth repeater 61, shown in FIG. 26, consists of two slab elements 1a and 1b in which major faces 4a and 4b of slab elements 1a and 1b, respectively, are located proximate to each other while their tail sections 3a and 3b are spaced away from each other. As can be easily understood, fifth repeater 61 could consist of two slab elements 1' which is indicated at 61' in FIG. 29. As can also be appreciated, a plurality of fifth repeaters 61 and 61' may be employed either alone or in conjunction with single slab elements 1 and/or 1' to form a multiplicity of different patterns only some of which are depicted in FIGS. 26, 29, 30, 31, 32, 33, 35 and 36.
Sixth repeater 66 is shown in FIG. 27 and, when employed in a repeating fourth closed pattern 65, also utilizes fourth repeaters 56 and 56'. Sixth repeater 66 consists of one slab element 1 and one slab element 1' wherein the first major face 4 of slab element 1 is located proximate to second major face 7 of slab element 1'. Fourth repeater 56' is virtually identical to fourth repeater 56 except that the former is made with slab elements 1' rather than slab elements 1.
As was true of fifth repeaters 61 and 61', third repeater 57 may alternatively consist of two slab elements 1' as shown at 71 in FIG. 28. Further, by combining rows of third repeaters 57 with alternating rows of third repeater 71, repeating fifth closed pattern 70 is created as also shown in FIG. 28. Obviously, other repeaters may be employed with my invention, but I have chosen to illustrate only some of those repeaters for simplicity. One of ordinary skill in the art could readily arrive at other repeaters and configurations from the foregoing. Accordingly, variations thereof are contemplated without departing from the spirit or circumventing the scope of the invention as set forth in the claims hereto appended.
The varied patterns exemplified in FIGS. 24 through 36 employ a large number of slab elements disposed in a common plane with faces of each of most of those slab elements proximately located relative to faces of at least four other slab elements. That the above relationship is met is borne out by examination of any one of the several slab elements contained in the interior, as opposed to the periphery, of the above patterns and the proximate relationship had with the neighboring slab elements.
Although not susceptible to that same variety of patterns, the further preferred embodiment of my invention depicted in FIGS. 18 through 23 do provide an interlocking feature not found with their separate sections due, again, to the L-shape outline of the slab elements. The limited number of patterns possible is due solely to the similarity of each section whereas adjacent slab elements are otherwise capable of having a wide variety of orientations with respect to each other due to meeting the dimensional criteria of my invention.
With reference to FIGS. 18 through 23, there is shown another preferred embodiment of my slab element 120. Slab element 120 has three regular hexagon sections 121, 122, 123 which are integrally made into the one slab element. Each section 121, 122, and 123 may include a chamfer 20 along the upper edge of each face as hereinabove described with respect to slab elements 1 and 1'. The lateral faces 121a through 121f; 122a through 122f; and 123a through 123f of each section 121, 122 and 123, respectively, are all approximately equal in length. Sections 121 and 122 adjoin along faces 121f and 122c. Face 121f of section 121 and face 122c of section 122 are substantially coextensive in size and shape and spatially coincident such that no portion of either of those faces extends beyond the other. The upper edges of the vertical plane along which the two faces coincide is shown by reference numeral 124. When the slab element 120 is provided with chamfers 20, 20, upper edge 124 may be viewed as a false joint. Similarly, sections 122 and 123 spatially coincide at faces 122a and 123d, respectively, which are coextensive in size and shape and coincide along a vertical plane 125. Thus, the slab element 120 clearly defines an overall L-shaped slab element having three identifiable portions of the same regular hexagon shape. A ground cover (not shown) made up of a plurality of slab elements 120 would appear as though comprised of a multiplicity of single regular hexagon slab elements but would have greater stability due to interlocking than previously available for single hexagonal slab elements which do not interlock.
FIGS. 7 through 11, and 12 through 17, depict two additional preferred embodiments, respectively, of a slab element according to my invention. These two additional slab elements are substantially S-shaped rather than L-shaped and satisfy the above dimensional criteria except that φ=(n/X+Z-3)45°, wherein a 3 has been substituted for the 2 in the formula. The respective slab elements 30 and 40 of these two embodiments, comprise three sections, two minor sections located on opposite sides of a single major section, as opposed to the two sections, one major and one minor, of the preferred embodiment slab element 1. Slab element 30, comprises a main hexagonal section 2 and square tail section 3 which are identical in all material respects to the same numbered sections of slab element 1' of FIG. 6. However, unlike slab element 1', slab element 30 includes a second tail section 31. Second tail section 31 is virtually identical to tail section 3 and is comprised of four peripherally adjoining minor lateral faces 32, 33, 34 and 35, each of which is equal in length to the minor faces 5, 6, 8 and 9 of the hexagonal main section 2. Lateral faces 33, 34, and 35 are external while face 32 is internal. As with tail section 3, the minor faces 32, 33, 34 and 35 of second tail section 31 preferably define substantially a square when viewed from the top as in FIG. 8. Finally, second tail section 31 is integral to hexagonal main section 2 and adjoins the hexagonal main section 2 along its now internal minor face 8 at internal minor face 32 of second tail section 31. Minor face 32 and third minor face 8 are substantially coextensive in size and shape and are spatially coincident with each such that no portion of either of those faces extends beyond the other. The vertical plane along which minor face 32 and third minor face 8 spatially coincide has its upper edge designated 36. When the slab element 30 is provided with chamfers 20, 20, 20, edge 36 may be viewed as a false joint in which case, along with false joint 21a, three identifiable polygons of known shape, namely a hexagon and tow squares, are clearly discernible in slab element 30 as is especially shown in FIG. 8.
Similarly, slab element 40 comprises a main hexagonal section 2, square tail section 3, and second tail section 41 which are integral. The main hexagonal section 2 and square tail section 3 are identical in all material respects to the same numbered sections of slab element 1 of FIG. 1. Moreover, second tail section 41 is virtually identical to tail section 3 and is comprised of four adjoining minor lateral faces 42, 43, 44 and 45, each of which is equal in length to the minor faces 5, 6, 8 and 9, of the hexagonal main section. Lateral faces 43, 44 and 45 are external while lateral face 42 is internal. As with tail section 3, the minor lateral faces 42, 43, 44 and 45, of second tail section 41 preferably define substantially a square when viewed from the top as in FIG. 13. Also, as with second tail section 31 in slab element 30, tail section 41 is integral to the hexagonal main section 2 of slab element 40. Second tail section 41 adjoins the hexagonal main section 2 along the now internal fourth minor face 9 of the hexagonal main section 2 at minor face 42 of the second tail section 41. Minor face 42 and fourth minor face 9 are substantially coextensive in size and shape and are spatially coincident with each other such that no portion of either of those faces extends beyond the other. The vertical plane along which minor face 42 and fourth minor face 9 spatially coincide has its upper edge designated 46. When the slab element 40 is provided with chamfers 20, 20, 20, edge 46 may be viewed as a false joint in which case, along with dummy joint 21a, three identifiable polygons of known shape, namely a hexagon and two squares are clearly discernible in slab element 40 as especially shown in FIG. 13.
Slab elements 30 and 40 provide the same interlocking ability as previously described with respect to slab elements 1 and 1'. Slab elements 30 and 40 however do not provide for a ground cover which can have as many varied patterns as are possible with the slab elements 1 and 1'. Slab elements 30 and 40 moreover, are particularly useful in combination with slab element 1 and 1', to provide an overall ground cover which is attractive in appearance.
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An interlocking slab element for covering the ground or the like which has a main hexagonal section and at least one tail section integral therewith which are oriented substantially in one plane. The main section has a first pair of adjoining peripheral edges or faces and a second pair of adjoining minor peripheral edges or faces with the first and second pairs of minor peripheral edges or faces being oppositely disposed in spaced-apart relationship. The main section further has a pair of spaced-apart parallel major peripheral edges or faces interconnecting the first and second pairs of minor peripheral faces. The tail section has four minor peripheral faces or edges, with one of the four minor faces of the tail section being substantially coextensive in size and shape and spatially coincident with one of the minor faces of the main section. Finally, each of the major peripheral faces is approximately twice the length of the minor faces, and the inner section of each major face with the adjoining minor face defines an angle of approximately 135°, and the minor faces of the tail section define substantially a square.
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[0001] This application is a Divisional of co-pending application Ser. No. 11/520,765 filed on Sep. 14, 2006, the entire contents of which are hereby incorporated by reference and for which priority is claimed under 35 U.S.C. §120. This nonprovisional application also claims priority under 35 U.S.C. §119(a) on Patent Application Nos. 094145193 and 095118691 filed in Taiwan, R.O.C. on Dec. 20, 2005 and May 26, 2006, respectively, the entirety of which is herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a package structure, and more particularly, to a light source package structure capable of refracting light therein multiple times for enabling the light to be discharged out of the package structure by a large angle.
BACKGROUND OF THE INVENTION
[0003] Nowadays, it is commonly seen that backlight modules are used for electronic devices with flat panel displays, which includes devices as small as hand-held palm pilots and as large as big-screen TVs. Although most backlight modules still adopt cold cathode fluorescent lamp (CCFL), the utilization of light emitting diode (LED) as the light source of large-sized liquid crystal display (LCD) is becoming popular following the advance of LED technology. As the design challenge of a backlight module is to generate uniform illumination across the LCD surface and luminance that is high enough to produce good contrast in a day environment, LED is preferred over CCFL because it has following advantages: (1) as LED is smaller in size than that of CCFL and it is more solid than CCFL as well, not only the assembly of backlight module can be facilitated, but also the backlight modules adopting LEDs as the light source thereof are lighter and smaller comparing to those CCDL backlight modules; (2) it is noted that the color quality of LCDs adopting LED backlight module is better than that of LCDs adopting CCFL backlight module, since LED can provide a wider color gamut as it is being used in the backlight module for LCDs; (3) Comparing to the mercury-contained CCFL, LED is environmental benign.
[0004] Although LEDs are preferred, it is required to package an LED light source for enabling the light source package to generate uniform illumination across a specific surface and transferring the LED from point light source into surface light source. Please refer to FIG. 1 , which is a cross-sectional view of a LED package disclosed in U.S. Pat. No. 6,679,621, entitled “Side Emitting LED and Lens”. The LED package of FIG. 1 can control the direction of light beams being discharged out of the LED by disposing various refraction surfaces of different shapes at various positions on the LED package, so that the light beams can be emitted out of the LED package in a direction substantially perpendicular to the central axis of the LED package, and thus a side-emitting device with large illuminate areas can be provided. As seen in FIG. 1 , light emitted from near focal point F that is directly incident on reflecting surface I is reflected from surface I to refracting surface H and refracted by surface H to exit the lens of the LED package in a direction substantially perpendicular to the central axis of the LED package. Light emitted from near focal point F that is directly incident on refracting surface 156 is refracted by surface 156 to also exit the lens in a direction substantially perpendicular to the central axis. However, it is noted that the LED package of FIG. 1 can only refract light beams emitted by the LED only once by the lens thereof, and moreover, the process for manufacturing the LED package is complicated since it not only requires a step to form a lens on top of an LED while covering the same, it also requires a step of filling the gap between the lens and the LED by a transparent material using a specific pumping-suction means.
[0005] Moreover, a LED capsule, disclosed in U.S. Pat. No. 6,682,211, entitled “Replaceable LED Lamp Capsule”, uses a housing having a plurality of microstructures formed thereon for reflecting light beams emitted from a LED. However, the forgoing LED capsule is bulky that it is not suitable to be applied as the light source of LCDs.
[0006] In addition, a LED package, disclosed in U.S. Pat. No. 6,670,207, entitled “Radiation Emitter Device Having an Integral Micro-groove Lens”, is able to disperse light emitted from a LED by arranging a lens with micro-grooves in front of the LED. However, as LEDs are not ideal point light sources by themselves, the dispersing of light enabled by the use of the lens with micro-grooves is not as expected, so that the LED package with lens of micro-grooves is not popular.
[0007] Therefore, there is a need for an improved LED package structure capable of overcoming the aforesaid shortcomings.
SUMMARY OF THE INVENTION
[0008] The primary object of the present invention is to provide a light source package structure capable of refracting light therein multiple times for enabling light to be emitted out of the package structure in a direction substantially perpendicular to the central axis of the light source package structure for providing a side-emitting light-emitting device.
[0009] To achieve the above object, the present invention provides a light source package structure, comprising: an accommodating space, for accommodating a light source; a first refraction surface, having at least a tapered structure formed at the upper portion of the same, for receiving light discharging from the light source while refracting the same to form a first refracting light; and at least a second refraction surface, for receiving and refracting the first refracting light to form a first discharging light being emitted out of the light source package structure.
[0010] Preferably, the tapered structure can be a pyramid or a corn.
[0011] Preferably, the first refraction surface is substantially the exterior of a first lens containing the accommodating space therein for enabling the exterior of the light source to be tightly attached to the interior of the accommodating space while sealing the same.
[0012] Preferably, the second refraction surface can be shaped like a round-tipped structure or a tapered structure, whereas the tapered structure can be a pyramid or a corn, and the profile of the round-tipped structure can be defined by an arc.
[0013] Preferably, the first refraction surface is designed as a rugged surface.
[0014] Preferably, the second refraction surface is designed as a rugged surface.
[0015] Preferably, a flat light source can be configured by arranging an array of the light source package structures in a matrix while the matrix is covered and sealed by a material of diffusion capability.
[0016] Preferably, a refraction cap is formed on top of the second fraction surface while enabling the refraction cap to receive and refract the portion of the first refracting light failed to incident to the second fraction surface and thus form a second discharging light emitting therefrom. Moreover, the refraction cap further comprises: a third refraction surface, for receiving and refracting the portion of the first refracting light failed to incident to the second fraction surface and thus forming a second refracting light; a fourth refraction surface, connected to the third refraction surface, for receiving and refracting the second refracting light so as to form a third refracting light; and a fifth refraction surface, connected to the fourth and the second refraction surfaces, for receiving and refracting the third refracting light so as to form a third refracting light so as to form the second discharging light.
[0017] Preferably, the light source package structure further comprises: a refraction cap, disposed outside the second refraction surface while covering the same, for receiving and reflecting the first and the second discharging light incident thereon and thus forming a third discharging light.
[0018] Preferably, a layer of transparent material is coated on the exterior of the light source.
[0019] Preferably, an included angle is formed between the normal vector of a portion of the second refraction surface and the central axis of the light source package structure, whereas the included angle is ranged between 0 degree and 180 degrees.
[0020] Moreover, to achieve the above object, the present invention provides another light source package structure, comprising: an accommodating space, for accommodating a light source; a first refraction surface, having at least a round-tipped structure formed at the upper portion of the same, for receiving light discharging from the light source while refracting the same to form a first refracting light; and at least a second refraction surface, for receiving and refracting the first refracting light to form a first discharging light being emitted out of the light source package structure.
[0021] Furthermore, to achieve the above object, the present invention provides further another light source package structure, comprising: an accommodating space, for accommodating a light source; a first refraction surface, having at least a tapered structure and at least a round-tipped structure formed at the upper portion of the same, for receiving light discharging from the light source while refracting the same to form a first refracting light; and at least a second refraction surface, for receiving and refracting the first refracting light to form a first discharging light being emitted out of the light source package structure.
[0022] In addition, to achieve the above object, the present invention provides a light source package structure, comprising: an accommodating space, for accommodating a light source; a first refraction surface, for receiving light discharging from the light source while refracting the same to form a first refracting light; at least a second refraction surface, for receiving and refracting the first refracting light to form a first discharging light being emitted out of the light source package structure; and a reflection surface, connected to the at least one second refraction surface, for reflecting the portion of the first refracting light emitted from the top of the first refraction surface while enabling the reflected first refracting light to incident to the second refraction surface.
[0023] Other aspects and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a schematic diagram illustrating a conventional LED package disclosed in U.S. Pat. No. 6,679,621.
[0025] FIG. 2A is a three-dimensional diagram showing a light source package structure according to a first preferred embodiment of the invention.
[0026] FIG. 2B is a cross sectional view of FIG. 2A .
[0027] FIG. 2C to FIG. 2F illustrate profiles of the first refraction surface capable of being employed by the light source package structure of FIG. 2B .
[0028] FIG. 2G is a cross sectional view of a light source package structure having a rugged first refraction surface.
[0029] FIG. 3A is a cross sectional view of a light source package structure according to a second preferred embodiment of the invention.
[0030] FIG. 3B illustrates the structure of the refraction cap used in the light source package structure of FIG. 3A .
[0031] FIG. 4 is a cross sectional view of a light source package structure according to a third preferred embodiment of the invention.
[0032] FIG. 5A and FIG. 5B are cross sectional views of light source package structures according to a fourth preferred embodiment of the invention, whereas the two light source package structures have refraction packages of different design.
[0033] FIG. 6A and FIG. 6B are schematic diagrams depicting paths of light being refracted by a light source package structure of the invention.
[0034] FIG. 7A is used to define the viewing angle with reference to a light source package structure of the invention.
[0035] FIG. 7B illustrates the relationship between viewing angle and the intensity of light discharging out of a light source package structure of FIG. 7A .
[0036] FIG. 8A is a cross sectional view of a light source package structure according to a fifth preferred embodiment of the invention.
[0037] FIG. 8B illustrates the relationship between viewing angle and the intensity of light discharging out of a light source package structure of FIG. 8A .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0038] For your esteemed members of reviewing committee to further understand and recognize the fulfilled functions and structural characteristics of the invention, several preferable embodiments cooperating with detailed description are presented as the follows.
[0039] Please refer to FIG. 2A and FIG. 2B , which are respectively a three-dimensional view and a cross-sectional view of a light source package structure according to a first embodiment of the invention. The light source package structure 2 is comprised of an accommodating space 20 for accommodating a light source 9 , a first refraction surface 21 , and at least a second refraction surface 22 . The first refraction surface is disposed superimposing the light source 9 for receiving light discharging from the light source 9 while refracting the same to form a first refracting light, the upper part of the first refraction surface further comprising a refracting structure for refracting the light emitted from the light source, in which at least a tapered structure 210 is formed at the upper portion of the first refraction surface 21 while the first refraction surface 21 is substantially the exterior of a first lens containing the accommodating space 20 therein for enabling the exterior of the light source 9 to be tightly attached to the interior of the accommodating space 20 while sealing the same. It is noted that the tapered structure 210 is a structure can be a pyramid and a corn.
[0040] The light source 9 shown in FIG. 2A can be a simple LED or a LED coated with a layer of conventional transparent material, such as polymethyl methacrylate (PMMA) and resins of the like, as those disclosed in TW Pat. No. M270491. Moreover, each of the second refraction surfaces 22 is used for receiving and refracting the first refracting light to form a first discharging light being emitted out of the light source package structure 2 in a direction perpendicular to the central axis of the light source package structure 2 . Wherein, an included angle is formed between the normal vector 51 of a portion of the second refraction surface 22 and the central axis of the light source package structure 2 , whereas the included angle is ranged between 0 degree and 180 degrees.
[0041] Please refer to FIG. 2C to FIG. 2F , which illustrate profiles of the first refraction surface capable of being employed by the light source package structure of FIG. 2B . There are a variety of structures that can be formed on the upper portion of the first refraction surface for refracting light in a direction proximate to perpendicular to the central axis of the light source package structure. In FIG. 2C , the profile of the first refraction surface 21 a is shaped like a corn or pyramid, such that light beams cab be refracted thereby in a direction perpendicular to the central axis of the light source package structure. In FIG. 2D , a sawtooth structure 211 comprising a plurality of pyramids is formed at the upper portion of the first refraction surface 21 b. In FIG. 2E , at least a round-tipped structure with a specific curvature 212 is formed at the upper portion of the first refraction surface 21 c. It is noted that a combination 213 of a plurality of tapered structures and a plurality of round-tipped structures can be formed at the upper portion of the first refraction surface 21 d, as seen in FIG. 2F . In addition, both the first and the second refraction surfaces can be designed as rugged surfaces illustrated in FIG. 2G .
[0042] Please refer to FIG. 3A , which is a cross sectional view of a light source package structure according to a second preferred embodiment of the invention. The light source package structure 3 is comprised of: an accommodating space 30 for accommodating a light source 9 ; a first refraction surface 31 , covering the light source 9 for receiving light discharging from the light source 9 while refracting the same to form a first refracting light; a second refraction surface 32 , for receiving and refracting the first refracting light to form a first discharging light being emitted out of the light source package structure 3 ; and a refraction cap 33 , being formed on top of the second fraction surface 32 while enabling the refraction cap 33 to receive and refract the portion of the first refracting light failed to incident to the second fraction surface and thus form a second discharging light emitting therefrom; wherein an included angle, being ranged between 0 degree and 180 degrees, is formed between the normal vector of a portion of the second refraction surface 32 and the central axis of the light source package structure 3 .
[0043] In the embodiment shown in FIG. 3A , the refraction cap 33 is comprised of: a third refraction surface 330 , for receiving and refracting the portion of the first refracting light failed to incident to the second fraction surface 32 and thus forming a second refracting light; a fourth refraction surface 331 , connected to the third refraction surface 330 , for receiving and refracting the second refracting light so as to form a third refracting light; and a fifth refraction surface 332 , connected to the fourth and the second refraction surfaces 331 , 32 , for receiving and refracting the third refracting light so as to form the second discharging light. By the disposition of the refraction cap 33 , light beams, before being emitted from the top of the light source package structure 3 , are being refracted at least two times more than those without the refraction cap 33 , so that the emitting light is refracted by a large angle and thus almost perpendicular to the central axis of the light source package structure 3 . In FIG. 3A , the normal vector of a portion of the third refraction surface 330 is parallel to the central axis of the light source package structure 3 . In FIG. 3B , for increasing the angle of the first refracting light incident to the third refraction surface 330 a where it is refracted by a comparatively larger angle to form the second refracting light, the profile of the third refraction surface 330 a can be the profile of pyramid or corn.
[0044] Please refer to FIG. 4 , which is a cross sectional view of a light source package structure according to a third preferred embodiment of the invention. The light source package structure 7 of FIG. 4 is comprised of: an accommodating space 70 for accommodating a light source 9 ; a first refraction surface 71 ; at least a second refraction surface 72 ; and a reflection surface 73 . The first refraction surface 71 is placed to cover the light source 9 for receiving light discharging from the light source 9 while refracting the same to form a first refracting light, whereas the first refraction surface 71 is shaped like a column. The light source 9 can be a simple LED or a LED coated with a layer of conventional transparent material. The second refraction surface 72 is used for receiving and refracting the first refracting light to form a first discharging light being emitted out of the light source package structure 7 in a parallel manner, whereas an included angle is formed between the normal vector of a portion of the second refraction surface 72 and the central axis of the light source package structure 7 . The reflection surface 73 is disposed at the upper portion of the light source package structure 7 and is connected to the second refraction surface 72 for reflecting the portion of the first refracting light emitted from the top of the first refraction surface 71 while enabling the reflected first refracting light to incident to the second refraction surface 72 . It is noted that each of the first refraction surface 71 , the second refraction surface 72 and the reflection surface 73 can be a tapered structure or a round-tipped structure, while all being designed as rugged surfaces. In addition, the first refraction surface 71 is substantially the exterior of a first lens containing the accommodating space 70 therein for enabling the exterior of the light source 9 to be tightly attached to the interior of the accommodating space while sealing the same, which is similar to that shown in prior embodiment and thus is not describe further herein.
[0045] FIG. 5A and FIG. 5B are cross sectional views of light source package structures according to a fourth preferred embodiment of the invention, whereas the two light source package structures have refraction packages of different design. As the key of the invention is to design a light source package structure capable of refracting light beams emitted from a LED more than once, a refraction package 42 is disposed outside the second refraction surface of those prior embodiments, while covering the same for receiving and reflecting the first and the second discharging light incident thereon and thus forming a third discharging light, as seen in FIG. 5A . In FIG, 5 A, the light source package structures, disclosed in FIG. 2A , FIG. 3A , FIG. 4 , are defined to be a first refracting part 41 , while enabling the first refracting part 41 to be covered by at least a refraction package 42 , so that the light of the light source 9 is first refracted by the first refracting part 41 and then further being refracted by the refraction package 42 , by which light can be discharged out of the light source package structure of FIG. 5A more close to a direction perpendicular to the central axis thereof. As seen in FIG. 5A and FIG. 5B , the first refracting part 41 is composed of a first refraction surface 411 and a second refraction surface 412 , by which the light refracted by the first refraction surface 411 is directed to the second refraction surface 412 where it is being refracted again and incident to the refraction package 42 . Generally, the top of the first refracting part 41 can be designed as a reflection surface, which is used for reflecting the portion of the first refracting light of the first refraction surface 411 while enabling the reflected first refracting light to incident to the second refraction surface 412 .
[0046] Moreover, the refraction package 42 can be structured similar to those shown in forgoing embodiments that it is comprised of a sixth refraction surface 421 and a seventh refraction surface 422 , wherein the light discharged out of the first refracting part 41 can be refracted by the sixth and the seventh refraction surfaces in a successive manner. In the embodiment shown in FIG. 5A , the structure of the refraction package 42 is the same as that of the first refracting part 41 .
[0047] However, the structure of the refraction package 42 a can be different from that of the first refracting part 41 , as shown in FIG. 5B . The refraction package 42 a is substantially a curved screen covering the first refracting part 41 for receiving the light discharged out of the first refracting part 41 while refracting the same, in which the refraction package 42 a is further comprised of: a sixth refraction surface 421 a, for or receiving the light discharged out of the first refracting part 41 while refracting the same; and a seventh refraction surface 422 a, for receiving the light discharged out of the sixth refraction surface 421 a while refracting the same. It is noted that the refraction package 42 a is designed to refract the light discharged out of the first refracting part 41 more than twice and thus improved the effect of refraction desired by the light source package structure.
[0048] FIG. 6A and FIG. 6B are schematic diagrams depicting paths of light being refracted by a light source package structure of the invention. In FIG. 6A , when the light beams 90 a, 91 a, 92 a emitted from the light source composed of LEDs are respectively incident to their corresponding portions of the first refraction surface 21 , they are refracted toward the normal vector of its corresponding portion and forming three first refracting light beams 90 b, 91 b, 92 b accordingly as each of the light beams 90 a, 91 a, 92 a is traveling from a sparse media into a dense media. Thereafter, the three first refracting light beams 90 b, 91 b, 92 b are further respectively incident to their corresponding portion of the second refraction surface 22 , they are refracted away from the normal vector of its corresponding portion and forming three discharging light beams 90 c, 91 c, 92 c accordingly as each of the light beams 90 b, 91 b, 92 b is traveling from a dense media into a sparse media. Eventually, by the abovementioned two refraction, the three discharging light beams 90 c, 91 c, 92 c, are directed to travel in a direction perpendicular to the central axis of the light source package structure 2 .
[0049] In FIG. 6B , a refraction cap is arranged at the upper portion of the light source package structure and is designed to receive the portion of the first refracting light failed to incident to the second fraction surface directly so as to form a second discharging light to be emitted therefrom in a direction perpendicular to the central axis of the light source package structure. First, when the light beam 93 a emitted from a LED is incident to its corresponding portion of the tapered structure 310 of the first refraction surface 31 , it is refracted toward the normal vector of its corresponding portion and forming a first refracting light beams 93 b as it is traveling from a sparse media into a dense media. Following, as the first refracting light 93 b is passing through the third refraction surface 330 , that is, the first refracting light 93 b is traveling from a dense media into a sparse media, it is refracted away from the normal vector of its corresponding portion of the third refraction surface 330 incident thereby and forming a second refracting light 93 c. It is noted that the second refracting light 93 c still can not be refracted enough to discharge out of the light source package structure in a direction perpendicular to the central axis of the light source package structure since the original light beam 93 a is discharged toward the top of the light source package structure in a direction almost parallel to the central axis. Therefore, the second refracting light 93 c is refracted once again by the fourth refraction surface 331 to form a third refracting light 93 d, and then the third refracting light 93 is once again directed to incident to a fifth refraction surface 332 to be refracted and form a discharging light to be emitted out of the light source package structure in a direction perpendicular to the central axis of same. In the embodiment shown in FIG. 6B , both the fourth and the fifth refraction surfaces can be designed as irregular surfaces or rugged surfaces.
[0050] Please refer to FIG. 7A and FIG. 7B , which are respectively a diagram used to define the viewing angle with reference to a light source package structure and diagram illustrating the relationship between viewing angle and the intensity of light discharging out of a light source package structure of FIG. 7A . In FIG. 7A , the central axis of the light source package structure is defined as 0 degree viewing angle while the left direction perpendicular thereto is defined as −90 degree viewing angle and the right direction perpendicular thereto is defined as 90 degree viewing angle. As seen in FIG. 7B , within the range of 60 degree and −60 degree viewing angles, the intensities of light emitted from the light source package structure of the invention are comparatively weak, and the intensities are detected to be much more intense when the viewing angle is exceeding the range of 60 degree and −60 degree. Therefore, it is obvious that the light source package structure is capable of enabling most of the light emitted thereby to be discharged in a direction almost perpendicular to the central axis thereof.
[0051] Please refer to FIG. 8A , which is a cross sectional view of a light source package structure according to a fifth preferred embodiment of the invention. As seen in FIG. 8 , instead of arranging a tapered structure at the upper portion of the first refraction surface, the top of the first refraction surface is indented, by which the overall height of the light source package structure can be reduced for enhancing the usability of the invention. In FIG. 8B , the relationship between viewing angle and the intensity of light discharging out of a light source package structure of FIG. 8A is similar to that shown in FIG. 7B and thus is not described further herein.
[0052] In a preferred aspect, a flat light source can be configured by arranging an array of the light source package structures in a matrix while the matrix is covered and sealed by a material of diffusion capability, such as a diffusion plate or diffusion film. In addition, a collimating plate can be selectively arranged superimposing the diffusion plate or diffusion film. The so-manufactured flat light source can have various usages, such as being employed in the backlight module of LCDs, being employed in an indoor light fixture, or being employed as the light source of a commercial billboard, but is not limited thereby. Moreover, it is relative easy to pack a light source with the light source package structure of the invention. As a hollow accommodating space is formed inside the first refraction surface, the packing can be achieved simply by wearing the light source package structure onto the light source. Therefore, the step of forming a lens on top of an LED while covering the same, and the specific pumping-suction step for filling the gap between the lens and the LED by a transparent material, both disclosed in U.S. Pat. No. 6,679,621, are no longer required.
[0053] While the preferred embodiment of the invention has been set forth for the purpose of disclosure, modifications of the disclosed embodiment of the invention as well as other embodiments thereof may occur to those skilled in the art. Accordingly, the appended claims are intended to cover all embodiments which do not depart from the spirit and scope of the invention.
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The present invention relates to a light source package structure, which comprises: an accommodating space for accommodating a light source, a first refraction surface, and at least a second refraction surface. The first refraction surface receives light discharging from the light source while refracting the same to form a first refracting light, the upper part of the first refraction surface further comprising a refracting structure for refracting the light emitted from the light source. The second refraction surface receives and refracts the first refracting light to form a discharging light being emitted out of the light source package structure. Wherein, an included angle is formed between the normal vector of a portion of the second refraction surface and the central axis of the light source package structure. It is noted that the aforesaid package structure can be used in various packaging for improving refraction. In a preferred embodiment, a light source of light emitting diode (LED) is packaged by the light source package structure of the invention for enabling the light emitted from the LED to be discharged out of the package structure by a large angle after being refracted multiple times, so that the LED package structure can be adopted as a flat light source for diverse purpose applied in industry.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a nozzle for ventilating a vehicle interior, such as used to direct air from an air conditioning system.
2. Description of Prior Developments
In the case of a known air nozzle of this type (DE 197 48 998 C1), in order for the air nozzle when not in use to have a covering which can be closed in a visually neat manner and which fits unobtrusively into the harmony and aesthetics of the interior trim, the nozzle insert carrying the air-guiding vanes is designed as a roller-like, hollow pivoting insert. This insert is mounted pivotably about its roller axis and has a casing opening which is essentially congruent with the air outflow opening. The roller insert is coupled to the panel designed as a rolling and closing screen in such a manner that with increasing pivoting of its casing opening away from the air outflow opening, it covers the opening to the same extent with the rolling and closing screen. This constructive configuration of the air nozzle always requires the nozzle front side to have an external contour curved in the form of a circular arc, which signifies a restriction on the structural freedom of the design of the dashboard in which such air nozzles are generally arranged.
SUMMARY OF THE INVENTION
The invention is based on the object of constructively modifying a nozzle for ventilating a vehicle interior of the type mentioned above in such a manner that the shape of the nozzle housing, in particular its front contour, can be configured in any desired manner without having to omit a covering for the nozzle opening when not in use.
The air nozzle according to the invention has the advantage that, in contrast to the roller insert, a slide can be constructively adapted to any configuration of the front contour of the nozzle housing without a problem and places no demands on the configuration of the front contour of the nozzle housing in terms of design. The air nozzle can therefore advantageously be used in all dashboards or instrument panels of differing design. Moving a slide into the depth of the nozzle housing to enable the panel to close the air outflow opening causes the air-guiding vanes to be displaced sufficiently far out of the air outlet opening that the movement of the panel in order to close the outlet opening is not impeded. This is also necessary in particular, since the gripping strip conventionally fitted onto an air-guiding vane and intended for manual pivoting of the air-guiding vanes and for setting of the air outflow direction has to protrude somewhat out of the air outlet opening over the contour of the housing, to enable the gripping strip to be gripped in an ergonomic manner, and would therefore never permit the closing of the panel.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described below in more detail with reference to exemplary embodiments illustrated in the drawing, in which, in each case in a largely schematic illustration:
FIG. 1 shows a longitudinal section of a nozzle for ventilating the central plane of a vehicle interior,
FIG. 2 shows part of a section along the line II—II in FIG. 1,
FIG. 3 shows a plan view in the direction of arrow III in FIG. 1,
FIG. 4 shows an identical illustration as in FIG. 1 of a nozzle according to a further exemplary embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The nozzle illustrated in longitudinal section in FIG. 1 is used for the ventilation of the central plane of a vehicle interior and is integrated as a so-called central nozzle in the dashboard 10 of a motor vehicle. As can be seen in the front view, part of which is illustrated in FIG. 3, two such central nozzles for separately ventilating the left-hand and right-hand halves, i.e. the driver's side and front-passenger's side, of the vehicle interior are inserted into the middle of the dashboard 10 . The illustration here is of the central nozzle which is on the left in FIG. 3 when not in use and of the right central nozzle when in use. When in use, conditioned air flows out of the nozzle and ventilates the associated region of the passenger interior, and when not in use no ventilation takes place. Each nozzle is assigned an adjusting wheel 11 for regulating the quantity of air flowing out. In FIG. 3, only the adjusting wheel 11 assigned to the left central nozzle is illustrated.
Each nozzle has a housing 12 which is inserted into a recess in the dashboard 10 , has an air outflow opening 13 on the front side and, with its end side 121 which faces away from the air outflow opening 13 , is fitted on an air duct (not illustrated here) via which conditioned air is fed to the nozzle from an air-conditioning system. The quantity of air flowing into the housing 12 from the air duct is regulated by means of a pivoting flap 14 which is coupled via a linkage 15 to the adjusting wheel 11 and, by manual actuation of the adjusting wheel 11 , the flap can be pivoted about its pivot axis 16 into any desired pivoted position. In the one final pivoted position (illustrated by dash-dotted lines in FIG. 1 ), the pivoting flap 14 covers the entire housing cross section 12 , with the result the nozzle is completely closed. In its other final pivoted position, the pivoting flap 14 is aligned parallel to the axis of the housing 12 and releases the housing cross section completely.
Arranged in the housing 12 is a frame-shaped slide 17 whose frame sides bear against the inner wall of the housing 12 with a clearance, and which can be displaced longitudinally in the direction of the housing axis. In order to exclude any possible tilting of the slide 17 in the housing 12 , the slide 17 is guided by guide pins, protruding from opposite frame sides, in longitudinal guides 18 which are incorporated in the housing wall. Air-guiding vanes 19 , 20 are accommodated in a pivotable manner in the frame-shaped slide 17 . A first set of air-guiding vanes 19 aligned parallel to one another is aligned horizontally, and a second set, which is arranged upstream of the first set, as seen in the direction of flow of the air, of air-guiding vanes aligned parallel to one another is aligned vertically.
In order to pivot the air-guiding vanes 19 , 20 about their respective pivot axes, a gripping strip 21 is fitted onto one of the horizontally aligned air-guiding vanes 19 . Vertical displacement of the gripping strip 21 enables the air-guiding vanes to be pivoted, and horizontal displacement of the gripping strip 21 enables the vertical air-guiding vanes 20 to be pivoted. The front edges of the horizontal air-guiding vanes 19 are aligned with the front frame opening 171 of the slide 17 , which frame opening, for its part, is flush with the air outflow opening 13 of the housing 12 , in the front position (illustrated in FIG. 1) of the slide 17 . In this front slide position, the gripping strip 21 protrudes through the air outflow opening 13 and protrudes over the front contour of the housing 12 in a manner favorable for grasping it.
The air outflow opening 13 of the housing 12 can be covered completely by means of a panel 22 , the panel 22 being designed in such a manner that when the air outflow opening 13 is fully closed, the nozzle and the dashboard 10 appear as a solid surface. In the exemplary embodiment of FIGS. 1-3, the panel is designed as a rolling and closing screen 23 , specifically, preferably as a flexible plastic component which is accommodated in a displaceable manner laterally in two guide grooves 24 which are each incorporated on one of each of the opposite housing walls. Alternatively, the rolling and closing screen 23 can also be composed of a multiplicity of parallel bar-type vanes which are connected to one another in a movable manner and enter with their ends in the guide grooves 24 . The guide grooves 24 are of curved design and extend laterally over the entire outflow opening 13 and partially in the longitudinal direction of the housing 12 . The last-mentioned section of the guide grooves 24 is of sufficiently long dimensions that the rolling and closing screen 23 can be brought completely out of the region of the air outflow opening 13 and can be accommodated by this section of the guide groove 24 . In FIG. 3, the left central nozzle is illustrated with the air outflow opening 13 concealed by the rolling and closing screen 23 , and the right central nozzle is illustrated with the air outflow opening 13 released by the rolling and closing screen 23 .
In the exemplary embodiment of FIG. 1, the rolling and closing screen 23 and the slide 17 are driven by a common electric motor 25 , the electric motor 25 displacing the slide 17 axially in the housing 12 via a gear mechanism 26 and a coupling linkage 27 , and displacing the rolling and closing screen 23 in the guide grooves 24 via a gear mechanism 28 . The displacement path s, by which the slide 17 can be moved from its frontmost position (illustrated in FIG. 1) into the depth of the housing 10 , is dimensioned in such a manner that the air-guiding vanes 19 , 20 and the gripping strip 21 release the movement space, required by the rolling and closing screen 23 , within the air outflow opening 13 between the two guide grooves 24 .
The electric motor 25 is switched on by means of the adjusting wheel 11 so as to rotate in one or other direction of rotation, and automatically switches off after the air outflow opening 13 is closed or opened. If the pivoting flap 15 is brought by the adjusting wheel 11 into its closing position (illustrated by dash-dotted lines in FIG. 1 ), the motor 25 is switched on at the end of the rotational path of the adjusting wheel 11 . Via the gear mechanism 26 and the coupling linkage 27 , the slide 17 is first of all moved into the depth of the housing 12 by the displacement path s, and then via the gear mechanism 28 , the rolling and closing screen 23 is slid completely over the air outflow opening 13 . If the rolling and closing screen 23 covers the air outflow opening 13 entirely, the electric motor 25 is shut down by a limit switch. If the adjusting wheel 11 is then moved out of this position in the opposite direction, resulting in the pivoting flap 14 being moved out of its closing position (illustrated by dash-dotted lines in FIG. 1 ), the electric motor 25 is switched on beforehand, and, in a reverse sequence, first of all draws the rolling and closing screen 23 away from the air outflow opening 13 and then slides the slide 17 back into its front position (illustrated in FIG. 1 ). When the slide 17 reaches its final position, the electric motor 25 is shut down by a limit switch.
In an alternative embodiment of the invention, the linkage 15 between the pivoting flap 14 and the adjusting wheel 11 can be omitted, and the pivoting flap 14 can be driven by the electric motor 25 . The adjusting wheel 11 then just specifies the pivoting angle of the pivoting flap 15 in accordance with the desired quantity of air, and a control unit connected to the adjusting wheel 11 activates the electric motor 25 in such a manner that the pivoting flap 14 takes up the selected pivoted position.
In a further alternative design of the air nozzle in FIG. 1, the electric motor 25 can be omitted, and the displacement movement of the slide 17 can be derived from the rotational movement of the adjusting wheel 11 . In this case, the adjusting wheel 11 , after it has transferred the pivoting flap 14 into its closing position (illustrated by dash-dotted lines in FIG. 1 ), can be advanced by an additional path in which the slide 17 is displaced into the depth of the housing 12 by the displacement path s. If the adjusting wheel 11 is rotated back again, the slide 17 is first of all displaced into its front position and then, on further rotation of the adjusting wheel 11 , the pivoting flap 14 is moved out of its closing position. The rolling and closing screen 23 is transferred into its closing position covering the air outflow opening 13 and into its open position completely releasing the air outflow opening 13 by hand. For this purpose, a gripping element (not illustrated in FIG. 1 ), which protrudes out of the air outflow opening 13 over the front side of the housing 12 , is fastened to the rolling and closing screen. Alternatively, the rolling and closing screen 23 can also be actuated via the adjusting wheel 11 , the closing movement of the rolling and closing screen 23 again following the displacement movement of the slide 17 , or the opening movement of the rolling and closing screen 23 preceding the displacement movement of the slide 17 into its front position.
The air nozzle illustrated schematically in longitudinal section in FIG. 4 differs from the air nozzle described in FIGS. 1-3 insofar as the panel 22 for closing and releasing the air outflow opening 13 is designed as a covering plate 29 which is matched to the front contour of the housing 12 and can be pivoted by means of two arms 30 fastened rotatably to the housing 12 . In the exemplary embodiment of FIG. 4, the covering plate 29 is pivoted by hand, to which end there is fastened to the lower end of the covering plate 29 a gripping element 31 which protrudes over the front contour of the housing 12 through the air outflow opening 13 and can be grasped by hand. As is not illustrated in more detail, the displacement movement of the slide 17 into the depth of the housing 12 and out of the depth of the housing 12 is derived from the pivoting movement of the covering plate 29 , specifically in such a manner that before the covering plate 29 starts to be pivoted over the air outflow opening 13 , the slide 17 is moved into the depth of the housing 12 by the displacement path s, and at the end of the movement pivoting the covering plate 29 away from the air outflow opening 13 , is replaced back into the front position (as is illustrated in FIG. 1 ).
In a further exemplary embodiment, the opening of the covering plate 29 can be triggered by means of an automatic touch control (not illustrated here in more detail). Briefly touching the covering plate 29 causes its locking to be released, and the covering plate 29 pivots by means of spring force into its open position releasing the air outflow opening 13 . The covering plate 29 is transferred by hand, with the opening spring becoming stressed, into its closing position.
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A nozzle for ventilating a vehicle interior, having a housing which has an air outflow opening which can be closed by a panel when not in use, and having an insert which accommodates air-guiding vanes in a pivotable manner and which is held movably in the housing for the purpose of moving the air-guiding vanes out of the air outlet opening during closing of the panel. In order to integrate the nozzle housing in dashboards of differing design, the insert is designed as a frame-like slide which can be displaced longitudinally in the housing and can be moved into the depth of the housing by a defined displacement path to enable the panel to close the air outflow opening.
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BACKGROUND OF THE INVENTION
This invention relates to composite prelaminated tapes for forming closures for disposable diapers which can be opened and refastened without destroying either the diaper or the tape.
At least as early as 1955, it had been suggested to use strips of normally tacky and pressure-sensitive adhesive tape to secure conventional cloth diapers on an infant; see, e.g., Chambers U.S. Pat. No. 2,714,889 and Ekberg U.S. Pat. No. 3,221,738. A few years later, when disposable diapers became extremely popular, strips of pressure-sensitive adhesive tape were again employed as closures; see, e.g., Gellert U.S. Pat. No. 3,620,217.
A disposable diaper typically has a thin, flexible, low density polyethylene film cover, an absorbent filler inside of the cover, and a porous inner liner overlying the filler. The diaper is positioned at the crotch of an infant with the two ends of the diaper extending toward the front and back respectively. Edges on each side of the diaper are then either positioned adjacent to each other or overlapped with a strip of pressure-sensitive adhesive tape being adhered to the cover at the border adjacent each of the two edges and holding the diaper closed.
After a tape closure has been opened, it is frequently discovered that the diaper has not been soiled and hence that there is no need to replace it. If the diaper cover has not been torn, a second strip of tape can sometimes be applied as a replacement closure, but this is often inconvenient. As a result, considerable work has been undertaken to develop a tape diaper closure that is not only capable of bonding firmly to the diaper cover but is also capable of being opened without destroying the tape diaper closure or the diaper cover and subsequently reclosed. Closures of this type have generally involved a combination of two or more tapes, one of which remains permanently adhered to one edge of the diaper and the other being removably adhered to the other edge of the diaper. Examples of such products are shown in Ness et al, U.S. Pat. No. 3,951,149; Milnamow U.S. Pat. No. 3,987,793; Feldman et al, U.S. Pat. No. 3,999,546; Richman et al, U.S. Pat. No. 4,020,842; and Schotz, U.S. Pat. No. 4,227,530.
Typically, tape closures for diapers are fabricated by positionably mounting a plurality of individual rolls of the appropriate tapes and combining them in situ to form a composite strip of tape, the width of which is substantially the same as the length of the diaper closure to be fabricated. The composite roll is then severed at right angles to the edges of the composite strip at intervals corresponding to the width of the desired tape closure and adhered at an appropriate location along the border adjacent the sides of the diaper as exemplified in Hamaguchi et al U.S. Pat. No. 3,616,114. Although this manufacturing process is effective, relatively sophisticated machinery is necessary to accomplish the superimposition of several rolls of tape to form a composite strip of tape in situ. Thus, it is desirable to provide diaper manufacturers with a composite prelaminated tape in a single roll from which closures may readily be prepared.
Commonly assigned copending U.S. patent application Ser. No. 891,131 of Pape et al describes a composite prelaminated tape comprising a pressure-sensitive adhesive fastening tape subdivided into bonded and fastening sections comprising a release tape, a fingerlift and a unifying strip. A problem which may be experienced with the Pape et al composite tape is the exposure of a small area of adhesive adjacent to the unifying strip which tends to adhere to the outer diaper cover and tear the cover upon opening of the closure. The present invention is an improvement over that invention.
SUMMARY OF THE INVENTION
The present invention provides novel composite prelaminated tapes for forming closures for disposable diapers of the type comprising a body of fluid-absorbing material having a fluid-impermeable polymeric foil outer cover, with a pressure-sensitive adhesive tape closure permanently mounted at a first border location adjacent one edge of the diaper and adapted for attachment to a second border location adjacent another edge when the two edge locations are juxtaposed or overlapped.
In accordance with the invention, the composite prelaminated tapes for forming the closures comprise a composite of
(a) a pressure-sensitive adhesive fastening tape,
(b) a fastening tape fingerlift,
(c) a target tape,
(d) a target tape fingerlift,
(e) a release tape and
(f) a unifying strip for both distributing tensile forces and to cover any exposed area of the fastening tape adhesive of the diaper.
The composite permits a portion of the fastening tape to be adhered permanently to an outer aspect of the diaper at a first border location and the remaining portion of the fastening tape and the target tape can be lifted from the release tape and adhered to a second border location such that when the fastening tape is lifted from the second border location, the target tape remains adhered to the second border location. The fastening tape can thereafter be repeatedly lifted from the target tape and re-adhered thereto. The unifying strip overlaps a portion of the fastening tape, thereby insuring the fastening tape does not tear the diaper cover by adhering to it.
Composite closures of the type just described are advantageously prepared from a roll of tape comprising a composite elongate strip of pressure-sensitive adhesive sheet material wound convolutely upon itself about an annular core. This composite strip is especially suited for preparing tape closures of the type described by simply severing the elongate strip of tape parallel to the axis of the core at intervals corresponding to the predetermined width of the closure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be more easily understood by referring to the accompanying drawings, in which certain dimensions are exaggerated to facilitate understanding. Like numbers refer to like parts in the several views, wherein:
FIG. 1 shows a roll of composite tape suitable for use in practicing the invention;
FIG. 2 is an enlarged cross-sectional view of the composite tape of FIG. 1;
FIG. 3 is an enlarged cross-sectional view showing juxtaposed diaper edges, a closure formed from the tape of FIGS. 1 and 2 applied to one of the edges;
FIG. 4 is an enlarged cross-sectional view showing the tape closure ready to close two juxtaposed diaper edges; and
FIG. 5 is an enlarged cross-sectional view showing how the tape closure is opened without destroying either the tape or the diaper leaving the target tape in place.
DETAILED DESCRIPTION
In FIGS. 1 and 2, tape roll 10 is formed of composite tape 11 wound convolutely upon itself about a core. Composite tape 11 is subdivided into bonded section 16 and fastening section 17 and made up of fastening tape 12, target tape 18, release tape 21 and unifying strip 24.
Fastening tape 12 comprises any suitable tape backing 13 such as treated creped paper, polymeric film, etc., typically provided with a coating of a suitable release agent to facilitate unwinding of the composite tape when wound upon itself about the core. In one embodiment of the invention, one face of the backing 13 is coated with a layer 15 of a tacky and aggressive pressure-sensitive adhesive. Suitable adhesives include conventional rubber-resin adhesives which have tack characteristics modified by the inclusion of tackifying resins such as those described in U.S. Pat. No. 4,136,071. The aggressive pressure-sensitive adhesives used for layer 15 may also include conventional rubber-resin adhesives modified to have peel strengths between about 6 and 10 newtons per 25 mm, preferably about 8 newtons per 25 mm. A suitable method for measuring the peel strengths of adhesive layers on a steel, polyethylene or polypropylene surface is described hereinbelow.
Description of Test Procedure
90° Peel Adhesion. A 330-micrometer thick sheet of low density polyethylene (e.g., Eastman 1550 P-16421) is cast on a highly polished chrome roll and cooled to room temperature. Test samples approximately 80 mm×300 mm are then cut from this polyethylene sheet and a highly aggressive double-coated pressure-sensitive adhesive tape is used to bond the non-shiny surface of the polyethylene to a smooth steel panel. A 25 mm×300 mm specimen of tape to be evaluated as a potential diaper closure is then obtained and the adhesive surface is placed in contact with the shiny surface of the polyethylene sheet and forced into intimate contact with one forward and back pass of a mechanically operated 100 g roller. Within one minute thereafter the steel test panel is then mounted in the lower jaw of an "Instron" tensile testing machine with the tape surface upward. The free end of the tape strip is then mounted in the upper jaw of the tensile testing machine and pulled upward at 90°. The upper and lower jaws are separated at a rate of approximately 300 mm/min., noting the average force required for removal.
Target tape 18, formed of any suitable tape backing material, is positioned so that it coincides with and covers part of adhesive layer 15. The top surface of target tape 18 is releasably adhered to adhesive layer 15 except in the center of the tape roll where a portion of unifying strip 24 is located between adhesive layer 15 and target tape 18. The bottom surface of target tape 18 is coated with a layer 19 of normally tacky and pressure-sensitive adhesive. This adhesive layer 19 must form a strong shear bond to the outer surface of the diaper where it is adhered during use and may be the same as adhesive layer 15.
A first fingerlift 20 is positioned between fastening tape 12 and target tape 18. The first fingerlift 20 is adhered to fastening tape 12 by adhesive layer 15. Fingerlift 20 facilitates the lifting of fastening tape 12 from the target tape 18.
Release tape 21, formed of any suitable tape backing material, is positioned such that it substantially covers, and is adhered to adhesive layer 19. The top surface of release tape 21 may be provided with a coating of release agent so that target tape 18 may be readily separated from release tape 21.
A second fingerlift 23 is adhesively attached to target tape 18 by adhesive layer 19. The fingerlift 23 is attached to an end portion of target tape 18 and facilitates the separation of target tape 18 from release tape 21 in order to allow initial positioning of target tape 18 and fastening tape 12 on the opposed side of the diaper.
Fingerlifts 20 and 23 which are typically formed of narrow strips of polymeric film, are adhered to backing 13 and target tape 18 by adhesive layers 15 and 19 respectively. The fingerlifts 20 and 23 extend outwardly beyond the edge of fastening tape 12 and target tape 18 to permit and facilitate the separation of the various tapes. The separation of fastening tape 12 from target tape 18 is facilitated to obtain the position shown in FIG. 5 when it is desired to reopen the diaper closure.
Unifying strip 24, typically formed of a narrow strip of the same material as fingerlifts 20 and 23 is positioned between end portions of tape 11 such that its centerline coincides with the junction of target tape 18 and release tape 21 and adhesive layers 15, 19 and 22. Thus, one part of unifying strip 24 is adhered to adhesive layer 22 and an approximately equal part is adhered to adhesive layer 15 with target tape 18 and release tape 21 layered between as shown most clearly in FIG. 2.
As previously indicated, FIGS. 3-5 illustrate the use of closures formed by severing composite tape 11 at intervals corresponding to the predetermined width of the closure, parallel to the axis of the tape core. Thus, in FIG. 3, diaper edges 30 and 35 are juxtaposed with surfaces 31 and 36 corresponding to the outer surface of a diaper cover, conventionally made of low density polyethylene film. As shown in FIGS. 2 and 3, adhesive layer 15 forming bonded section 16 of fastening tape 12 is adhered to diaper cover 31 in the area immediately adjacent the edge 30. Unifying strip 24 overlies and extends onto adhesive surface 15 and extends onto interior surface 32 of the diaper as held by adhesive layer 22. Adhesive layer 22 must form a strong shear bond to diaper surface 32 and may be the same as either adhesive layer 15 or adhesive layer 19.
As shown in FIG. 3, release tape 21 is permanently adhered to the inner surface 32 of diaper edge 30. Overlying and adhered to the back surface of both unifying strip 24 and release tape 21 is target tape 18. Because of the presence of a release agent on the back surface of release tape 21, target tape 18 may be separated from release tape 21 by grasping fingerlift 23 and pulling upwardly, away from tape 21. Tape 18 is then permanently adhered to the outer surface 36 of diaper edge 35 by placing the fastening section 17 of tape 12 onto the outer surface 36, thereby adhering tape 18 to the outer surface 36 by adhesive layer 19. The fastening tape 12 is thereafter separated from the target tape by grasping fingerlift 20 and pulling upwardly, yielding the arrangement shown in FIG. 5.
It will be observed, especially in FIG. 4, that when the diaper edges 30 and 35 are placed in a tensional relationship from the movement of a diapered baby, the tensional forces place fastening tape 12 in shear. The shear forces on one end of fastening tape 12 are then divided to the bottom surface 32 of diaper edge 30 and the top surface 31 of diaper edge 30 through unifying strip 24 due to the adhesive attachment of unifying strip 24 to fastening tape 12 and release tape 21. The division of the shear forces to the two surfaces 31 and 32 of diaper edge 30 substantially diminishes the likelihood of the tape closure being pulled off diaper edge 30 by tearing the film forming either target tape 18 or surfaces 31 and 32.
When it is desired to reopen the diaper closure, the end of fastening tape 12 is lifted free, by grasping fingerlift 20 off target tape 18 to which it bonds firmly enough to prevent inadvertent opening of the closure but not so firmly that it cannot be lifted free without tearing target tape 18. The unifying strip 24 protects the diaper cover 36 from exposure to adhesive layer 15, thereby insuring the diaper cover 36 will not be inadvertently torn upon opening of the diaper closure. Once lifted free, this end of fastening tape 12 can again be resealed by placing it in contact with the target tape 18; indeed the process can be successfully repeated many times.
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A composite adhesive tape system for interconnecting surfaces, parts and the like which includes a main fastening tape portion coated with an aggressive, tacky adhesive, a target tape portion and a release tape portion which covers the target tape portion and a centrally located layer which covers part of the release tape and partly folds under the target tape portion and methods for manufacturing and using the tape system as described. This system is particularly useful for providing novel prelaminated tape systems for diapers.
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BRIEF DESCRIPTION OF THE INVENTION
This invention relates to a coupling device for use as a toy, key ring, loose-leaf paper binder, jewelry coupler, apparel fastener and the like. More specifically, this invention relates to a friction coupling device.
BACKGROUND OF THE INVENTION
A well-known coupling toy, known as a chinese finger, employs a net-like woven structure which expands transversely due to compression when coupling engagement is made and contracts transversely when a pull-apart force is applied. It is also well known to connect a flexible tube to a rigid metal tube. Another coupling of interest is the paper file described in U.S. Pat. No. 828,974 to Schmidmer wherein a rigid U-shaped metal insert fits into upwardly extending springs. In U.S. Pat. No. 3,263,444 to DiCroce, a finger ring is described wherein a polyethylene insert-coupling, having a compressible enlarged end, is insertable into a comparably shaped recess of a metal ring.
SUMMARY OF THE INVENTION
In one form of a coupling device in accordance with the invention a longitudinal connecting element is used and formed of a flexible, at least partially resilient and stretchable, material which has a bore at least at one end. A longitudinal inner insert element is provided with a shape selected to frictionally engage the wall surrounding the bore of the connecting element. The insertion of the inner element into the bore is achieved with greater ease than their separation to provide a convenient coupling device. When another end of a connecting element is applied over the insert, the two ends are held together with great effectiveness.
When the outer connecting and inner insert elements are formed of a plastic material such as vinyl, a particularly effective coupling is achieved whereby the connecting element is conveniently moved over the insert while requiring a substantially greater separation force.
The operation of the coupling device is enhanced when its vinyl plastic components are formed of lower and higher hardness. In this manner a softer resilient connecting element permits an elongation during assembly and contraction against the harder insert element when a pull-apart force is applied. Since both elements have smooth vinyl surfaces, which have a high affinity for each other, a strong coupling is obtained.
A coupling device in accordance with the invention is advantageously employed to make a separable ring by employing a longitudinal vinyl tube as the connecting element with sufficient softness and resilience to frictionally grip a harder, less pliable and less stretchable and shorter insert element placed in the ends of the tube. The completed ring is primarily formed by the outer and softer connecting element.
With another coupling device in accordance with the invention, a more rigid ring is formed by using a relatively rigid vinyl insert element which has sufficient length to bend into a ring and whose ends frictionally enter a shorter and softer vinyl tubular outer connecting element.
The convenience of the push-on, pull-off coupling device in accordance with the invention can be further appreciated when used in an application such as a clothing fastener. For example, a pair of vinyl tubular connecting elements can be fastened to opposite sides of the closing edges of a garment. Vinyl inserts mounted in respective ends of one connecting element are easily pushed into the ends of the other connecting element to close the garment.
The ease with which a coupling device in accordance with the invention can be closed can be appreciated particularly in comparison with the degree of difficulty of opening the coupling device. The flexibility of the outer connecting element enhances this effect in that the pull-apart force applied, for example, to opposite sides of a ring tends to be shared between the coupling and the portion of the connecting element opposite the coupling.
The coupling device can be advantageously formed of commonly available hollow, light-weight tubular material cut to desired lengths. The inner insert's external diameter is then selected to snugly fit into the through-bore of the external connecting element. The length of the insert is selected to achieve the desired frictional coupling with sufficient separation force to form a desired coupling. The resultant coupling can be economical and practically employed in many applications.
When a tubular form of a coupling device of this invention is opened, i.e one end of the outer connecting element is pulled off the insert, the latter unexpectedly remains frictionally retained by the other end of the connecting element substantially at the insert's normal fully inserted position. This adherence is particularly effective with vinyl materials and enables use of relatively short inserts.
It is, therefore, an object of the invention to provide a convenient, simple and practical coupling device. It is a further object of the invention to provide an economical, push-on pull-off coupling device for use in many applications.
These and many other objects and advantages of the invention can be understood from the following description of several coupling device embodiments described in conjunction with the drawings.
THE DRAWINGS
FIG. 1 is a partial perspective view of an unassembled coupling device in accordance with the invention;
FIG. 2 is a partial circumferential section of an unassembled and connected coupling device in accordance with the invention;
FIG. 3 is a partial circumferential section view of the coupling device of FIG. 2 with a separating force being applied;
FIG. 4 is a partial circumferential section view of the coupling device of FIG. 3 after disconnection;
FIG. 5 is a partial circumferential section view of a coupling device employing a highly bent, thick-walled connecting element;
FIG. 6 is a radial section view of the coupling device of FIG. 5;
FIG. 7 is a partial section circumferential view of a ring formed with multiple coupling devices of this invention;
FIG. 8 is a partial section view of the assembled and connected coupling device with an insert having a different orientation;
FIG. 9 is a partial section view of an assembled and connected coupling device employing a selectively shaped insert;
FIG. 10 is a partial section view of the coupling device shown in FIG. 9 while being subjected to a pull-apart force;
FIG. 11 is a perspective view of a loose-leaf notebook assembled with coupling devices in accordance with the invention;
FIG. 12 is a partial circumferential section view of another embodiment for a coupling device in accordance with the invention; and
FIG. 13 is a partial circumferential section view of a rigid form for a coupling device in accordance with the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
With reference to FIG. 1, a portion of the coupling device 10 is shown formed of a connecting element 12 and an insert element 14. The connecting element 12 can be a singular piece, which has its ends 16 bent around to form a ring to engage the insert 14 at its opposite ends 18--˜'. Alternatively, the connecting element 12 can be a two-piece part with each piece provided with a suitably shaped end 16 to engage the insert 14. The ends 16 of the connecting element 12 are provided with a bore 20 sized to snugly receive the insert 14. As will be described further in detail, the connecting element 12 can be formed of tubular material with a through bore sized to receive insert 14.
The insert 14 is shown as a tubular section with inclined end surfaces 18 which are beveled relative to the longitudinal axis of the insert. The beveled ends 18 facilitate entry into the bores 20 of the connecting elements 12 as illustrated in FIG. 2. The insert 14 partially extends into each end of the through bore 20 of a single connecting element 12 and snugly engages the wall 22 of the bore 20 to form a tight frictional engagement therewith. The materials and sizing of the insert 14, bore 20 and connecting element wall 22 surrounding the bore 20 are so selected that assembly of the coupling device 10 is accomplished by a simple push-on effort.
The assembled coupling device 10 for a ring, as shown in FIG. 2, illustrates the relative hardness between the insert 14 and connecting element 12. The softer, outer connecting element 12 is slightly expanded at 24 by the insert 14. This assures a tight frictional grip between the insert 14 and connecting element 12. The harder insert 14 has sufficient firmness to withstand the compressive action of the expanded segment 24 of the connecting element. Although the vinyl insert 14 bends slightly with the ring curvature of the connecting element 12, the insert does not completely conform as shown by the small gaps 28 between the insert ends 18 and the wall 22.
The pulling apart of the connected coupling device 10 involves a force which exceeds that needed to assembly. This is illustrated in the view of FIG. 3 wherein the connecting element 12 is shown slightly elongated as a result of a longitudinal separating force as suggested by arrows 30. Gaps 28 disappear due to straightening of element 12 when pulled as described. This increases surface contact area and coupling tensile strength. The pull-apart force causes a very slight decrease of the transverse dimension of the softer connecting element 12 whose inwardly directed or contracting force profoundly increases the frictional gripping between the elements. Due to intersurface affinity, the increase of the frictional grip is suprisingly great.
When the connecting element 12 and insert 14 are each formed of a plastic material such as vinyl, their surfaces have strong affinity for each other so that the pull-apart force required to disconnect the coupling device 10 is considerably greater than that required to connect. With vinyl materials the release force exceeds the connecting force by a factor of about two and one-half or greater.
After disconnection as illustrated in FIG. 4, one of the ends, such as 16, of connecting element 12 unexpectly remains attached to insert 14 even though the insert was extended equidistantly into the ends 16--16'. As a result, the coupling device 10 can be conveniently reconnected after separation, thus loss of the insert element is practically prevented.
The coupling device of FIG. 2 employs an external connecting element 12 formed of a material capable of bending into a ring. The connecting element is sufficiently flexible around the end located bore 20 so that a compressional force during assembly of the coupling device 10 results in a slight transverse enlargement to enable the element 12 to readily fit over the element 12. The stretchy resilient character of the material for insert 14 is further sufficient to assure a slight visually difficult to discern contractional effect of the external element 12 when the coupling device 10 is being disconnected.
The insert 14, instead of having flexibility of the connecting element 12, has sufficient rigidity so that the insert 14 can withstand the contractional force encountered during disconnection and assure enhanced frictional coupling. The hardness of the insert 14 is thus higher than that of the connecting element 12.
When the elements 12, 14 of the coupling device 10 are formed of a vinyl plastic material, the hardness of the materials is preferably in the range of from about 70 to about 100 durometers for the insert element 14 and from about 50 to about 80 durometers for the more flexible and less rigid connecting element 12. Furthermore, the relative hardness between the two elements is selected sufficiently different to preserve a difference of at least about 10 up to about 50 durometers. In a preferred example for a coupling device formed of vinyl elements, the insert element 14 has a durometer hardness of about 95 while the durometer hardness for the connecting element 12 is about 60 durometers.
The tapering of the insert element 14 at its ends 18 facilitates entry into the ends 16 of the external element 12. The insert 14 is a tubular section cut to form similarly shaped converging beveled ends 18 leaving a central cylindrical region 32 of sufficient length, L, to assure high frictional engagement with the wall 20 of the connecting element 12.
With insert ends 18 beveled in the manner shown in FIG. 1, a distinct advantage is provided with regard to separating the joined coupling. With the beveled insert 14 positioned as in FIG. 2, the coupling may be most readily separated by pushing outward with an instrument such as a pencil or pen barrel or a thumb nail in the direction of arrow 31 against the juncture between ends 16--16'. This method of separation can be accomplished with generally less than half the force required to pull the coupling apart longitudinally in the manner of FIG. 3.
The length of the cylindrical region 32 may vary for different connecting strengths. However, if the length, L, is too great, the strength of the coupling is too large and an excessively large force is needed to separate the coupling device. Such force could break the more flexible outer connecting element 12. On the other hand, when the length, L, is too short, the retaining strength of the coupling device 10 is small and its inadvertent disconnection may occur.
Another factor which affects the connected strength of the coupling device 10 is the extent of the oversize of the cylindrical section 32 of the insert 14 relative to the cross-sectional size of the bore 20 of the connecting element 12 into which the insert 14 is to be placed. Generally, the amount of oversize is made sufficiently small so that the push-on force required to connect the coupling device is not excessively high. On the other hand, if the insert is too small, the frictional coupling is too light. Since precisely dimensioned tubular vinyl extruded plastic materials are not available, the amount of oversize is chosen to assure proper frictional coupling engagement, and to compensate for dimensional manufacturing inconsistencies. Generally, the insert's diameter oversize may be from about 0.0005 inches to about 0.040 inches (0.5 mil to 40 mil). Preferably, however, the diameter oversize is about 15 mils to assure a reasonably snug fit of the insert 14 inside the connecting element 12.
When an oversize of 15 mils is employed, the material yields slowly and achieves a semi-permanent set, so as to effectively result in a functionally optimum oversize of about 5 mils. Heating the assembled coupling or connecting element alone prior to assembly to a temperature of about 90° C. rapidly accelerates this yielding process. Some return to the original oversize of 15 mils may occur if the coupling is left disconnected for a long period of time.
The softness of the connecting element 12 permits one to use the oversized insert element 14 whose placement inside an end 16 of the connecting element causes the slight enlargement at 24 over the insert 14. This enlargement may vary depending upon the interference fit between the insert element 14 and the connecting element 12.
The release force needed to disconnect the coupling device 10 generally is substantially greater than the force needed to connect the coupling device. The magnitude of the release force tends to be sensitive to the amount of time that the vinyl elements have been coupled. For example, after 10 seconds a vinyl coupling device as illustrated in FIGS. 1 through 4 required a release force of about 5 pounds, which after 5 minutes, increased to six pounds and after 24 hours to about eight pounds. However, the force can also be quickly restored by simply applying suitable lateral compressional finger pressure to the joined insert and connecting elements.
The effectiveness of the coupling device in accordance with the invention can be further appreciated with reference to the embodiments shown in FIGS. 5 and 6. Therein a tubular vinyl connecting element 40 is employed with a wall 41 whose thickness, W, is substantial in comparison with the diameter, D, of the inner bore 42. In that case the outer connecting element 40 may have the same durometer hardness as in the example of FIGS. 1 through 4, but the larger wall thickness increases the stiffness. When a short bending radius is employed to form a ring with a connecting element 30, the thickwalled connecting element ends 44 may not neatly mesh, leaving a gap 43. This gap can be advantageously employed to insert a tool or finger nail to aid the disconnection of the coupling. This method for disconnection tends to compress and expand the ends 44 (rather than elongation with contraction), thus facilitating disconnection of the coupling.
The variation in thickness of connecting element 12 can be appreciated. For example, a vinyl tube 12 for the coupling embodiment of FIGS. 1 through 4 has been used wherein the diameter of bore 20 was 0.125 inches and the wall thickness about 1/32 of an inch. In the embodiment of FIGS. 5 and 6 the wall thickness was doubled to 1/16 of an inch with the same bore size of 1/8 of an inch. In these embodiments the insert element 14 had a cylindrical region length, L, of about 1/4 inch.
A ring may be formed with a coupling device 10 as shown in FIG. 7 by employing a pair of couplings 10.1 and 10.2 at approximately diametral positions. The outer connecting element 12 is formed of a pair of flexible material tubes which are connected with a pair of inserts 14.
In FIG. 8 the insert 14 is shown in an inverted position for a ring relative to that illustrated for the insert in previous figures. The insert element 14 still has the beveled end surfaces 18 but the shorter side is now facing an inward direction relative to the curvature for the outer connecting element 12. The security of the coupling is enhanced against abrupt upward pulls such as in the direction of arrow 30. In this respect the ease of disconnecting obtained as described with the orientation of insert 14 in FIG. 2 is not available.
In FIGS. 9 and 10 a coupling device 48 is shown using an insert 50 formed with a central cylindrical region 52 and tapered ends 54, 54'. The ends 54 taper slightly at a conical half angle α which is so selected that upon elongation or application of a release force 30 as illustrated in FIG. 10, the external connecting element 56 reduces the gaps 28 to the tapered ends 54 for increased frictional engagement. The tapered ends of insert 50 enable use of a relatively weak connecting force in comparison with a greater release force. The insert 50 may be formed of a solid vinyl or metal. The range for the conical half angle α may be from about 0.5° to about 15° .
The coupling device of this invention may be advantageously employed as three coupling rings 60 for a three ring loose-leaf paper binder 62 as shown in FIG. 11. Although the flexible coupling elements shown in the previous figures are suitable for such application, a more rigid form for a coupling device 64 as illustrated in FIG. 12 may be preferred. The coupling device 64 in FIG. 12 has a tubular insert element 14 provided with a stiffening member 66 in the form of a springy wire or stiff plastic rod which will reinforce the inner wall of the connecting element 12. This tends to prevent excessive bending of the ring 64 when used in an application such as the three ring notebook shown in FIG. 11. The stiffening element 66 may be sized to frictionally fit within the insert bore 68 and is of sufficient length to assure substantial circumferential support.
FIG. 13 shows another form for a more firmly composed coupling device 70 which includes an insert element 72 and outer tubular connecting element 74 formed of vinyl materials as previously described. In coupling device 70 the insert 72 is substantially longer than the connecting element 74 and, in fact, of sufficient length to be bent into a ring as illustrated. The ends 76, 76' of the insert 72 are beveled as illustrated to enable their entry into the bore 78 of the softer connecting element 74 and the bevels are oriented to fit close to each other. The insert 72, being of a harder material than the connecting element 74, provides the desired rigidity and resistance against excessive bending so that it can be used as a ring binder as illustrated in FIG. 11. The ring in FIG. 13 is shown formed with a single coupling 70 although it can be appreciated that two or more can be employed. The ends 80 of the connecting element 74 may be rounded or tapered to facilitate opening and closing of the pages in a loose-leaf notebook in which couplings 70 may be used.
Having thus described several embodiments for the coupling device in accordance with the invention, its advantages can be appreciated. Variations from the described embodiments can be made within the scope of the invention to be determined by the following claims.
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A coupling device is described and formed of a flexible tubular outer connecting element and a more rigid insert element sized to snugly fit into the bore of the connecting element. The elements are formed of vinyl material of different hardness so that their connection is accompanied with high frictional surface engagement. The resilience of the outer connecting element is selected sufficiently high to contract slightly and more tightly grip the insert in response to a separating force while facilitating connection with a slight expansion in response to a compressional connecting force applied to the elements. In one embodiment a ring fastener is formed for use as a key ring, or loose-leaf paper binder, apparel fastener and the like. Several embodiments are described.
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FIELD OF THE INVENTION
The invention relates to the implantation of stimulation leads within a patient, and in particular, the implantation of electrode leads within a patient's spine to treat disorders, such as chronic pain.
BACKGROUND OF THE INVENTION
It is known to treat chronic pain by electrically stimulating the spinal cord, spinal nerve roots, and other nerve bundles. Although not fully understood, the application of electrical energy to particular regions of the spinal cord induces parasthesia (i.e., a subjective sensation of numbness or tingling) in the afflicted body regions associated with the stimulated spinal regions. This parasthesia effectively masks the transmission of chronic pain sensations from the afflicted body regions to the brain. Since each body region is associated with a particular spinal nerve root, it is important that stimulation be applied at the proper longitudinal position along the spinal cord to provide successful pain management and avoid stimulation of unaffected regions of the body. Also, because nerve fibers extend between the brain and the nerve roots along the same side of the spine as the body regions they control, it is equally important that stimulation be applied at the proper lateral position of the spinal cord. For example, to treat unilateral pain (i.e., pain sensed only on one side of the body), electrical stimulation is applied to the corresponding side of the spinal cord. To treat bilateral pain (i.e., pain sensed on both sides of the body), electrical stimulation is either applied directly to the midline of the spinal cord or applied to both lateral sides of the spinal cord.
In a typical procedure, one or more stimulation leads are introduced through the patient's back into the epidural space under fluoroscopy. The specific procedure used to implant the stimulation lead will ultimately depend on the type of stimulation lead used. Currently, there are two types of commercially available stimulation leads: a percutaneous lead and a surgical lead.
A percutaneous lead comprises a cylindrical body with ring electrodes, and can be introduced into contact with the affected spinal tissue through a Touhy-like needle, which passes through the skin, between the desired vertebrae, and into the spinal cavity above the dura layer. For unilateral pain, a percutaneous lead is placed on the corresponding lateral side of the spinal cord. For bilateral pain, a percutaneous lead is placed down the midline of the spinal cord, or two percutaneous leads are placed down the respective sides of the midline.
A surgical lead has a paddle on which multiple electrodes are arranged in independent columns, and is introduced into contact with the affected spinal tissue using a surgical procedure, and specifically, a laminectomy, which involves removal of the laminar vertebral tissue to allow both access to the dura layer and positioning of the lead.
After the stimulation lead(s) (whether percutaneous or surgical) are placed at the target area of the spinal cord, the lead(s) are anchored in place, and the proximal ends of the lead(s), or alternatively lead extensions, are passed through a tunnel leading to a subcutaneous pocket (typically made in the patient's abdominal area) where a neurostimulator is implanted. The lead(s) are connected to the neurostimulator, which is then operated to test the effect of stimulation and adjust the parameters of the stimulation for optimal pain relief. During this procedure, the patient provides verbal feedback regarding the presence of paresthesia over the pain area. Based on this feedback, the lead position(s) may be adjusted and re-anchored if necessary. Any incisions are then closed to fully implant the system.
Various types of stimulation leads (both percutaneous and surgical), as well as stimulation sources and other components, for performing spinal cord stimulation are commercially available from Medtronic, Inc., located in Minneapolis, Minn., and Advanced Neuromodulation Systems, Inc., located in Plano, Tex.
The use of surgical leads provides several functional advantages over the use of percutaneous leads. For example, the paddle on a surgical leads has a greater footprint than that of a percutaneous lead. As a result, an implanted surgical lead is less apt to migrate from its optimum position than is an implanted percutaneous lead, thereby providing a more efficacious treatment and minimizing post operative procedures otherwise required to reposition the lead. As another example, the paddle of a surgical lead is insulated on one side. As a result, almost all of the stimulation energy is directed into the targeted neural tissue. The electrodes on the percutaneous leads, however, are entirely circumferentially exposed, so that much of the stimulation energy is directed away from the neural tissue. This ultimately translates into a lack of power efficiency, where percutaneous leads tend to exhaust a stimulator battery supply 25%-50% greater than that exhausted when surgical leads are used. As still another example, the multiple columns of electrodes on a surgical lead are well suited to address both unilateral and bilateral pain, where electrical energy may be administered using either column independently or administered using both columns.
Although surgical leads are functionally superior to percutaneous leads, there is one major drawback—surgical leads require painful surgery performed by a neurosurgeon, whereas percutaneous leads can be introduced into the epidural space minimally invasively by an anesthesiologist using local anesthesia.
There, thus, remains a need for a minimally invasive means of introducing stimulation leads within the spine of a patient, while preserving the functional advantages of a surgical lead.
SUMMARY OF THE INVENTION
Although the present inventions should not be so limited in their broadest aspects, they lend themselves well to medical applications, wherein access to a target site must be made through a limited opening, yet the resulting medical platform used to perform a medical procedure at such target site is larger than the access opening. The present inventions lend themselves particularly well to the percutaneous installation and subsequent operation of a stimulation lead assembly within the epidural space of a patient to treat ailments, such as chronic pain.
In accordance with a first aspect of the present inventions, a stimulation kit comprising first and second tissue stimulation leads is provided. The first stimulation lead comprises a first elongated body, a first stimulation element (e.g., an electrode), and a first coupling mechanism longitudinally extending along at least a portion of the first elongated body. The second stimulation lead comprises a second elongated body, a second stimulation element (e.g., an electrode), and a first complementary coupling mechanism configured to slidably engage the first coupling mechanism, e.g., in a rail and slot arrangement. The stimulation kit may optionally comprise a stimulation source configured to be coupled to the first and second stimulation leads. Optionally, each of the stimulation leads comprises a plurality of stimulation elements in order to provide a more extensive stimulation coverage.
In one embodiment, the first and second elongated bodies are cylindrically-shaped, although other shapes are possible depending on the particular application. The size of the elongated bodies can be any size that is consistent with the stimulation procedure in which the stimulation leads will be employed. Although, for medical procedures, such as spinal cord stimulation, the greatest cross-sectional dimension of at least one of the elongated bodies is preferably 5 mm or less in order to minimize the size of the opening through which the stimulation leads will be introduced. The elongated bodies can have the same length, or alternatively, one elongated body can be shorter than the other, such that, e.g., the shorter elongated body can be entirely delivered within the patient's body without any portion extending from the access opening. In one embodiment, the stimulation elements of the respective stimulation leads face the same direction, e.g., to focus the stimulation energy in one direction.
The stimulation elements may be mounted directly on the elongated bodies, or alternatively, may be mounted to some other element of the stimulation leads. For example, the second stimulation lead may have a flap on which the respective stimulation element is disposed. In this case, the flap may extend along a portion of the complementary coupling mechanism, so that it can be secured by the coupling mechanism of the first stimulation lead when the portion of the complementary coupling mechanism slidably engages the coupling mechanism of the first stimulation lead and released by the coupling mechanism of the first stimulation lead when the portion of the complementary coupling mechanism slidably disengages the coupling mechanism of the first stimulation lead.
In one embodiment, the distal end of the second elongated body is configured to be in close contact with the first elongated body when engaging each other. Alternatively, the first elongated body is configured to deploy from the first elongated body by slidably disengaging at least a portion of the complementation coupling mechanism from the coupling mechanism of the first stimulation lead. In this case, the distal end of the second elongated body can be pre-curved to provide it with a predefined configuration. Optionally, the second elongated body may be configured to be actively changed from a first geometry to a second geometry after deployment from the first elongated body. For example, the kit may comprise a stylet configured to be introduced through the second elongated body to change the second elongated body from the first geometry to the second geometry. Or the secondary stimulation lead may comprise a pullwire configured to be pulled to change the second elongated body from the first geometry to the second geometry.
The kit may have more than two stimulation leads. For example, the first stimulation lead may comprise another coupling mechanism longitudinally extending along at least a portion of the respective elongated body, in which case, the kit may further comprise a third stimulation lead comprising an elongated body, a stimulation element mounted on the elongated body, and another complementary coupling mechanism configured to slidably engage the other coupling mechanism of the first stimulation lead.
In one preferred method of using the stimulation kit to treat a disorder (e.g., chronic pain) in a patient, the first stimulation lead is delivered into the epidural space of the patient's spine, and the second stimulation lead is delivered into the epidural space by sliding the complementary coupling mechanism along the coupling mechanism of the first stimulation lead. Stimulation energy can then be conveyed from the stimulation elements into the neural tissue.
Preferably, the first and second stimulation leads are delivered through a percutaneous opening within the patient's skin, thereby minimizing patient discomfort and damage to otherwise healthy tissue. Although delivered in a minimally invasive manner, the larger footprint created by the coupled stimulation leads provides the assembly with more stability and greater coverage area. Thus, although not necessarily limited in its broadest aspects, the advantages of a surgical lead are retained by the present invention, without the disadvantages associated with invasive surgical procedures otherwise required to implant surgical leads.
In accordance with a second aspect of the present inventions, a method of treating a disorder (e.g., chronic pain) is provided. The method comprises delivering a first stimulation lead into the epidural space of the patient's spine, and delivering a second stimulation lead into the epidural space by slidably engaging the second stimulation lead along the first stimulation lead. A third stimulation lead can optionally be delivered into the epidural space by slidably engaging the third stimulation lead along the first stimulation lead. In one preferred method, the stimulation leads are delivered into the epidural space through a percutaneous opening. For example, the first stimulation lead can be introduced through a delivery device into the epidural space, and then the second stimulation lead can be delivered along the first stimulation lead.
In one preferred method, the stimulation leads are coupled to a stimulation source, in which case, the method may further comprise conveying stimulation energy (e.g., electrical energy) from the stimulation source to the stimulation leads to stimulate neural tissue within the patient's spine. The stimulation energy may be focused into the neural tissue, as opposed to conveying the stimulation energy in all radial directions. In the preferred method, the stimulation leads are implanted within the patient's spine, e.g., to provide extended relief.
In accordance with a third aspect of the present inventions, a medical kit is provided. The medical kit is similar to the previously described stimulation kit, with the exception that the medical kit comprises first and second medical leads with respective operative elements that are not limited to stimulation elements, but rather can be any elements that are capable of performing a medical function within a targeted tissue region.
In accordance with a fourth aspect of the present inventions, a method of performing a medical procedure on a patient is provided. This method is similar to the previously described method, with the exception that it is not limited to stimulation of tissue within the epidural space of the patient.
In accordance with a fifth aspect of the present inventions, a stimulation kit is provided. The stimulation kit is similar to the previously described stimulation kit, with the exception that it comprises a guide and a stimulation lead. The guide is similar to the first stimulation lead of the previously described stimulation kit, with the exception that it need not have a stimulation element.
In accordance with a sixth aspect of the present inventions, a medical kit is provided. The medical kit is similar to the previously described medical kit, with the exception that it comprises a guide and a medical lead. The guide is similar to the first medical lead of the previously described medical kit, with the exception that it need not have an operative element.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings illustrate the design and utility of preferred embodiment(s) of the invention, in which similar elements are referred to by common reference numerals. In order to better appreciate the advantages and objects of the invention, reference should be made to the accompanying drawings that illustrate the preferred embodiment(s). The drawings, however, depict the embodiment(s) of the invention, and should not be taken as limiting its scope. With this caveat, the embodiment(s) of the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 is a plan view of a modular stimulation lead kit arranged in accordance with a preferred embodiment of the present invention;
FIG. 2 is a cutaway top view of a stimulation lead assembly formed from the kit of FIG. 1 ;
FIG. 3 is a cutaway perspective view of a primary stimulation lead used in the kit of FIG. 1 ;
FIG. 4 is a cutaway perspective view of a secondary stimulation lead used in the kit of FIG. 1 ;
FIG. 5 is a cross-sectional view of the stimulation lead assembly of FIG. 2 , taken along the line 5 - 5 ;
FIG. 6 is a cutaway view of an alternative stimulation lead assembly that can be formed from the kit of FIG. 1 ;
FIG. 7 is a cross-sectional view of the stimulation lead assembly of FIG. 6 , taken along the line 7 - 7 ;
FIGS. 8A-8D are various views illustrating the installation of the kit of FIG. 1 into a patient's spine;
FIG. 9 is a plan view of another modular stimulation lead kit arranged in accordance with another preferred embodiment of the present invention;
FIG. 10 is a cutaway top view of a stimulation lead assembly formed from the kit of FIG. 9 ;
FIG. 11 is a cross-sectional view of the secondary stimulation lead of FIG. 10 , taken along the line 11 - 11 ;
FIGS. 12A-12B are various views illustrating the installation of the kit of FIG. 9 into a patient's spine;
FIG. 13 is a partially cutaway top view of the distal end of an alternative primary stimulation lead that can be used in kit of FIG. 1 ;
FIG. 14 a is a cutaway top view of an alternative stimulation lead assembly that can be formed from the kit of FIG. 1 when the primary stimulation lead of FIG. 13 is used, wherein the secondary stimulation leads are shown in a normally curved geometry that converges towards the primary stimulation lead;
FIG. 15 a is a cross-sectional view of the stimulation lead assembly of FIG. 14 a , taken along the line 15 a - 15 a;
FIG. 14 b is a cutaway top view of an alternative stimulation lead assembly that can be formed from the kit of FIG. 1 when the primary stimulation lead of FIG. 13 is used, wherein the secondary stimulation leads can be placed into a curved geometry that converges towards the primary stimulation lead when a stylet is introduced;
FIG. 15 b is a cross-sectional view of the stimulation lead assembly of FIG. 14 b , taken along the line 15 b - 15 b;
FIG. 14 c is a cutaway top view of another alternative stimulation lead assembly that can be formed from the kit of FIG. 1 when the primary stimulation lead of FIG. 13 is used, wherein the secondary stimulation leads can be placed into a curved geometry that converges towards the primary stimulation lead when a pullwire is tensioned;
FIG. 15 c is a cross-sectional view of the stimulation lead assembly of FIG. 14 c , taken along the line 15 c - 15 c;
FIG. 14 d is a cutaway top view of still another alternative stimulation lead assembly that can be formed from the kit of FIG. 1 when the primary stimulation lead of FIG. 3 is used, wherein the secondary stimulation leads can be placed into a curved geometry that bows away from the primary stimulation lead;
FIG. 15 d is a cross-sectional view of the stimulation lead assembly of FIG. 14 d , taken along the line 15 d - 15 d;
FIG. 15 e is a cross-sectional view of the stimulation lead assembly of FIG. 14 d , taken along the line 15 e - 15 e;
FIG. 15 f is a cross-sectional view of the stimulation lead assembly of FIG. 14 d , taken along the line 15 f - 15 f;
FIG. 16 is a cutaway top view of an alternative stimulation lead assembly;
FIG. 17 is a cross-sectional view of a portion of the stimulation lead assembly of FIG. 16 , particularly showing an electrode flap of a secondary stimulation lead constrained by the primary stimulation lead; and
FIG. 18 is a cross-sectional view of a portion of the stimulation lead assembly of FIG. 16 , particularly showing the electrode flap of the secondary stimulation lead released by the primary stimulation lead.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 , a modular stimulation lead kit 100 arranged in accordance with one preferred embodiment of the present invention is shown. In its simplest form, the stimulation kit 100 generally comprises a primary stimulation lead 102 and two secondary stimulation leads 104 , which are configured to be percutaneously delivered and implanted into the epidural space of a patient's spine, an implantable electrical stimulation source 106 configured for delivering stimulation energy to the stimulation leads 102 / 104 , and an optional extension lead 108 configured for connecting the stimulation leads 102 / 104 to the remotely implanted stimulation source 106 . As will be described in further detail below, the secondary stimulation leads 104 can be attached to the primary stimulation lead 102 to form a modularized stimulation lead assembly 110 , as illustrated in FIG. 2 .
It should be noted that although the kit 100 illustrated in FIG. 1 is described herein as being used in spinal cord stimulation (SCS) for the treatment of chronic pain, the kit 100 , or a modification of the kit 100 , can be used in an SCS procedure to treat other ailments, or can used in other applications other than SCS procedures, such as peripheral nervous system stimulation, sacral root stimulation, and brain tissue stimulation, including cortical and deep brain stimulation. In the latter case, the stimulation leads 102 / 104 can be delivered through a miniature cranial burr hole into the brain tissue.
The primary stimulation lead 102 comprises an elongated sheath body 112 having a proximal end 114 and a distal end 116 . The sheath body 112 is composed of a suitably flexible material (such as polyurethane, silicone, etc.), which may either be resilient or non-resilient, and may be formed via an extrusion process or by any other suitable means. The distal end 116 of the sheath body 112 is soft and tapered to prevent injury to nerve roots that exit the spinal cord when delivered into the epidural space of the patient's spine. In the illustrated embodiment, the sheath body 112 is cylindrically-shaped and sized to fit through a Touhy-like needle (not shown). In this case, the diameter of the sheath body 112 is preferably less than 5 mm to allow it to be percutaneously introduced through a needle. More preferably, the diameter of the sheath body 112 is within the range of 1 mm to 3 mm, so that the primary stimulation lead 102 , along with the secondary stimulation leads 104 described below, can comfortably fit within the epidural space of the patient. The sheath body 112 may have other cross-sectional geometries, such as elliptical, rectangular, triangular, etc. If rectangular, the width of the primary stimulation lead 102 can be up to 5 mm, since the width of an epidural space is greater than its height. The sheath body 112 may have an optional lumen (not shown) for receiving a stylet (not shown) that axially stiffens the sheath body 112 to facilitate percutaneous introduction of the primary stimulation lead 102 within the epidural space of the patient's spine, as will be described in further detail below.
The primary stimulation lead 102 further comprises a plurality of terminals 118 (in this case, three) mounted on the proximal end 114 of the sheath body 112 , and a plurality of stimulation elements, and in particular electrodes 120 (in this case, three), mounted on the distal end 116 of the sheath body 112 . The terminals 118 are formed of ring-shaped elements composed of a suitable biocompatible metallic material, such as platinum, platinum/iridium, stainless steel, gold, or combinations or alloys of these materials, and can be mounted to the sheath body 112 in an interference fit arrangement.
In the illustrated embodiment, the electrodes 120 are formed on one circumferential side of the sheath body 112 (shown best in FIG. 3 ) in order to focus stimulation energy in one direction, thereby maximizing energy efficiency. The electrodes 120 can be formed onto the sheath body 112 using known deposition processes, such as sputtering, vapor deposition, ion beam deposition, electroplating over a deposited seed layer, or a combination of these processes. Alternatively, the electrodes 120 can be formed onto the sheath body 112 as a thin sheet or foil of electrically conductive metal affixed to the wall of the sheath body 112 . The electrodes 120 can be composed of the same electrically conductive and biocompatible material as the terminals 118 , e.g., platinum, platinum/iridium, stainless steel, gold, or combinations or alloys of these materials.
The primary stimulation lead 102 further comprises a plurality of conductors 122 (shown in FIG. 3 ) extending through the sheath body 112 and connecting each electrode 120 with a respective terminal 118 . The conductors 122 are composed of a suitably electrically conductive material that exhibits the desired mechanical properties of low resistance, corrosion resistance, flexibility, and strength.
Like the primary stimulation lead 102 , each secondary stimulation lead 104 comprises an elongated sheath body 132 having a proximal end 134 and a distal end 136 , a plurality of terminals 138 (in this case, four) mounted to the proximal end 134 of the sheath body 132 , a plurality of electrodes 140 (in this case, four) mounted to the distal end 136 of the sheath body 132 , and a plurality of conductors 142 (shown in FIG. 4 ) extending through the sheath body 132 and respectively connecting the electrodes 120 to the terminals 118 . The sheath bodies 132 of the secondary stimulation leads 104 are similar to the sheath body 112 of the primary stimulation lead 102 , with the exception that the distal ends 136 are tapered in only one direction. In this manner, the stimulation lead assembly 110 , as illustrated in FIG. 2 , forms a lower profile distal end to facilitate placement of the assembly 110 within the epidural space of the patient's spine. Like the sheath body 112 of the primary stimulation lead 102 , the sheath bodies 132 of the secondary stimulation leads 104 may each have an optional lumen (not shown) for receiving a stylet (not shown) to facilitate percutaneous introduction of the secondary stimulation lead 104 within the epidural space of the patient's spine, as will be described in further detail below.
The terminals 118 and electrodes 120 of the secondary stimulation leads 104 are similar to the terminals 118 and electrodes 120 of the primary stimulation lead 102 , with the exception that there are four sets of terminals 118 and electrodes 120 instead of three. Notably, the electrodes 120 of the secondary stimulation leads 104 face the same direction as the electrodes 140 of the primary stimulation leads 102 , so that the entire stimulation lead assembly 110 is capable of focusing electrical energy in a single direction, as shown in FIG. 3 . Also, as illustrated in FIG. 3 , the electrodes 120 / 140 are arranged on the respective sheath bodies 112 / 132 , such that the electrodes 140 of the secondary stimulation leads 104 are offset from the electrodes 120 of the primary stimulation lead 102 in the longitudinal direction, thereby preventing accidental shorting between adjacent electrodes when the assembly 110 is formed.
Further details regarding the structure and composition of standard percutaneous stimulation leads are disclosed in U.S. Pat. No. 6,216,045, which is expressly incorporated herein by reference.
The primary stimulation lead 102 and the respective secondary stimulation leads 104 are configured to slidably engage each other to form the lead assembly 110 illustrated in FIG. 2 . In particular, referring to FIGS. 3-5 , the primary stimulation lead 102 comprises a pair of circumferentially opposed slots 150 extending along the length of the sheath body 112 . The slots 150 can be formed in the sheath body 112 using any one of a variety of manners, but in the illustrated embodiment, the slots 150 are formed during the extrusion process. Alternatively, the slots 150 can be formed by embedding, or otherwise mounting, discrete slotted members (not shown) along the sheath body 112 . In contrast, each of the secondary stimulation leads 104 comprises a rail 152 extending along the sheath body 132 . Like the slots 150 , the rail 152 can be formed on the sheath body 132 using any one of a variety of manners, such as forming the rail 152 during the extrusion process. Alternatively, the rail 152 can be formed of a discrete member (not shown) that is bonded, or otherwise mounted, to the sheath body 132 . In other embodiments, the primary stimulation lead 102 may have a pair of circumferentially opposed rails extending along its sheath body 112 , while the secondary stimulation leads 104 may have slots 150 extending along their sheath bodies 132 . In any event, the rails 152 and slots 150 are sized to snuggly engage each other in a sliding relationship, as best shown in FIG. 5 .
Thus, it can be appreciated that the secondary stimulation leads 104 can be coupled to the primary stimulation lead 102 by sliding the rails 152 of the respective secondary stimulation leads 104 along the respective slots 150 of the primary stimulation lead 102 , thereby forming the stimulation assembly 110 illustrated in FIG. 2 . The opposing slots 150 of the primary stimulation lead 102 and the rails 152 of the secondary stimulation leads 104 are circumferentially offset ninety degrees from the centers of the respective electrodes 120 . In this manner, all of the electrodes 120 , which generally face in the same direction, as described above, are ensured to face in a direction perpendicular to the plane of the assembly 110 , thereby maximizing transmission of the stimulation energy into the target neural tissue when the assembly 110 is fully implanted within the epidural space of the patient's spine.
Although a rail and slot arrangement has been disclosed as the preferred means of slidably engaging the primary and stimulation leads 102 / 104 , other means of slidably engaging the leads can be provided. For example, instead of slots, the primary stimulation lead can have loop structures (not shown) that extend along the opposing sides the respective sheath body. The secondary stimulation leads 104 can then be introduced through the respective sets of loop structures in order to couple the leads together.
In the illustrated embodiment, the slots 150 have distal rail stops (not shown), i.e., the distal ends of the slots 150 terminate prior to the distal tip of the sheath body 112 to prevent the distal ends 136 of the secondary stimulation leads 104 from sliding distal to the distal end 116 of the primary stimulation lead 102 . Alternatively, the distal ends of the slots 150 may have chamfered openings 151 , as illustrated in FIG. 13 . In this manner, the distal ends of the secondary stimulation leads 104 will diverge from the distal end of the primary stimulation lead 102 when the leads 102 / 104 are slidably engaged with each other. That is, when the rail 152 of a secondary stimulation lead 104 is slid along the respective slot 150 of the primary stimulation lead 102 , the distal end of the rail 152 will be diverted out of the chamfered opening 151 at the distal end of the slot 150 , thereby expanding the footprint of the resulting assembly 110 , as illustrated in FIG. 14 a . The secondary stimulation lead 104 may have a proximal rail stop (not shown) to prevent further sliding of the respective secondary stimulation lead 104 when fully deployed.
The distal ends of the secondary stimulation leads 104 can be pre-curved inward towards the primary stimulation lead 102 , as illustrated in FIG. 14 a , so that the distal ends of the secondary stimulation leads 104 , when deployed from the primary stimulation lead 102 , extend in a parallel direction with the distal end of the primary stimulation lead 102 . The distal ends of the secondary stimulation leads 104 can be pre-curved in any one of a variety of manners. For example, as illustrated in FIG. 15 a , a pre-curved resilient member 153 composed of a suitable material, such as nitinol, can be formed within the sheath body 132 . Preferably, the cross-section of the resilient member 153 resembles of flat plate, so that the sheath body 132 consistently bends in a pre-defined plane, i.e., within the plane of the assembly 110 .
Alternatively, as illustrated in FIG. 14 b , the distal ends of the secondary stimulation leads 104 are not pre-curved, but rather normally exhibit a straight geometry after exiting slot 150 of the primary stimulation lead 102 (shown in phantom in FIG. 14 b ), such that the distal ends of the secondary stimulation leads 104 diverge from the primary stimulation lead 102 . Alternatively, the distal ends of the secondary stimulation leads 104 may not be resilient. In either case, the secondary stimulation lead 104 comprises a lumen 155 through which a curved stylet 157 is introduced, as illustrated in FIG. 15 b . The distal end of the stylet 157 is curved, such that, when introduced through the lumen 155 , the distal end of the respective stimulation lead 104 assumes a geometry that curves inward towards the primary stimulation lead 102 , as illustrated in FIG. 14 b . Differently curved stylets 157 can be used in order to provide the distal end of the secondary stimulation lead 104 with the desired curved geometry. Alternatively, rather than providing a curved stylet 157 and a normally straight secondary stimulation lead 104 , the distal end of the secondary stimulation lead 104 can be pre-curved much like the stimulation lead 104 illustrated in FIG. 14 a . In this case, the distal end of the stylet 157 can be straight, so that its introduction through the lumen 157 straightens the pre-curved distal end of the secondary stimulation lead 104 , as shown in phantom in FIG. 14 b.
As another alternative, a steering mechanism can be used to control the shape of the secondary stimulation lead 104 . In particular, as illustrated in FIG. 14 c , the distal ends of the secondary stimulation leads 104 normally exhibit a straight geometry, in which case, the resilient member 153 is likewise formed into a straight geometry. As illustrated in FIG. 15 c , the secondary stimulation lead 104 comprises a pullwire lumen 159 and an associated pullwire 161 mounted to the inside surface of the distal end of the resilient member 153 . When the pullwire 161 is relaxed, the distal end of the secondary stimulation lead 104 assumes the straight geometry. In this case, the distal ends of the secondary stimulation leads 104 diverge from the primary stimulation lead 102 , as illustrated in FIG. 14 c . In contrast, when the pullwire 161 is pulled, the distal end of the secondary stimulation lead 104 assumes a geometry (shown in phantom) that curves inward towards the primary stimulation lead 102 . Notably, the proximal-most portion of the distal ends of the secondary stimulation leads 104 does not contain the resilient member 153 , so that the respective stimulation lead 104 bends at this portion when the pullwire 161 is pulled. Rather than providing a normally straight secondary stimulation lead 104 , the distal end of the secondary stimulation lead 104 can be pre-curved much like the stimulation lead 104 illustrated in FIG. 14 a . In this case, the pullwire 161 can be mounted to the outside surface of the distal end of the resilient member 153 , such that relaxation of the pullwire 161 causes the distal end of the secondary stimulation lead 104 to assume a curved geometry that converges towards the primary stimulation lead 102 , whereas the application of tension on the pullwire 161 causes the distal end of the secondary stimulation lead 104 to assume a lesser curved or straight geometry that diverges from the primary stimulation lead 102 .
As still another alternative, a portion of the secondary stimulation lead 104 may not have a rail, so that it bows outward after the primary stimulation lead 102 and secondary stimulation lead 104 are fully engaged, as illustrated in FIG. 14 d . As best seen in FIGS. 15 d - f , the rail 152 extends along the distal-most and proximal-most portions of the distal end of the second stimulation lead 104 , but does not extend along a medial-portion of the distal end of the second stimulation lead 104 . As a result, after the distal end of the respective rail 152 (i.e., the rail 152 located on the distal-most portion of the second stimulation lead 104 ) abuts the distal rail stop (not shown) in the corresponding slot 150 , further distal movement of the secondary stimulation lead 104 relative to the primary stimulation lead 102 causes the medial-portion, which is not engaged with the slot 150 of the primary stimulation lead 102 , to bow outward from a straight geometry (shown in phantom). In contrast, proximal movement of the secondary stimulation lead 104 relative to the primary stimulation lead 102 causes the medial-portion to return from the bowed geometry back to its straight geometry.
It should be noted that although the assemblies 110 illustrated in FIGS. 2 and 14 a - d are formed of three stimulation leads, less or more than three stimulation leads can be used. For example, if an assembly formed only of two stimulation leads is desired, only one slot 150 on the primary stimulation lead 102 is required. In this case, the primary stimulation lead 102 may only have one slot 150 formed along one side of the respective body 112 , or alternatively, if the primary stimulation lead 102 comprises two opposing slots 150 , only one will be used to couple the lone secondary stimulation lead 104 thereto. On the other hand, if an assembly formed of more than three stimulation leads is desired, the secondary stimulation leads 104 may have a pair of circumferentially opposed rails 152 . For example, if there are five stimulation leads, two secondary stimulation leads 103 (which are similar to the secondary stimulation leads 104 , but with a pair of circumferentially opposing rails 152 ) can be coupled to the primary stimulation lead 102 by sliding the rails 152 of the respective secondary stimulation leads 104 along the respective slots 150 of the primary stimulation lead 102 , thereby forming a partial assembly similar to that illustrated in FIG. 3 . Then, two additional secondary stimulation leads 105 (which are similar to secondary stimulation leads 105 , but have a pair of circumferentially opposed slots 150 ) can be coupled to the secondary stimulation leads 105 by sliding the slots 150 of the additional secondary stimulation leads 102 along the respective rails 152 , thereby forming a full assembly 160 , as illustrated in FIGS. 6 and 7 .
Referring back to FIG. 1 , the implantable stimulation source 106 is designed to deliver electrical pulses to the stimulation leads 102 / 104 in accordance with programmed parameters. In the preferred embodiment, the stimulation source 106 is programmed to output electrical pulses having amplitudes varying from 0.1 to 20 volts, pulse widths varying from 0.02 to 1.5 milliseconds, and repetition rates varying from 2 to 2500 Hertz. In the illustrated embodiment, the stimulation source 106 takes the form of a totally self-contained generator, which once implanted, may be activated and controlled by an outside telemetry source, e.g., a small magnet. In this case, the pulse generator has an internal power source that limits the life of the pulse generator to a few years, and after the power source is expended, the pulse generator must be replaced. Generally, these types of stimulation sources 106 may be implanted within the chest or abdominal region beneath the skin of the patient.
Alternatively, the implantable stimulation source 106 may take the form of a passive receiver that receives radio frequency (RF) signals from an external transmitter worn by the patient. In this scenario, the life of the stimulation source 106 is virtually unlimited, since the stimulation signals originate from the external transmitter. Like the self-contained generators, the receivers of these types of stimulation sources 106 can be implanted within the chest or abdominal region beneath the skin of the patient. The receivers may also be suitable for implantation behind the ear of the patient, in which case, the external transmitter may be worn on the ear of the patient in a manner similar to that of a hearing aid. Stimulation sources, such as those just described, are commercially available from Advanced Neuromodulation Systems, Inc., located in Piano, Tex., and Medtronic, Inc., located in Minneapolis, Minn.
The optional extension lead 108 comprises an elongated sheath body 144 having a proximal end 146 and a distal end 148 , much like the sheath bodies 112 / 132 of the stimulation leads 102 / 104 , a distal adapter 154 coupled to the distal end 148 of the sheath body 144 , a connector 156 coupled to the proximal end 146 of the sheath body 144 , and a plurality of electrical conductors (not shown) extending through the sheath body 144 . The length of the extension lead 108 is sufficient to extend from the spine of the patient, where the proximal ends of the implanted stimulation leads 102 / 104 protrude from to the implantation site of the stimulation source 106 —typically somewhere in the chest or abdominal region. The distal adapter 154 is configured to receive the proximal ends of the stimulation leads 102 / 104 , and the proximal connector 156 is configured to couple to the stimulation source 106 .
Having described the stimulation lead kit 100 , its installation and use in treating chronic pain will now be described with reference to FIGS. 8A-8D . After the patient has been prepared (which may involve testing the efficacy of spinal cord stimulation on the patient, and, once determining that the patient can be effectively treated with spinal cord stimulation, identifying and marking the appropriate vertebral intervals on the patient's skin and applying a local anesthetic to this region), a needle 10 , such as, e.g., a Touhy needle, is inserted through the patient's skin 12 between the desired vertebrae 14 , and into the epidural space 16 within the spine at a position inferior to target stimulation site 18 ( FIG. 8A ). In the illustrated method, the Touhy needle 10 will serve as the primary delivery mechanism for the primary stimulation lead 102 . Alternatively, if an optional introducer (not shown) is used, a guide wire (not shown) is introduced through the needle 10 and advanced to or near the target stimulation site 18 . The needle 10 is removed, the introducer is then introduced over the guide wire and advanced to the target stimulation site 18 , and the guide wire is then withdrawn. In this case, the introducer will serve as the primary delivery mechanism for the primary stimulation lead 102 .
After the deliver mechanism is in place, the primary stimulation lead 102 is then inserted through the needle or the introducer (whichever is in place), and positioned in the epidural space at the target stimulation site 18 , with the electrodes 120 facing the dural layer 20 surrounding the spinal cord 22 ( FIG. 8B ). If the primary stimulation lead 102 has a stylet lumen, a stylet can be used to provide additional axial stiffness and to facilitate control. Next, the needle 10 or introducer is removed, and one of the secondary stimulation leads 104 is delivered through the percutaneous opening 24 left by the removal of the needle 10 , and into the epidural space 16 by slidably engaging the secondary stimulation lead 104 along the primary stimulation lead 102 ( FIG. 8C ). In particular, the rail 152 of the secondary stimulation lead 104 is inserted into the corresponding slot 150 of the primary stimulation lead 102 , and the secondary stimulation lead 104 is pushed until the distal end of the rail 152 abuts the distal end of the slot 150 , thereby signifying that the secondary stimulation lead 104 is fully engaged with the primary stimulation lead 102 (with the electrodes 120 / 140 of the stimulation leads 102 / 104 adjacent, but offset from, each other) and is in its proper location within the epidural space 16 of the patient. The other secondary stimulation lead 104 is then delivered into the epidural space by slidably engaging it along the primary stimulation lead 102 in the same manner, thereby completing the stimulation lead assembly 110 ( FIG. 8D ). If the secondary stimulation leads 104 have stylet lumens, a stylet can be used to provide additional axial stiffness and to facilitate control. Once the assembly 110 is completed, the electrodes 120 / 140 will span the midline of the spinal cord 22 , much like the electrodes of a standard surgical lead do.
Next, the proximal ends of the stimulation leads 102 / 104 are connected to a tester (not shown), which is then operated in a standard manner to confirm proper location of the stimulation lead assembly 110 and to adjust the stimulation parameters for optimal pain relief. Once this optimization process has been completed, the tester is disconnected from the stimulation leads 102 / 104 , which are then anchored in place using standard lead anchors (not shown). Next, the stimulation lead assembly 110 is coupled to the stimulation source 106 and implantation is completed (not shown). In particular, a subcutaneous pocket is created in the patient's abdominal area for implantation of the stimulation source 106 , and a tunnel is subcutaneously formed between the spine region and the subcutaneous pocket. The optional lead extension 108 is passed through the tunnel, after which the adapter 154 of the extension 108 is connected to the proximal ends of the stimulation leads 102 / 104 and the connector 156 of the lead extension 108 is connected to the stimulation source 106 . The stimulation source 106 is programmed and tested, and then placed within the subcutaneous pocket, after which all incisions are closed to effect implantation of the stimulation lead assembly 110 and stimulation source 106 . The stimulation source 106 can then be operated to convey stimulation energy from the stimulation source 106 to the electrodes 120 / 140 of the stimulation lead assembly 110 , where it is, in turn, conveyed into the neural tissue for pain relief. If necessary or desired, e.g., if the electrodes 120 / 140 malfunction or stimulation otherwise ceases to provide therapeutic benefit, the stimulation lead assembly 110 can be subsequently retrieved from the patient's spine by removing the assembly 110 at the same time or by removing the assembly one stimulation lead 102 / 104 at a time by slidably disengaging the stimulation leads 102 / 104 . In the case of the assembly 110 illustrated in FIG. 14 , the rail and slot arrangement will pull the deployed distal end of the secondary stimulation leads 104 along side of the primary stimulation lead 102 when retrieved.
It can be appreciated that the relatively large footprint made by the stimulation lead assembly 110 , much like a prior art surgical lead, provides a more stable platform for the electrodes 120 / 140 . Also, like a prior art surgical lead, the electrodes 120 / 140 face in a single direction, thereby focusing the stimulation energy into the affected neural tissue where it is needed. Unlike a surgical lead, however, the stimulation lead assembly 110 can be percutaneously delivered into the patient's spine in a minimally invasive and relatively pain-free manner, without requiring extensive patient recovery.
Referring now to FIG. 9 , a modular stimulation lead kit 200 arranged in accordance with another preferred embodiment of the present invention is shown. The kit 200 is similar to the previously described kit 100 , with the exception that the kit 200 comprises secondary stimulation leads 204 that minimize the profile of the resulting assembly (shown in FIG. 10 ), as it exits the spine of the patient. In particular, each secondary stimulation lead 204 comprises a shortened sheath body 232 , electrodes 240 mounted to the sheath body 232 , electrical conductors 242 extending from the sheath body 232 , and a connector 244 that receives the proximal ends of the electrical conductors 242 . The connector 244 comprises a plurality of terminals 238 that are similar to the previously described lead terminals 138 . The sheath body 232 is composed of the same material and has the same general shape as the sheath body 132 of the previously described secondary stimulation lead 104 . The sheath body 232 , as illustrated in FIG. 9 , however, is much shorter, so that it can be entirely received within the epidural space of the patient, i.e., the sheath body 232 will not extend out of the patient's back when fully deployed within the epidural space. The electrical conductors 242 , because they are exposed, are preferably composed of an electrically insulative material.
The kit 200 further comprises a pusher 214 that can be used to facilitate introduction of the respective secondary stimulation lead 204 along the primary stimulation lead 102 once the entire sheath body 232 of the secondary stimulation lead 204 is within the patient's back. The pusher 214 comprises a cylindrical rod 216 having a distal tip 218 and a proximal end 220 , and a handle 222 mounted on the proximal end 220 of the rod 216 . The distal tip 218 of the rod 216 is adapted to be received within an opening 224 (shown in FIG. 11 ) at the proximal end of the sheath body 232 , thereby facilitating stable engagement between the pusher 214 and respective secondary stimulation lead 204 .
The kit 200 can be installed and used in the same manner as the previously described kit 100 in treating chronic pain. In particular, the patient is prepared and the primary stimulation lead 102 is delivered into the epidural space 16 of the patient's spine, so that the electrodes 120 are placed adjacent the target stimulation site 18 in the same manner described above with respect to FIGS. 8A and 8B . One of the secondary stimulation leads 204 is then delivered into the epidural space 16 in the same manner as the secondary stimulation lead 104 described above was delivered, with the exception that the pusher 214 is used to advance the secondary stimulation lead 204 along the primary stimulation lead 102 until fully deployed within the epidural space 16 ( FIG. 12A ). The remaining stimulation lead 204 is delivered into the epidural space 16 in the same manner to complete the stimulation lead assembly 210 ( FIG. 12B ).
Notably, because the percutaneous opening 24 need only support, at most, two sheath bodies at one time, it can be made smaller, or alternatively, additional stimulation leads with shortened sheath bodies can be introduced within the epidural space 16 without increasing the size of the percutaneous opening. After the stimulation lead assembly 210 has been formed within the epidural space, it is tested and optimized. The extension lead 108 is then connected between the stimulation leads 102 / 204 and the stimulation source 106 , and the incisions are closed to fully implant the system, as previously described above.
Referring now to FIG. 16 , an alternative embodiment of a secondary stimulation lead 304 engaged with one side of the primary stimulation 102 is illustrated. Although not shown, another secondary stimulation lead 304 can be engaged with the opposite side of the primary stimulation lead 102 . The secondary stimulation lead 304 is similar to the previously described secondary stimulation lead 104 , with the exception that the secondary stimulation lead 304 comprises a flap 303 on which the electrodes 140 are mounted. The secondary stimulation lead 304 can, alternatively, have a shortened sheath body much like the secondary stimulation lead 204 illustrated in FIG. 9 . The flap 303 is designed to be constrained by the primary stimulation lead 102 to facilitate percutaneous delivery of the secondary stimulation lead 102 , and released by the primary stimulation lead 102 to deploy the electrodes 140 into contact with the neural tissue.
In particular, the edge of the flap 303 comprises a coupling mechanism 305 that is designed to fit snugly within the respective slot 150 of the primary stimulation lead 102 , along with the rail 152 of the secondary stimulation lead 102 , when the secondary stimulation lead 304 is slidably engaged with the primary stimulation lead 102 , as illustrated in FIG. 17 . As the rail 152 of the secondary stimulation lead 102 exits the slot 150 of the primary stimulation lead 102 , however, the coupling mechanism 305 of the flap 303 will release from the slot 150 , thereby allowing the flap 303 to deploy, placing the electrodes 140 into contact with the underlying tissue, as illustrated in FIG. 18 . It should be noted, that, when the secondary stimulation lead 304 is used in the kit 100 or kit 200 , the slots 150 in the primary stimulation lead 102 will not terminate as hereinbefore described, but will rather open up at the distal tip of the primary stimulation lead 102 , so that the flap 303 can exit the respective slot 150 and be released by the primary stimulation lead 102 .
Installation and use of the secondary stimulation lead 304 in forming the stimulation lead assembly 110 illustrated in FIG. 2 , or alternatively the stimulation lead assembly 210 illustrated in FIG. 10 , is similar that previously described above.
Although in all of the previous embodiments, the primary stimulation lead 102 was used to provide a means of guiding the secondary stimulation leads 104 into the percutaneous opening within the patient and adjacent the target tissue region, as well as to provide a means of stimulating the tissue region, a guide member similar to the primary stimulation lead 102 , but lacking stimulation capability, can be alternatively used to similarly guide the secondary stimulation leads 104 through the percutaneous opening to the target tissue region. In this case, only the secondary stimulation leads 104 will be used to stimulate tissue.
Although particular embodiments of the present invention have been shown and described, it should be understood that the above discussion is not intended to limit the present invention to these embodiments. It will be obvious to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the present invention. Thus, the present invention is intended to cover alternatives, modifications, and equivalents that may fall within the spirit and scope of the present invention as defined by the claims.
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A medical kit and method for treating an ailment, such as chronic pain is provided. The kit comprises first and second medical leads, e.g., stimulation leads. Each lead comprises an elongated body and at least one operative element. The first medical lead comprises a coupling mechanism, such as a slot, and the second medical lead comprises a complementary mechanism, such as a rail, that slidably engages the coupling mechanism of the first medical lead. The method may comprise delivering the first medical lead into a patient's body, e.g., into the epidural space of the patient, and delivering the second medical lead into the patient's body by sliding the complementary coupling mechanism of the second medical lead along the coupling mechanism of the first medical lead.
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BACKGROUND
[0001] A tuned mass damper (TMD) provides improved damping to structures and devices at a single frequency by tuning the damper's natural frequency to be at or close to the single frequency. TMDs are attached to the structure at an effective position, usually the anti-node, to counteract the device's vibration. The vibration stimulates the TMD to oscillator independently, 180 degrees out of phase, reducing the device's vibration.
[0002] A TMD typically is adjusted at the factory by changing springs or removing material from the oscillating mass, estimating the frequency of the device to be damped. The typical TMD comprises a mass, a spring and a damping means which form a system with a specific natural resonant frequency and because of that structure it is difficult to tune that frequency.
SUMMARY
[0003] A TMD according to invention is adjustable by utilizing an adjustment screw that is retracted or advanced, changing the number of active coils in a spring that engages a damping mass in a sealed TMD. The screw adjustment changes the spring rate and the natural frequency of the spring-mass combination but does not compress the spring.
[0004] Objects, benefits and features of the invention will be apparent to one of ordinary skill in the art from the drawing and following description.
BRIEF DESCRIPTION OF THE DRAWING
[0005] The drawing is a cross section of a tubular adjustable tuned mass damper that embodies the present invention.
DESCRIPTION
[0006] The TMD 10 shown in the drawing comprises a tubular structure attached by a bracket 12 to a device or structure 14 that is subject to oscillations which are damped by the TMD 10 . The TMD 10 has two removable end-plates 16 , 17 providing access to the interior of the TMD where a cylindrical mass 18 is located in a cylindrical chamber 19 and supported by a plurality of ball bearings 20 , constrained within grooves 22 running lengthwise along the mass (arrow A1) to enable sufficient lateral movement for the mass to oscillator back and forth (arrow A1). Gas flow, arrow, across the mass 18 damps those oscillations as it moves in the chamber 19 .
[0007] A primary coil spring 24 is placed between one end of the mass 18 and internal wall 10 a of the chamber 19 . A screw 26 is threaded into a threaded passage 10 b , entering the center of the spring 24 where it captures one or more of the spring's coils, which should have the same screw pitch as the adjustment screw 26 if no movement of mass 18 is desired during adjustment. Rotating the screw 26 changes the spring stiffness and thereby the natural resonant frequency of the mass 18 and spring 24 combination. Rotating the screw 26 does not, however, displace the spring. It only grabs one or more coils, making them effectively rigid. One end of the TMD is sealed from the atmosphere when the end plate 16 is attached by screws or rivets, not shown. The other end plate 17 is similarly attached for sealing the side with the screw 26 , but also contains a small passage 17 a , closed by a removable plug (not shown), through which the adjustment screw 26 can be turned. A sealing and locking material can be included between the wall 10 a and the screw 26 , for example at location 10 c , producing a screw friction lock and also sealing the interior of the chamber 19 from the atmosphere through the screw threads.
[0008] While the invention envisions in its most basic sense manually turning the adjustments screw 26 , it is also feasible to automate the process by attaching a screw actuator, such as a low speed motor, to the housing 10 with a shaft extending through passage 17 a to the adjustment screw 26 . With this variation of the invention, the spring can be automatically adjusted on device 14 through a sensing apparatus, such as an accelerometer, to fine tune the TMD during operation, further reducing the vibrations of the device 14 .
[0009] One skilled in the art may make modifications, in whole or in part, to a 20 described embodiment of the invention and its various functions and components without departing from the true scope and spirit of the invention.
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A tuned mass damper is adjusted by turning a screw inside the damper that engages coils on a spring, reducing or increasing spring stiffness without displacing the spring.
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The invention relates to alumina-titanium oxide-zirconia fused grains, to a method of manufacturing such grains, and to a slide gate including such grains.
BACKGROUND OF THE INVENTION
Slide gates are parts used in continuous casting of steel for opening and closing distributors or outlet orifices from casting ladles in fluid communication via a sliding nozzle with ingot molds. Slide gates must therefore present good mechanical strength, in particular against thermal shocks and spalling, and good chemical resistance, in particular against corrosion.
Conventionally, slide gates are obtained by sintering a mixture of alumina-zirconia fused grains and zirconia-mullite fused grains. The alumina-zirconia/zirconia-mullite composite is particularly good at withstanding thermal shocks because of its reinforcement by microcracking. During heating, the allotropic transformation of zirconia is accompanied by a large change in volume. This dimensional variation leads to the formation of microcracks. These microcracks also appear at the interfaces between zirconia-mullite particles and the alumina-zirconia matrix because of the large difference in thermal expansion between alumina-zirconia (α 1000°C. =9.6×10 −6 /° C.) and zirconia-mullite (α 1000°C. =6.9×10 −6 /° C.). These two phenomena lead to the part being microcracked, thereby increasing its capacity for absorbing energy in the event of thermal shocks.
Nevertheless, zirconia-mullite presents the disadvantage of presenting low resistance to corrosion, thus constituting the weak point of the composite.
OBJECT AND SUMMARY OF THE INVENTION
There thus exists a need for a novel grain suitable for taking the place of mullite-zirconia grain when manufacturing slide gates, that enables slide gates to be made that present improved resistance to corrosion. The object of the invention is to satisfy that need.
According to the invention, this object is achieved by means of an alumina-titanium oxide-zirconia fused grain presenting, for a total of 100%, the following chemical composition:
Al 2 O 3 : more than 10%, preferably more than 15%, and less than 50%, preferably less than 35%; TiO 2 : more than 10%, preferably more than 15%, and less than 40%, preferably less than 30%, more preferably less than 25%; ZrO 2 : more than 50%, and preferably less than 70%, or less than 61%; impurities: less than 2%;
the percentages being percentages by weight based on the oxides, the grain not presenting a TiO 2 phase, and more than 98% by weight of the zirconia being monoclinic.
In a preferred embodiment of the invention, the composition of the grain comprises about 60% of ZrO 2 , about 20% of Al 2 O 3 , and about 18% to 20% of TiO 2 .
Surprisingly, the inventors have found that substituting mullite-zirconia grains with grains of the invention makes it possible to manufacture composite slide gates that withstand corrosion better, without degrading ability to withstand thermal shocks.
In addition, the inventors have found that the absence of the TiO 2 phase improves resistance to corrosion. The grain of the invention preferably presents the following phases only:
Al 2 O 3 with Zr 5 Ti 7 O 24 and/or, (ZrTiO 4 or ZrO 2 ) with aluminum titanate Al 2 TiO 5 .
A preferred grain presents the phases Al 2 O 3 −Zr 5 Ti 7 O 24 , the most preferred grain presenting the phases ZrO 2 −Al 2 TiO 5 .
Finally, the grain of the invention can be melted by electrofusion, thus enabling large quantities of grains to be manufactured with advantageous efficiency. The price/performance ratio is thus excellent.
Preferably, the fused grain of the invention further includes one or more of the following optional characteristics:
its chemical composition further presents a quantity of tin oxide (Sno 2 ) of more than 2%, preferably more than 5%, and/or less than 10%, the ranges of the other ingredients not being changed. For a total of 100%, the chemical composition of the grain is then as follows, percentages being by weight based on the oxides:
Al 2 O 3 : more than 10%, preferably more than 15%, and less than 50%, preferably less than 35%, or less than 20%; TiO 2 : more than 10%, preferably more than 15%, and less than 40%, preferably less than 30%, more preferably less than 25%; ZrO 2 : more than 50%, and preferably less than 76%, or less than 70%; SnO 2 : more than 2%, preferably more than 5%, and less than 10%, or less than 6%; impurities: less than 2%;
the zirconia may be combined with the tin oxide; more than 98% of weight by the zirconia is in monoclinic phase.
Whatever the embodiment, the grain of the invention comprises preferably at least 0.1%, preferably at least 0.5% and/or less than 3% of MgO, in percentages by weight based on the oxides, the ranges of the other ingredients mentioned above not being changed.
For a total of 100%, chemical compositions of the grain are then as follows, percentages being by weight based on the oxides:
Al 2 O 3 : more than 10%, preferably more than 15%, and less than 50%, preferably less than 35%, or less than 20%; TiO 2 : more than 10%, preferably more than 15%, and less than 40%, preferably less than 30%, more preferably less than 25%; ZrO 2 : more than 50%, and preferably less than 76%, or less than 70%; SnO 2 : optional; MgO: optional; impurities: less than 2%;
When SnO 2 is present, its concentration is preferably more than 2%, preferably 5%, and/or less than 10%, or 6%.
When MgO is present, its concentration is preferably more than 0.1%, preferably 0.5%, and/or less than 3%, or 2.5%.
The “impurities” comprise ingredients other than SnO 2 , TiO 2 , Al 2 O 3 , ZrO 2 , and, when explicitly mentioned MgO, and in particular compounds forming part of the group comprising oxides, nitrides, oxynitrides, carbides, oxycarbides, carbonitrides, and metallic species of sodium and other alkalies, irons, silicon, vanadium, and chromium. Hafnium oxide which is naturally present in sources of zirconia at concentrations of less than 2% is not considered as an impurity. Residual carbon, expressed as C, forms part of the impurities in the composition of grains of the invention.
It is considered that an impurity content of less than 2% does not eliminate the technical effect procured by the invention.
The invention also provides a method of fabricating alumina-titanium oxide-zirconia fused grains of the invention, the method comprising the following successive steps:
a) mixing raw materials to form an initial charge;
b) melting the initial charge to obtain a molten liquid;
c) cooling said molten liquid so that the molten liquid is entirely solidified in less than 3 minutes, preferably less than 1 minute, more preferably less than 15 seconds, so as to obtain a solid mass;
d) optionally grinding said solid mass so as to obtain a mixture of grains.
According to the invention, the raw materials are selected in step a) so that the grains obtained in step d) are in accordance with the invention.
Preferably, one or several of the oxides from Al 2 O 3 , TiO 2 , ZrO 2 , SnO 2 , MgO, their precursors and their mixtures are intentionally, that is to say systematically and methodically, added in step a), in quantities guaranteeing that the grains obtained in step c) are in accordance with the invention.
Any conventional method of manufacturing alumina-titanium oxide-zirconia fused grains can be implemented, providing the composition of the initial charge enables grains to be obtained that presents a composition in accordance with that of grains of the invention.
In step a), the titanium may be introduced in any form, in particular in metallic form or in the form of a zirconia-titanium oxide alloy, or of alumina titanate.
Compositions enabling phases of Zr 5 Ti 7 O 24 and/or of alumina titanate Al 2 TiO 5 and/or of ZrTiO 4 to be obtained while avoiding a TiO 2 phase can easily be determined by the person skilled in the art from the ternary Al 2 O 3 −TiO 2 −ZrO 2 phase diagram, and more precisely along the pseudo-binary Al 2 TiO 5 −ZrO 2 diagram.
The contents of the various raw materials in the initial charge should also be determined to take account of the reduction in the content of SnO 2 during heating in step b). The magnitude of this reduction as a function of heating conditions is well known to the person skilled in the art.
In step b), it is preferable to use an electric arc furnace, however any known furnace could be envisaged, such as an induction furnace or a plasma furnace, providing it enables the initial charge to be melted completely. Heating is preferably performed under inert conditions, e.g. under argon, or under oxidizing conditions, preferably at atmospheric pressure.
In step c), cooling is rapid, i.e. so that the molten liquid solidifies completely in less than 3 minutes. Preferably, it is the result of casting into CS molds as described in U.S. Pat. No. 3,993,119 or from quenching. Advantageously, such rapid cooling avoids a TiO 2 phase appearing. Slow cooling would on the contrary lead to phases dissociating and thus produce the species: Al 2 O 3 +TiO 2 or ZrO 2 +TiO 2 .
In step d), the solid mass is ground, using conventional techniques.
Finally, the invention provides a slide gate made of sintered composite material presenting alumina-titanium oxide-zirconia fused grains of the invention bonded by an alumina-zirconia matrix.
DETAILED DESCRIPTION OF THE INVENTION
The following examples are provided by way of illustration and they do not limit the scope of the invention.
Reference 1 (ref. 1) is a ZrO 2 -mullite product sold by the supplier Treibacher Schleifmittel.
Reference 2 (ref. 2) is a product known as FAZ 40. This product is an alumina-zirconia sold by the supplier Sowa Denko.
To prepare the samples of Examples 1, 2, and 3, powders were mixed in a Turbula mixer for 2 hours and then melted in a graphite crucible under an atmosphere of argon in an induction furnace. Cooling depends on the inertia of the furnace. That produced samples that were generally small, requiring post-melting oxidation heat treatment.
For the other examples and the reference compositions, the powder mixtures were melted using an electric arc furnace, under air, with oxidizing electrical operation. Cooling was controlled using various methods (CS mold enabling the sample to cool rapidly, ingot cooled in free air, or reheater unit).
The raw materials were as follows: CC10 monoclinic zirconia sold by SEPR, AR75 alumina from Pechiney, tin oxide from Keeling & Walker Ltd., TiO 2 rutile from CRB GmbH.
The chemical composition, given in percentages by weight based on the oxides were measured using conventional methods: chemical analysis was performed by X-ray fluorescence.
The crystal phases present in the refractory compositions were determined by X-ray diffraction. In Table 1, “˜” means “traces”.
The coefficient of expansion at 1000° C. “a” was measured on pellets prepared from powders having the same size fraction (median diameter d<150 micrometers (μm)), compacted at 20 kilonewtons (kN) over 13 millimeters (mm), and then sintered (1450° C. for 3 hours (h) in air).
Grain corrosion by slag was evaluated with an optical microscope after calcining a grain-slay mixture at 1450° C. The slag was essentially constituted by SiO 2 (40%), CaO (40%) , Na 2 O (10%) , and Al 2 O 3 (5%). It presented a basicity index (CaO+MgO)/SiO 2 of 1. Although the grains were not intended to come into contact with slag, corrosion in slag serves to impose particularly severe conditions, making it possible to measure corrosion that is significant. A score “R” for resistance to corrosion was given in the range 0 to 4, with the resistance being better for higher R scores.
The allotropic transformation temperature “T” of the tested grains needs to be as close as possible to that of reference 2 (alumina-zirconia grains) so that microcracking is effective in improving the ability of the composite material made from a mixture of these two types of grain to absorb energy during thermal shocks, as explained in the introduction. In contrast, and for the same reason, the coefficient of expansion at 1000° C., “a” of a tested material should be as different as possible from that of reference 2.
“V” designates the rate of solidification of the molten liquid: “H” and “D” meaning “a few hours” and “a few days” respectively. “<10 s” means “less than 10 seconds”.
The results are summarized in Table 1 below.
TABLE 1
Chemical composition
Phases after
V
Al 2 O 3
TiO 2
MgO
ZrO 2
SnO 2
Phases
10 h at 1100° C.
a
T
R
Réf 1
6.9 · 10 −6 ° C. −1
1050° C.
1
Réf 2
9.6 · 10 −6 ° C. −1
1100° C.
0
3
H
40.4%
31.0%
28.6%
Zr 5 Ti 7 O 24. , Al 2 O 3 ,
5.4 · 10 −6 ° C. −1
500° C.
1
TiO 2
4
<10 s
21.5%
20.2%
58.3%
mZrO 2 , Al 2 TiO 5
mZrO 2 , Al 2 TiO 5 ,
7.3 · 10 −6 ° C. −1
770° C.
4
~TiO 2
5
H
20.2%
19.5%
60.3%
mZrO 2 , Al 2 TiO 5 ,
mZrO 2 , Al 2 O 3 ,
7.3 · 10 −6 ° C. −1
770° C.
2
~Zr 5 Ti 7 O 24
TiO 2 , ~Al 2 TiO 5
6
D
25.7%
21.0%
53.3%
mZrO 2 , Al 2 TiO 5 ,
2
~Al 2 O 3 , ~Al 2 Ti 7 O 15
7
<10 s
19.6%
15.9%
58.6%
5.9%
mZrO 2 , Al 2 TiO 5 ,
8.2 · 10 −6 ° C. −1
960° C.
3
~SnO 2
8
D
18.8%
14.5%
62.4%
4.3%
mZrO 2 , Al 2 O 3 ,
2
TiO 2 , ~Al 2 TiO 5 ,
~Zr 0.6 Sn 0.4 TiO 4
9
D
12.4%
10.0%
75.3%
2.3%
mZrO 2 , Al 2 O 3 ,
2
TiO 2 , ~Al 2 TiO 5 ,
~Zr 0.6 Sn 0.4 TiO 4
10
<10 s
18.3%
22.2%
2.0%
57.4%
mZrO 2 , solid
mZrO 2 , solid
4.9 · 10 −6 ° C. −1
842° C.
4
solution AlTiMgO
solution
AlTiMgO
11
H
18.1%
22.0%
2.0%
57.9%
mZrO 2 , solid
mZrO 2 , solid
6 · 10 −6 ° C. −1
811° C.
2
solution AlTiMgO
solution
AlTiMgO
Table 1 above shows that the grains of the invention present coefficients of expansion “a” that are far enough removed from those of alumina-zirconia grains (reference 2) to generate microcracking in sintered composite materials made from those two types of grain. Grains of the invention can thus take the place of prior art mullite-zirconia grains for fabricating composite material slide gates, the alumina-titanium oxide-zirconia fused grains of the invention being bonded together by an alumina-zirconia matrix.
Table 1 also shows the advantage of rapid cooling (Examples 4 and 7), and also the drawback of the presence of a TiO 2 phase (Example 3), in improving resistance to corrosion.
Other measurements have also shown that grains of the invention present a coefficient of expansion that varies as a function of temperature in a manner that is similar to that of zirconia-mullite grains. In particular, the allotropic transformation of zirconia leads to a break in the variation of the coefficient of expansion. In order to ensure that this break takes place at a temperature that is as high as possible, advantageously substantially at the same temperature as for alumina-zirconia grains, it is preferable for the zirconia in the grains of the invention to be entirely in monoclinic form (more than 98%).
Since titanium is a stabilizer for zirconia, it is preferable for its content to be small in the initial charge. Preferably the TiO 2 content in the initial charge is thus less than 40%, preferably less than 30%, more preferably less than 25%.
As the examples 10 and 11 show, the presence of magnesia further improves the performances of the grains of the invention. Preferably, the grains of the invention comprise at least 0.1%, preferably at least 0.5% of MgO. The examples 10 and 11 show that a concentration close to 2%, in particular comprised between 1.5 and 2.5%, provides very good results.
In particular, a heat treatment during 10 h at 1100° C., representative of the heat conditions encountered in use, show that the phases, and therefore the properties of the grains, remain steady.
Besides, it is noteworthy that the presence of MgO, according to the invention, avoids the formation of TiO 2 , which is harmful.
However, the concentration of MgO is preferably less than 3%, in percentages by weight based on the oxides. Beyond this limit, a part of the magnesia stabilizes the zirconia and the percentage of monoclinic zirconia may be less than 98%.
Examples 10 and 11 are regarded as the most preferable since they give an optimal compromise between the different properties.
In a preferred embodiment of the invention, the grains of the invention thus present the following concentrations by weight, in percentages by weight based on the oxides:
Al 2 O 3 : more than 16% and/or less than 20%; TiO 2 : more than 20% and/or less than 24%; MgO: more than 1% and/or less than 3%; ZrO 2 : more than 55% and/or less than 60%;
Without being restricted to this theoretical explanation, the inventors consider that grains of the invention act in the same way as mullite-zirconia grains to microcrack the composite material, and thus make it better at withstanding thermal shocks.
Unlike zirconia-mullite grains, grains of the invention nevertheless do not lead to a silica-containing environment, which would lead to low resistance to corrosion. Using alumina-titanium oxide-zirconia grains of the invention instead of prior art mullite-zirconia grains thus serves to retain effective resistance to thermal shocks, while improving resistance to corrosion.
Naturally, the implements described are merely examples and they could be modified, in particular by substituting equivalent techniques, without thereby going beyond the ambit of the invention.
|
An alumina-titanium oxide-zirconia fused grain presenting, for a total of 100%, the following chemical composition:
Al 2 O 3 : more than 10% and less than 50%; TiO 2 : more than 10% and less than 40%; ZrO 2 : more than 50%; and impurities: less than 2%;
the percentages being percentages by weight on the basis of the oxides. The invention is applicable to slide gates for continuous casting of steel.
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FIELD OF THE INVENTION
This invention relates to an improved optical brightener. More particularly, it relates to an inclusion compound having equimolar amounts of a fluorescent bis(benzoxazolyl) stilbene and a cyclodextrin. The invention also relates to the use of such inclusion compounds as optical brighteners in photographic elements having a paper support.
BACKGROUND OF THE INVENTION
A valuable class of photographic supports and elements comprises a paper base material having thereon a polyolefin coating containing a white pigment and an optical brightener. Such supports are particularly useful in the preparation of photographic elements such as color prints because they exhibit good brightness and excellent dimensional stability and are highly resistant to the action of aqueous acid and alkaline photographic processing solutions. The polyolefin coating provides a very smooth surface which is desirable when thin layers, such as silver halide emulsion layers, are to be coated thereover, U.S. Pat. No. 3,411,908 describes such a support which has achieved widespread commercial acceptance.
The purpose of the optical brightener is to make the white areas of the support appear even brighter. The optical brightener fluoresces upon irradiation with UV (ultraviolet) light, emitting visible light, usually bluish in hue, thus enhancing the brightness of the support. Optical brighteners for use in photographic print materials must absorb UV light, especially in the region from 360 to 420 nm, and reemit such light so as to enhance the brightness of the print, and have the desired brightening power. The optical brightener must also be stable to the temperatures, as high as 310°-330° C., used in extruding the polyolefin onto the paper base material.
Moreover, the optical brightener must be nonmigrating so that it remains in the polyolefin coating and does not exude as a surface film on the polyolefin. Such exudation not only can give rise to a nonuniform brightness of the reflection surface of the support, but also readily transfers to any other surface contacted with it. For example, brightener transferred nonuniformly to the back side of the adjacent layer of support results in visual imperfections. Brightener when migrated to the surface of the front side, can when wound in roll form, adversely affect subsequent coating and finishing operations and, in consequence, the quality and performance of the final element.
In general, prior art brighteners do not exhibit the combination of absorption/emission characteristics and brightening power, heat stability, and resistance to brightener exudation to the levels desired for photographic supports and elements. Thus, what has been desired is a photographic element comprising an optically brightened support, such support having improved resistance to brightener exudation and wherein the brightener exhibits excellent absorption/exmission characteristics, brightening power and heat stability.
Tomko et al, U.S. Pat. No. 4,794,071, provides a particularly efficacious photographic element containing a fluorescent bis(benzoxazolyl) stilbene optical brightener mixture that has a reduced tendency to migrate. The support provided by Tomko is especially useful for color prints, and is comprised of a paper base material having thereon a polyolefin coating containing a white pigment and a mixture of optical brighteners, such mixture comprising certain fluorescent bis(benzoxazolyl)-stilbenes. The support exhibits improved brightness at low brightener concentration and unexpected resistance to brightener exudation.
This invention provides, in one aspect, an improvement in the elements of Tomko et al. Thus, this invention provides an improved brightener which is complexed with a cyclodextrin. It also provides the use of such brightener inclusion compounds in photographic elements having a paper support. Complexed brighteners of this invention having a reduced tendency to migrate compared to the uncomplexed brighteners of Tomko et al.
In summary, it is desirable to have resin-coated paper used as a support for reflective photographic prints to have a bluish hue so that once the emulsion is placed on it a white D min results. In order to obtain a bluish tint, either pigments, dyes or optical brighteners may be added to the polyethylene. The method of adding the optical brighteners is preferred, since this does not result in a loss of brightness, which is the case for either pigments or dyes. However, it is known that many optical brighteners tend to migrate from the polyethylene, even at relatively low levels, due to limited solubility. This migration phenomenon is not desirable since it can cause non-uniform color of the support or may contaminate subsequent coating operations, or may cause the emulsion to not properly adhere to the support. Therefore, in the art, optical brighteners can only be used in limited amounts, and the rest of the bluish tint must be acquired using pigments and/or dyes.
Thus, it is desirable to improve D min in the support via use of an optical brightener that has a lessened tendency to migrate during prolonged storage or shipping, prior to sensitizing. This invention satisfies that need.
RELATED ART
U.S. Pat. No. 3,501,298 describes a photographic element having a support comprising a paper base having thereon a polyolefin coating which contains titanium dioxide and bis(alkylbenzoxazolyl)thiophenes.
U.S. Pat. No. 3,449,257 relates to compositions comprising hydrophobic polymers and nonmigrating optical brighteners and to paper supports coated with such compositions. The nonmigrating optical brighteners are 2,5-bis(benzoxazolyl)thiophenes.
U.S. Pat. No. 3,260,715 discloses fluorescent bis(benzoxazolyl)stilbenes, such as 4,4'-bis(benzoxazol-2-yl)stilbene, which are useful as fluorescent brightening agents for textile fibers, papers, resins and photographic color print materials.
U.S. Pat. No. 4,933,948 provides aqueous solutions useful in dye lasers contain a substituted cyclodextrin-fluorescent dye inclusion compound, and an excess of the cyclodextrin. Such solutions give greater fluorescent yields than similar inclusion compounds made from non-substituted cyclodextrins. Cyclodextrins have found applications in many areas. In the foods technology it is used for encapsulation of flavors, (see Rogers, W. I. et al. (1962), U.S. Pat. No. 3,061,444), for reduction of unpleasant odors (Hamilton, R. W. et al. (1970), U.S. Pat. No. 3,528,819). In his book, "Cyclodextrin Technology", Kluwer Academic Publishers, Dordrecht, the Netherlands, J. Szejtli reviews applications of cyclodextrin in the industry and medicine. Cyclodextrins have found use in separations of various mixtures; this separation was based on selective complexation. Alpha cyclodextrin was found to influence an alkaline hydrolysis of substituted phenyl acetates. Reiners et al. describe the method for reducing the free acid levels of glyceride oils by using cyclodextrins (U.S. Pat. No. 3,491,132).
SUMMARY OF THE INVENTION
In one aspect, this invention provides as a composition of matter,
an inclusion compound of (i) a cyclodextrin selected from the class consisting of unsubstituted α, β, and γ, cyclodextrin and α, β, and γ, cyclodextrins having a substituent bonded to an oxygen atom in a glucose unit in said cyclodextrin, said substituent being selected from the class consisting of:
a) alkyl radicals having 1 to 6 carbon atoms,
b) radicals having the formula --(--CH--CH--R 1 --O--) n --H wherein R 1 is selected from hydrogen and alkyl radicals having up to about six carbon atoms, and n is equal to a small whole number up to six, and
c) radicals having the formula --CHR 1 --CHOH--CHR 1 wherein R 1 has the same definition as above, such that said radicals bridge two cyclodextrin rings, and the number of said rings so bridged per molecule is from two to about six; said substituted cyclodextrin having not more than two substituents per glucose unit; said optical brightener having the formula ##STR1## wherein R 1 and R 2 are independently selected from hydrogen and alkyl radicals having up to about six carbon atoms.
In another aspect, this invention provides a photographic element comprising a paper support, and on at least one side thereof, a polyolefin coating containing an inclusion compound of the type described above.
It has been found in work conducted during development of this invention, that such photographic elements containing an inclusion compound of an optical brightener and a cyclodextrin are highly improved, because the migration behavior of the optical brightener is significantly retarded. Thus, the photographic elements have more uniform color, and improved adherence of emulsion layers to the support.
For these reasons, it is believed that this invention is a significant advance in the art, and readily adaptable by industry.
DESCRIPTION OF PREFERRED EMBODIMENTS
The invention hereinafter described particularly with regard to preferred embodiments as an optically brightened photographic support and a photographic element comprising such support. In addition, the invention is useful in other applications wherein an optically brightened polyolefin coating resistant to brightener exudation is desired.
The photographic support of this invention comprises a paper base material having thereon a polyolefin coating containing a white pigment and which is present in an inclusion compound with a cyclodextrin.
In a highly preferred embodiment, the optical brightener is a compound having formula I above. For these compounds, R 1 and R 2 are preferably the same. However, as illustrated below, it is not necessary that they be the same. Thus for example one may use a mixture of brighteners such as a mixture of compounds (A), (B) and (C): ##STR2##
The above-noted bis(benzoxazolyl)stilbenes are known optical brighteners. To obtain a mixture of such compounds, the individual compounds can be mixed according to conventional means or the mixture can be obtained as the product of the method of synthesis utilized. The individual compounds can be prepared by methods known in the art.
For example, compound A can be prepared by chlorination of a (benzoxazolyl)stilbenecarboxylic acid and subsequent reaction with an aminophenol. Details of such a preparation can be found in U.S. Pat. No. 4,282,355, the disclosure of which is hereby incorporated by reference.
Compound B can be prepared by the method described in U.S. Pat. No. 3,260,715, the disclosure of which is hereby incorporated by reference. Briefly, such method, illustrated particularly in Example 1 therein, comprises chlorination of a 4,4'-stilbenedicarboxylic acid and subsequent reaction with o-amino-phenol.
Compound C can be prepared as described in U.K. Patent Specification No. 1,026,368 the disclosure of which is hereby incorporated by reference. Such preparation comprises the step of reacting 1-amino-2-hydroxy-5-methylbenzene with 4,4'-stilbenedicarboxylic acid.
Alternatively, the mixture of (A), (B) and (C) can be conveniently obtained as a reaction product. For example, the mixture can be obtained by reaction 4,4'-stilbenedicarboxylic acid with 1-amino-2-hydroxy -5-methyl-benzene and 1-amino-2-hydroxybenzene in various proportions. This method is further described in U.S. Pat. No. 3,366,575, the disclosure of which is hereby incorporated by reference.
The relative amounts of components (A), (B) and (C) required to be present in the mixture to achieve the intended effects can be widely varied, as desired. Preferred mixtures include by weight about 15-90 percent of component (A), about 5-70 percent of component (B), and about 5-70 percent of component (C), such percentages being based on the total weight of the mixture. Highly preferred mixtures include about 40-70 percent of compound (A), about 10-35 percent of (B), and about 10-35 percent of (C).
The cyclodextrins are rings of 6, 7, or 8 glucose units, and such rings are generally referred to as α, β and γ cyclodextrin respectively. Unsubstituted cyclodextrins can be used to form the inclusion compounds of this invention. However, for this invention it is preferred that the cyclodextrins be substituted. Methyl β cyclodextrin is a highly preferred starting material for this invention.
The cyclodextrins used in this invention have an internal cavity that is not so large that two or more optical brightener molecules fit therein. β cyclodextrins are preferred for this invention. However, α and γ cyclodextrins can be used, when one molecule of optical brightener fits in the cavity thereof.
The substituted cyclodextrins employed in this invention are preferably selected from several types of compounds. First, it is preferred that the cyclodextrin be an α or β-cyclodextrin, i.e., that it have six or seven glucose units in the ring. More preferably, the substituted cyclodextrin is a beta cyclodextrin, i.e., it has seven glucopyranose units in the ring. The substituted alpha cyclo-dextrins can be used when the dye molecules are of a sufficient size to fit within the cavity formed by the ring of glucopyranose units. Second, it is preferred that the substituent or substituents in the cyclodextrin molecules be bonded to an oxygen atom in a ring glucose unit. It is also preferred that when the cyclodextrin has two or more substituents per molecule, the substituents be the same. Such compounds are preferred because they are more generally available; however, it is to be understood that this invention is not limited to their use.
Each glucose unit may have a substituent. However, it is not necessary that the cyclodextrin be that heavily substituted. In other words, not all of the ring glucose units need to be substituted. For this invention, it is only necessary that, on average, each cyclodextrin molecule has one substituent per cyclo-dextrin ring. The substituents may be in one or more of the 2-,3-, or 6-positions in the glucopyranose rings.
The cyclodextrin rings may be composed of glucose units (sometimes referred to herein as glucopyranose units) having up to three substituents. Again, it is not necessary that the units be that heavily substituted. Hence, it is preferred that the number of substituents per glucose unit be within the range of from about 0.5 to about 2.0. It is to be understood that the invention extends to the use of cyclodextrins somewhat outside this range. Thus, for example, one may use hexakis and heptakis tri-substituted compounds; i.e., α- and β-cyclodextrins having three substituents per glucose unit.
Compounds of the types discussed above have preferred types of substituents. One preferred type of substituent is an alkyl radical. Of the alkyl radicals, those having up to about six carbon atoms are preferred. The methyl group is a highly preferred substituent, especially when two or more substituents are on one glucose unit in the dextrin ring.
A second preferred type of substituent has the formula --(CH--CHR 1 --O--) n --H wherein R 1 is selected from the class consisting of hydrogen and alkyl groups having up to about six carbon atoms. In the above formula, n is a small whole number having a value up to about six; preferably, n is equal to 1. Preferred substituents of this type are hydroxyethyl and hydroxypropyl.
A third type of substituent on the cyclodextrin is a bridging group that links two cyclodextrin moieties. These bridging groups have the formula --CHR 1 --CHOH--CHR 1 -- wherein R 1 has the same significance as above. In these polymeric cyclodextrins, the number of cyclodextrin rings so bridged is from about two to about six. In other words, there can be two cyclodextrin rings linked by the bridging group, or there can be three of the rings liked by two bridging groups, and so on, such that there can be six rings linked by five bridging groups. It is to be understood that higher polymers can be used in the invention if they have properties analogous to the polymers within the range given above, and the increased size or molecular weight does not confer an undesirable property to the extent that it makes the material unsuitable for use in the invention.
The polymeric cyclodextrins may have substituents in addition to the group that links or bridges two cyclodextrin moieties. For example, the cyclodextrin moieties may have one or more carboxyalkyl (--R--COOH) substituents, wherein R is a lower alkylene radical having up to about 4 carbon atoms. Preferably such a substituent is carboxymethyl; --CH 2 --COOH. Preferably, there are two carboxymethyl groups per cyclodextrin ring.
For this invention a cyclodextrin, or mixture thereof, is combined with an optical brightener, or mixture thereof, under conditions which allow formation of an inclusion compound, or mixture of inclusion compounds to take place. This invention is not dependent upon the method employed for inclusion compound formation, and any method apparent to a skilled practitioner can be used.
During the course of development of this invention, it was found that a satisfactory method comprises mixing equimolar or substantially equimolar amounts, of cyclodextrin and optical brightener in a solvent such as dimethylformamide (DMF), warming the mixture to allow the dissolution to take place, and then removing the DMF from the resultant emulsion compound.
The amount of the brightener mixture which is used in the present invention is an amount effective to brighten the reflective layer. Such amounts of the mixture can be from 0.01 percent to 0.25 percent by weight based on the total weight of the polyolefin coating, including the white pigment. One employs an amount of brightener sufficient to give the increase in brighteness desired. The amount need not necessarily be the same as when the brightener is employed by itself; that is not in an inclusion compound. In other words, the optical brightness conferred by an inclusion compound may be less than, or greater than the parent optical brightener. Preferably, the amount is from about 0.01 percent to about 0.10 percent by weight in the polyolefin coating. As noted, the mixture is stable to the temperatures as high as 310°-330° C., used in extruding the polyolefin onto the paper base material.
The polyolefin can be any coatable polyolefin material known in the photographic art. Representative of these materials are polyethylene, polypropylene, polystyrene, polybutylene, and copolymers thereof. Polyethylene of low, medium or high density is preferred. The polyolefin can by copolymerized with one or more copolymers including polyesters, such as polyethylene terephthalate, polysulfones, polyurethanes, polyvinyls, polycarbonates, cellulose esters, such as cellulose acetate and cellulose propionate, and polyacrylates. Specific examples of copolymerizable monomers include vinyl stearate, vinyl acetate, acrylic acid, methyl acrylate, ethyl acrylate, acrylamide, methacrylic acid, methyl methacrylate, ethyl methacrylate, methacrylamide, butadiene, isoprene, and vinyl chloride. Preferred polyolefins are film forming and adhesive to paper. Polyethylene having a density in the range of from about 0.910 g/cm 3 to about 0.980 g/cm 3 is particularly preferred.
The optical brightener mixture can be incorporated into the polyolefin by conventional methods. Preferred are methods whereby the brightener is uniformly dispersed within the polyolefin. Such methods include a melt extrusion process, a kneader extruder, a roll mill, a high shear mixer, or a twin-screw compounder.
The white pigment incorporated in the polyolefin layer can be titanium dioxide, zinc oxide, zinc sulfide, zirconium dioxide, white lead, lead sulfate, lead chloride, lead aluminate, lead phthalate, antimony trioxide, white bismuth, tin oxide, white manganes, white tungsten and combinations thereof. The pigment is used in any form that is conveniently dispersed within the polyolefin. The preferred pigment is titanium dioxide. The titanium dioxide preferably is anatase, rutile or combinations of these forms. Enhanced image resolution in a photographic element can be obtained by the addition of functional amounts of such highly white-light reflective pigments to the polyolefin layer. Preferably, the white pigment is used in the range from about 3 to 35 percent, more preferably 5 to 25 percent by weight based on the total weight of the polyolefin coating. Titanium dioxide at levels of 5 to 20 percent is particularly useful.
In addition to the brightener mixture and the white pigment, the polyolefin coating can contain, if desired, a variety of additives including antioxidants such as 4,4'-butylidene-bis(6-tert-butyl-meta-cresol), di-lauryl-3,3'-thiodipropionate, N-butylated-p-aminiphenol, 2,6-di-tert-butyl-p-cresol, 2,6-di-tert-butyl-4-methylphenol, N,N-disalicyidene-1,2-diaminipropane, tetra(2,4-di-tert-butylphenyl)-4,4'-diphenyldiphenyldiphosphonite, octadecyl 3-(3',5'-di-tert-butyl-4'-hydroxyphenyl propionate), combinations of the above, and the like; heat stabilizers, such as higher aliphatic acid metal salts such as magnesium stearate, calcium stearate, zinc stearate, aluminum stearate, calcium palmitate, sodium palmitate, zirconium octylate, sodium laurate, and salts of benzoic acid such as sodium benzoate, calcium benzoate, magnesium benzoate and zinc benzoate; additional optical brighteners; antistatic agents; dispersing agents; uv stabilizers, coating aids; slip agents; lubricants; dyes; and the like, as is well known to those skilled in the art. Additionally, emulsion side resins can contain one or more pigments, such as the blue, violet or magenta pigments described in U.S. Pat. No. 3,501,298, or pigments such as barium sulfate, colloidal silica, calcium carbonate and the like.
The paper base material employed in accordance with the invention can be any paper base material which has heretofore been considered useful for a photographic support. The weight and thickness of the support can be varied depending on the intended use. A preferred weight range is from about 20 g/m 2 to about 500 g/m 2 . Preferred thicknesses (those corresponding to commercial grade photographic paper) are from about 20 μm to about 500 μm. It is preferred to use a paper base material calendered to a smooth surface. The paper base material can be made from any suitable paper stock preferably comprising hard or softwood. Either bleached or unbleached pulp can be utilized as desired. The paper base material can also be prepared from partially esterified cellulose fibers or from a blend of wood cellulose and a suitable synthetic fiber such as a blend of wood cellulose and polyethylene fiber.
As is known to those skilled in the art, the paper base material can contain, if desired, agents to increase the strength of the paper such as wet strength resins, e.g., the amino-aldehyde or polyamideepichlorohydrin resins, and dry strength agents, e.g., starches, including both ordinary starch and cationic starch, or polyacrylamide resins. In a preferred embodiment of this invention, the amino-aldehyde, polyamide-epichlorohydrin and polyacrylamide resins are used in combination as described in U.S. Pat. No. 3,592,731. Other conventional additives include water soluble gums, e.g., cellulose ethers such a carboxymethyl cellulose, sizing agents, e.g., a ketene dimer, sodium stearate which is precipitated onto the pulp fibers with a polyvalent metal salt such as alum, aluminum chloride or aluminum sulfate; fluorescing agents; antistatic agents; filters, including clays or pigments such as titanium dioxide; dyes; etc.
It is to be understood that although paper is a preferred support, the nature of the support is not a critical feature of the invention. Thus for example the paper support may be substituted by a synthetic paper or a plastic film.
The coating of the paper base material with the polyolefin preferably is by extrusion from a hot melt as is known in the art. The paper base material preferably is treated with corona discharge to obtain good adhesion before the polyolefin coating is extruded thereon, as described in U.S. Pat. No. 3,411,908. The invention can be practiced within a wide range of extrusion temperatures, e.g., 150°-350° C., and speeds e.g., about 60 m/min. to 460 m/min., depending on the particular intended application of the support. For many applications, preferred extrusion temperatures are about 310°-330° C. As noted, it is an advantageous feature of this invention that the mixture of optical brighteners is stable to such temperatures. Under these conditions, the aforedescribed polyolefin coating, over which the silver halide emulsion is applied, is coated onto the paper base material in a coverage of about 1 to 100 g/m 2 , at a uniform thickness ranging from about 1 to 100 μm. About the same coverage of clear polyethylene coating preferably is applied to the side of the paper base material opposite to the pigmented polyolefin coating. As such, the polyolefin coatings are particularly effective in preventing acid and alkaline photographic processing solutions from penetrating to the paper base.
As noted, photographic elements in accordance with this invention comprise the above-described optically brightened photographic support and at least one silver halide emulsion layer. Any of the known silver halide emulsion layers, such as those described in Research Disclosure, Vol. 176, December 1978, Item 7643 and Research DiscIosure, Vol. 225, January 1983, Item 22534, the disclosures of which are hereby incorporated by reference in their entirety, are useful in preparing photographic elements in accordance with this invention. Generally, the photographic element is prepared by coating the support with one or more layers comprising a dispersion of silver halide crystals in an aqueous solution of gelatin, and optionally, one or more stubbing layers, etc. The coating process is generally carried out on a continuously operating machine wherein a single layer or a plurality of layers are applied to the support. For multilayer elements, layers are generally coated simultaneously on the support as described in U.S. Pat. No. 2,761,791, and U.S. Pat. No. 3,508,947. Additional useful coating and drying procedures are described in Research Disclosure, Vol. 176, December 1978, Item 17643.
In a preferred embodiment of this invention, a conventional UV absorbing agent is disposed in the photographic element to enhance speed and improve image stability and/or sharpness.
EXPERIMENTAL
An optical brightener used to demonstrate this invention was Hostalux KS brightener (American Hoechst Corporation, Charlotte, N.C.) Hostalux KS is a mixture having the following composition:
TABLE I______________________________________ Approximate PercentOptical Brightener by Weight______________________________________Compound A 60Compound B 15Compound C 25 100______________________________________
Hostalux KS brightener is hereinafter referred to as "Hostalux KS".
Because of its meager solubility in most solvents, a warm (40o C) dimethyl formamide (DMF), was chosen as the proper solvent. Its mixtures with methyl beta cyclodextrin were made based on an equimolar ratio. Methyl beta cyclodextrin was obtained from Wacker, G.m.b.H., Germany. Its average DS-value (degree of substitution) was 1.8, that means the number of CH 3 groups per anhydroglucose unit.
A typical example involved the mixing of 0.750 g Hostalux KS with 2.450 g methyl beta cyclodextrin. The mixture was dissolved in a lL DMF and the solution was warmed to allow the complete dissolution of the Hostalux. The solution was allowed to evaporate slowly under low heat. Before the total evaporation, the solution was removed into a smaller beaker and sonicated for ca. 1 min. Then, it was placed in an oven at 90° C; the residual solvent was removed and the mixture was dried for 30 min.
Preblends of 12.5 weight percent anatase TiO 2 , 3 weight percent ZnO, 1.5 weight percent calcium stearate, 0.10 weight percent antioxidant, low levels of red and blue colorants and various levels and types of optical brighteners (as shown in Table I) in medium density polyethylene, were prepared on a twin screw extruder at around 410° F. These preblends were used to produce coatings on paper using a 3/4-inch Brabender extruder. Coatings of approximately 1 mil thick, and 1.5-inch wide were made.
The samples were measured for migration behavior by placing stacks of 12-inch long strips of the resin-coated paper in an oven controlled to either 100° F. or 140° F., both at 50 percent RH. Samples were periodically withdrawn, examined under UV light and given a visual rating based on the amount of the optical brightener present of the surface of the polyethylene coating. The number of days at these conditions to produce a severe level of migration is shown in Table II. A severe level had 20% or more percent of the surface of the coating containing an optical brightener.
TABLE II______________________________________ Hostalux Conc'nSample OB Type Weight Percent______________________________________1 Hostalux KS 0.0752 Hostalux KS 0.103 Hostalux KS 0.1254 Hostalux KS/Me-cyclodextrin 0.055 Hostalux KS/Me-β-cyclodextrin 0.0756 Hostalux KS/Me-β-cyclodextrin 0.107 Hostalux KS/Me-β-cyclodextrin 0.125______________________________________
TABLE III______________________________________ Migration (days)Sample 110° F. 140° F.______________________________________1 55 342 34 63 34 34 >55 >555 >55 >556 >55 >557 >55 >55______________________________________
Table III demonstrates that there is much less migration, when compositions of this invention are used.
Furthermore this invention can be extended to use of inclusion compounds of a cyclodextrin, preferably methyl β cyclodextrin with optical brighteners of the type disclosed in U.S. Pat. No. 2,618,636, and U.S. Pat. No. 2,713,046.
This invention has been described with particular reference to preferred embodiments thereof. A skilled practitioner, familiar with the above detailed description can make many substitutions and modifications without departing from the scope and spirit of the following claims.
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An improved photographic support, especially useful for color prints, is comprised of a paper base material having thereon a polyolefin coating containing a white pigment and an optical brightener, such as a mixture comprising inclusion compounds of certain fluorescent bis(benzoxazolyl)-stilbenes.
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SUMMARY OF THE INVENTION
The present invention is directed to a device for the evaluation and rehabilitation of individuals. More particularly, the present invention is directed to a device for rehabilitative therapy and evaluation which simulates mechanical assembly operations in which the individual is required to work in confined areas which are visually obscured.
BACKGROUND OF THE INVENTION
Because of the complex and intricate manipulations which the human hand performs particularly in mechanical assembly operations, the evaluation and rehabilitative therapy of the human hand is especially difficult. For example, the repair or assembly of mechanical devices such as automotive engines and associated structures frequently requires the individual to assemble or disassemble complex mechanical parts in confined areas in which the parts being assembled or disassembled are either partially or totally obscured. Individuals who have suffered injury or loss of function therefore have a difficult program of rehabilitation even after the injury has otherwise been remedied. The acquisition of the fine motor and sensory manipulations required for example, to place a nut on a bolt in a confined area where the individual cannot see what he or she is doing can require painstaking and arduous effort.
Accordingly, it is an object of the present invention to provide a regimen and device for rehabilitative therapy and evaluation which permits the individual to practice the assembly and disassembly of nuts and bolts within a confined, closed space. It is a further object of the present invention to provide a device for such therapy and evaluation in which the individual cannot actually see the assembly or disassembly procedure which is being practiced. Yet a further object of the present invention is to provide a device for rehabilitative therapy and evaluation in which the individual practices such therapy using only one hand in an environment in which the work cannot be seen. The attainment of these and other objects will however, be more readily apparent from the description of the present invention which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of the device of the present invention with the interior partitions withdrawn;
FIG. 2 is a perspective view of the structure of the present invention showing the interior partitions in phantom within the structure; and
FIG. 3 is a bottom view of the invention.
DETAILED DESCRIPTION OF THE INVENTION
According to the present invention, a device and method are provided for rehabilitative therapy and evaluation which comprises an enclosed structure having a visually obscured interior with one or more apertures in the exterior walls to permit insertion of the human hand. The interior of the structure is provided with one or more devices for performing or simulating manual operations within the enclosed structure. Typically, these devices are bolts projecting into the interior of the structure and adapted to receive nuts. While the bottom of the structure can be left open to facilitate access, the top is closed so that the individual using the device cannot see the actual operation which he is performing with the hand inserted into the structure. The interior of the structure is provided with one or more removable partitions which themselves are provided with apertures to permit insertion of the human hand into the various chambers which are thereby created.
The invention will however, be more fully appreciated by having reference to the drawings which describe a preferred embodiment and best mode of the invention. Directing attention to FIG. 1 of the drawings, a generally rectangular, box-like structure 1, is shown having vertical side walls 2, 3, 4 and 5 and a top 6. A round hole or aperture 17, is provided in the side wall 1, although it will of course, be understood that this aperture could be provided in any of the other side walls or the top and additional similar holes for access into the interior of the unit can also be provided. The interior surface of side walls 2 and 5 define pairs of grooves 7 and 8 to accommodate respectively vertical partitions 10 and 11. These vertical partitions are provided with round holes or apertures 14 and 16 as well as vertical slots 13. An additional vertical partition 12 is provided with semi-circular holes 15. A substantial number of smaller holes or apertures 9 are variously provided in the side walls 2, 3, 4 and 5 of the structure, as well as the top 6. These holes are to accommodate bolts or similar devices which project into the interior of the structure as shown at 19. The head of these bolts is shown in FIG. 1 on the exterior wall 3 at 20. These bolts have threads to accommodate nuts 21.
In actual use, the device of the invention is assembled as shown in phantom in FIG. 2 of the drawings with the partitions 10, 11, and 12 inserted into the respective slots so that the interior of the box-like structure is partitioned. The individual using the device of the present invention is required to insert his hand through the hole or aperture 17 into the interior of the structure and possibly also through one or more of the holes 14, 15 and 16 in the interior partitions 10, 11 and 12 to perform the manual operation of placing a nut 21 onto one of the bolts which project into the interior, of the structure. This must be done without being able to actually see the operation.
FIG. 3 of the drawings shows the assembled enclosure of the invention from the bottom with the partitions heretofore described in place.
It will of course be understood that the device of the present invention can take additional forms than illustrated in the drawings in order to vary the nature and difficulty of the required operation. For example, the partitions can actually be removed or replaced by other or different partitions and various arrangements of apertures can be provided to alter access into the interior chambers of the device. Additionally, the bolts which project into the interior can themselves be altered or replaced by other devices requiring manual manipulation. For example, the bolts can be spring loaded to increase the difficulty of placing a nut or other unit on the bolt, or an entirely different type of device can be provided. Holes such as those shown at 9 can also be provided in the partitions themselves to simulate manual operations at different angles and in different manner. The essential concept of the invention however, is to simulate manual operations within an enclosed and partitioned visually obscured structure to facilitate manual rehabilitative therapy and evaluation.
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A method and device for rehabilitation and evaluation are described in which the individual is required to perform manual operations within a visually obscured enclosure. Partitions are provided within the enclosure to simulate the performance of mechanical operations within a confined space. The operations themselves may typically be the placing and tightening of nuts on bolts which project into the enclosure.
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BACKGROUND
The present invention relates to a child seat which is mounted and secured to a vehicle seat by a seat belt.
An example of this type of child seat has been disclosed in U.S. Pat. No. 5,839,789, herein incorporated by reference. FIG. 8 is a rear view of a child seat of U.S. Pat. No. 5,839,789, and FIG. 9 is a perspective view showing the structure for an adult seat belt winding mechanism at the bottom of the child seat.
The child seat 110 is mounted and secured to a vehicle seat (not shown) with an adult seat belt 100 (comprising a lap belt 100 a and a shoulder belt 100 b ) of a vehicle and comprises a seat squab 112 on which a child is seated, a seat back 114 , and a pair of dogleg-shaped side walls 116 , 118 disposed on both sides of the combination of the seat squab 112 and the seat back 114 . The dogleg-shaped side walls 116 , 118 are provided with seat belt through apertures 120 , 122 , respectively, to allow the adult seat belt 100 to extend in the width direction of the child seat through these apertures 120 , 122 . The child seat 110 is also provided on the bottom thereof (the backside of the seat squab 112 ) with a wind-up reel 124 for winding the seat belt 100 extending between the seat belt through apertures 120 and 122 to tension the seat belt 100 . The wind-up reel 124 has a slit 124 a , for insertion of the seat belt, formed to penetrate the wind-up reel 124 in a diametrical direction. The slit 124 a has a deep groove configuration extending in the axial direction of the wind-up reel 124 and exposed at one end of the axial direction.
The seat belt through apertures 120 , 122 are formed in lower portions of the dogleg-shaped side walls 116 , 118 to face each other such that the lap belt 100 a composing the seat belt 100 extends substantially parallel to the top surface of the seat squab (not shown) of the vehicle seat when the lap belt 100 a is threaded through one of the through apertures 120 , 122 and is then threaded through the other.
The wind-up reel 124 is positioned halfway between the seat belt through apertures 120 and 122 such that the axial direction of the wind-up reel 124 is equal to the front-to-back direction of the child seat 110 . The slit 124 a is formed in the rear end of the wind-up reel 124 . The rear end of the wind-up reel 124 is exposed at the seat back side of the child seat 110 . In FIGS. 8 and 9 , numeral 126 designates guide members for introducing the seat belt 100 , inserted through the seat belt through apertures 120 , 122 , to the wind-up reel 124 .
Integrally connected to the wind-up reel 124 is a torsion rod 128 which is disposed to extend along the bottom surface of the child seat 110 in the front-to-back direction. Secured to the front end of the torsion rod 128 is a worm wheel 130 which is meshed with a worm drive 134 described later.
A worm shaft 132 is disposed adjacent to the worm wheel 130 to extend in a width direction perpendicular to the axial direction of the torsion rod 128 and the wind-up reel 124 . The worm drive 134 is fixed to the worm shaft 132 and is meshed with the worm wheel 130 . The both ends of the worm shaft 132 penetrate the dogleg-shaped side walls 116 , 118 so as to extend outside the child seat 110 through the right and left side walls 116 , 118 , respectively. The worm shaft 132 is provided at its both ends with knobs 136 , 138 for operation of rotating the worm shaft 132 about its axis.
By the operation of rotating either of the knobs 136 , 138 , the wind-up reel 124 is rotated through the worm shaft 132 , the worm drive 134 , the worm wheel 130 , and the torsion rod 128 , whereby the seat belt 100 engaged in the slit 124 a is wound around the wind-up reel 124 . The worm gear composed of the worm wheel 130 and the worm drive 134 has a self-locking function. Therefore, even though the user looses his/her grip of the knob 136 or 138 after the seat belt 100 is wound around the wind-up reel 124 , the wind-up reel 124 is stayed against the tension of the seat belt 100 by the self-locking function not to rotate in a direction opposite to the belt winding direction.
The child seat 110 is provided with clamps 140 , 142 for clamping the seat belt 100 which are disposed on both lateral sides of the wind-up reel 124 . Each clamp 140 , 142 is adapted to allow the seat belt 100 to pass therethrough in a direction for winding up the seat belt 100 around the wind-up reel 124 and not to allow the seat belt 100 to pass therethrough in a direction opposite to the belt winding direction. Since the seat belt 100 is clamped by the clamps 140 , 142 , the seat belt 100 is prevented from being pulled out through the seat belt through apertures 120 , 122 even when external force in a direction opposite to the belt winding direction is exerted to the seat belt 100 .
A release lever 144 for releasing the clamping on the seat belt 100 by the clamps 140 , 142 is provided at an upper portion of the seat back 114 . The release lever 144 is interconnected to the clamps 140 , 142 through a cable 146 . As the release lever 144 is lifted, the respective clamps 140 , 142 open to release the clamping on the seat belt 100 . As the release lever 144 is depressed, the respective clamps 140 , 142 close so that the seat belt 100 is clamped by the clamps 140 , 142 . In FIGS. 8 and 9 , numeral 148 designates guide members for introducing the cable 146 .
To secure the child seat 110 having the aforementioned structure to a vehicle seat, the release lever 144 is lifted into its open position to keep the clamps 140 , 142 open. In this state, the seat belt 100 is threaded through one of the seat belt through apertures 120 , 122 (in FIG. 8 , the through aperture 122 ) and is threaded through the other through aperture 122 or 120 (in FIG. 8 , the through aperture 120 ) so as to extend between the through apertures 120 and 122 . Then, a tongue (not shown) is latched into a buckle (not shown).
The seat belt 100 extending between the through apertures 120 and 122 is inserted into the clamps 140 , 142 and the halfway of the seat belt 100 is inserted into the slit 124 a from the rear end of the wind-up reel 124 . Then, the release lever 144 is depressed whereby the seat belt 100 is clamped by the clamps 140 , 142 .
After that, either of the knobs 136 , 138 is turned to rotate the wind-up reel 124 so that the seat belt 100 is wound around the wind-up reel 124 . Therefore, sufficient tension is applied to the seat belt 100 , thereby firmly securing the child seat 110 to the vehicle seat.
When a three-point seat belt composed of a lap belt 100 a and a shoulder belt 100 b is used for securing the child seat 110 disclosed in U.S. Pat. No. 5,839,789, tension is applied to the shoulder belt 100 b by winding up the shoulder belt 100 b around the wind-up reel 124 so that the shoulder belt 100 b tends to straighten between a deflection fitting and the tongue (both are not shown) to apply a raising force to the wind-up reel and the rear portion of the child seat 110 is thus biased upwardly.
Accordingly, there remains a need for a child seat which can be firmly secured to a vehicle seat even with a shoulder belt of a three-point seat belt.
In addition, in the child seat 110 disclosed in U.S. Pat. No. 5,839,789, it is difficult to recognize that sufficient tension has been really applied to the seat belt 100 by turning the knob 136 , 138 to wind up the seat belt 100 around the wind-up reel 124 .
Accordingly, there remains a need for a child seat which can wind up a seat belt to securely apply a predetermined tension to the seat belt.
SUMMARY OF THE INVENTION
According to an embodiment of the present invention, a child seat is provided which is mounted and secured to a vehicle seat by a seat belt designed primarily for use by an adult occupant (hereinafter, sometimes referred to as “adult seat belt”). More particularly, a child seat which is adapted to be firmly secured to a vehicle seat by winding an adult seat belt around a wind-up shaft to tension the adult seat belt is provided.
The child seat is adapted to be secured to a seat of a vehicle by a seat belt designed primarily for use by an adult occupant in the vehicle. The child seat includes a wind-up shaft, which has a slit into which the adult seat belt is inserted and which can rotate when the adult seat belt is inserted into the slit so as to wind up the adult seat belt thereby applying tension to the adult seat belt. The wind-up shaft extends in a vertical direction and includes a lap belt slit into which a lap belt of the adult seat belt can be inserted and a shoulder belt slit into which a shoulder belt of the adult seat belt can be inserted. The shoulder belt slit is located above the lap belt slit.
Since the wind-up shaft extends in a vertical direction and the shoulder belt slit is located above the lap belt slit, the shoulder belt extends substantially straight from a deflective fitting to a tongue when the shoulder belt is inserted in the shoulder belt slit and wound around the wind-up shaft. Therefore, the shoulder belt never applies a lifting force to the child seat, thereby stabilizing the attitude of the child seat.
According to another embodiment, it is preferable that the shoulder belt slit and the lap belt slit are disposed adjacent to each other and continue into each other via a common belt inlet.
In this embodiment, even when the lap belt is inserted into the shoulder belt slit for winding up the lap belt, the lap belt moves into the lap belt slit because of the tension applied to the lap belt. Similarly, even when the shoulder belt is inserted into the lap belt slit for winding up the shoulder belt, the shoulder belt moves into the shoulder belt slit because of the tension applied to the shoulder belt.
According to another embodiment, a child seat is adapted to be secured to a seat of a vehicle by a seat belt designed primarily for use by an adult occupant in the vehicle. The child seat includes a wind-up shaft, which has a slit into which the adult seat belt is inserted and which can rotate when the adult seat belt is inserted into the slit so as to wind up the adult seat belt, thereby applying tension to the adult seat belt. The child seat further includes a winding torque limiting means for preventing winding torque exceeding a predetermined value from being exerted on the wind-up shaft.
In this embodiment, the seat belt can be wound up to securely apply a predetermined tension to the seat belt. In addition, excessive winding torque is prevented from being exerted on the wind-up shaft.
According to another embodiment, the child seat preferably includes a knob for rotating the wind-up shaft. It is preferable that the winding torque limiting means forces the knob to idle when a torque exceeding the predetermined value is applied. According to this embodiment, the operator can recognize from the idling of the knob that the seat belt has been wound sufficiently.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become apparent from the following description, appended claims, and the accompanying exemplary embodiments shown in the drawings, which are described briefly below.
FIG. 1 is a rear perspective view of a child seat according to an embodiment of the present invention.
FIG. 2 is a front perspective view of the child seat in FIG. 1 .
FIG. 3 is a perspective view showing a rotational mechanism for rotating a wind-up shaft according to an embodiment of the present invention.
FIG. 4 is a partial perspective view showing a situation where a seat belt is engaged with a wind-up shaft according to an embodiment of the present invention.
FIG. 5 is a partial perspective view showing a situation where a seat belt is engaged with a wind-up shaft according to an embodiment of the present invention.
FIG. 6 is a rear perspective view of a child seat according to an embodiment of the present invention in which a seat belt is engaged with a wind-up shaft.
FIG. 7 is a rear perspective view of a child seat according to an embodiment of the present invention in which a seat belt is engaged with a wind-up shaft.
FIG. 8 is a rear view of a child seat of U.S. Pat. No. 5,839,789, as a conventional example.
FIG. 9 is a perspective view of a conventional child seat showing the structure of a wind up shaft rotational mechanism at the bottom of the child seat.
FIG. 10 is a perspective view of a knob according to an embodiment of the present invention in which the knob accommodates a finger grip.
FIG. 11 is a perspective view of the knob of FIG. 10 where the finger grip is in use.
FIG. 12 is an exploded front perspective view of the knob of FIG. 10 showing the knob and torque clutch.
FIG. 13 is an exploded rear perspective view of the knob of FIG. 10 showing the knob and torque clutch.
FIG. 14 ( a ) is a plan view of a knob according to an embodiment of the present invention showing operation of a torque clutch when the torque applied to the knob is equal to a predetermined value or less.
FIG. 14 ( b ) is a sectional view of the knob in FIG. 14 ( a ) taken along the line B—B.
FIG. 14 ( c ) is an enlarged view of portion C in FIG. 14 ( b ).
FIG. 15 ( a ) is a plan view of a knob according to the present invention showing operation of a torque clutch when the torque applied to the knob exceeds a predetermined value.
FIG. 15 ( b ) is a sectional view of the knob of FIG. 15 ( a ) taken along the line B—B.
FIG. 15 ( c ) is an enlarged view of portion C in FIG. 15 ( b ).
DETAILED DESCRIPTION
Embodiments of the present invention will be described below with reference to the accompanying drawings.
As shown in FIGS. 1-7 , a child seat 10 is adapted to be mounted and secured to a vehicle seat (not shown) with an adult seat belt 1 (comprising a lap belt 1 a and a shoulder belt 1 b ) of a vehicle.
The seat belt 1 is a well known seat belt of which a proximal end portion is connected to a retractor such that the seat belt can be wound up by the retractor; a distal end portion is connected to a vehicle body via a lap anchor; and a midway portion passes through a deflection fitting. The seat belt 1 passes through a belt through aperture of a tongue (not shown). A portion of the seat belt between the tongue and the deflection fitting is defined as the shoulder belt 1 b and a portion of the seat belt between the tongue and the lap anchor is defined as the lap belt 1 a . As well known in the art, in the state that the tongue is latched into the buckle, the shoulder belt 1 b extends obliquely from the tongue to the deflection fitting across the seat back. The lap belt 1 a extends substantially horizontally from the tongue to the lap anchor across a corner between the seat squab and the seat back.
The child seat 10 comprises a seat squab 12 on which a child is seated; a backrest portion 14 ; a pair of ribs 16 , 18 projecting rearwards from both side edges of the back face of the backrest portion 14 ; adult seat belt through apertures 20 , 22 which are formed in the ribs 16 , 18 , respectively; and a wind-up shaft 24 for winding up the adult seat belt which is positioned halfway between the seat belt through apertures 20 and 22 .
The wind-up shaft 24 extends vertically along the backrest portion 14 . The wind-up shaft 24 has a lap belt slit 24 a and a shoulder belt slit 24 b into which the lap belt 1 a and the shoulder belt 1 b of the adult seat belt are inserted, respectively. The shoulder belt slit 24 b is located above the lap belt slit 24 a . The lap belt slit 24 a and the shoulder belt slit 24 b are disposed adjacent to each other in a vertical direction and continue into each other via a common belt inlet 24 c.
As shown in FIGS. 4-5 , the lap belt slit 24 a and the shoulder belt slit 24 b are formed to penetrate the wind-up shaft 24 in the diametrical direction and to extend in the axial direction (vertical direction) of the wind-up shaft 24 . In this embodiment, the lap belt slit 24 a and the shoulder belt slit 24 b are formed linearly in the axial direction of the wind-up shaft 24 . The belt inlet 24 c is formed at a middle portion between the lap belt slit 24 a and the shoulder belt slit 24 b to cut a side peripheral surface of the middle portion of the wind-up shaft 24 .
The ribs 16 , 18 extend vertically along the back face of the backrest portion 14 . The seat belt through apertures 20 , 22 are also formed to extend vertically along the backrest portion 14 . The seat belt through apertures 20 , 22 have such size and arrangement as to allow the lap belt 1 a to extend substantially parallel to the upper surface of the seat squab of the vehicle and also allow the shoulder belt 1 b to extend substantially straight from the deflection fitting to the tongue when the seat belt 1 is threaded through one of the seat belt through apertures 20 , 22 and is then threaded through the other through aperture 20 or 22 and the tongue is latched into the buckle as shown in FIGS. 6-7 .
The lap belt slit 24 a is formed at such a level that the lap belt 1 a can be inserted into the lap belt slit 24 a while the lap belt 1 a extends in parallel with the top surface of the seat squab of the vehicle between the seat belt through apertures 20 and 22 . The shoulder belt slit 24 b is formed at such a level that the shoulder belt 1 b can be inserted into the shoulder belt slit 24 b while the shoulder belt 1 b threaded through the seat belt through apertures 20 and 22 extends substantially straight from the deflection fitting to the tongue.
The upper end of the wind-up shaft 24 is supported by a bracket 26 attached to the back face of the backrest portion 14 such a manner as to allow the rotation of the wind-up shaft 24 about its axis. The lower end of the wind-up shaft 24 is inserted into a mechanical box 28 arranged at a lower portion of the backrest portion 14 . Within the mechanical box 28 , a worm wheel 30 meshed with a worm drive 34 is fixed to the lower end of the wind-up shaft 24 .
The mechanical box 28 is arranged between lower end portions of the left and right ribs 16 and 18 . The both side faces of the mechanical box 28 are connected to the opposite faces of the ribs 16 , 18 , respectively. Through holes (not shown) are formed in the both side faces of the mechanical box 28 and the ribs 16 , 18 , respectively, so that a worm shaft 32 described later can pass through these through holes.
As shown in FIG. 3 , within the mechanical box 28 , the worm shaft 32 is arranged adjacent to the lower end (worm wheel 30 ) of the wind-up shaft 24 to extend in the width direction perpendicular to the extending direction of the wind-up shaft 24 . The worm drive 34 is fixed to the worm shaft 32 and is meshed with the worm wheel 30 . The both ends of the worm shaft 32 penetrate the both side faces of the mechanical box 28 and the left and right ribs 16 , 18 so as to extend outside the child seat 10 , respectively. The worm shaft 32 is provided at its both ends with knobs 36 , 38 for rotating the worm shaft 32 about its axis. The knobs 36 , 38 are provided with finger grips 40 (see FIGS. 10-11 described later) for facilitating the operation of the knobs 36 , 38 .
In FIG. 3 , numeral 26 a designates a bearing to which the upper end of the wind-up shaft 24 is rotatably fitted. Numeral 28 a designates a bracket holding the worm shaft 32 , and numeral 28 b designates bearings attached to the bracket 28 a for rotatably supporting the worm shaft 32 .
By the operation of rotating either of the knobs 36 , 38 , the wind-up shaft 24 is rotated through the worm shaft 32 , the worm drive 34 , and the worm wheel 30 , whereby the lap belt 1 a inserted in the lap belt slit 24 a or the shoulder belt 1 b inserted in the shoulder belt slit 24 b is wound around the wind-up shaft 24 . The worm gear composed of the worm wheel 30 and the worm drive 34 has a self-locking function. Therefore, even though the user looses his grip of the knob 36 or 38 after the lap belt 1 a or the shoulder belt 1 b is wound around the wind-up shaft 24 , the wind-up shaft 24 is stayed against the tension of the belt 1 a , 1 b by the self-locking function so as not to rotate in a direction opposite to the belt winding direction, thereby preventing slack from developing in seat belt 1 after the lap belt 1 a or the shoulder belt 1 b is wound up.
In this embodiment, each knob 36 , 38 is connected to the worm shaft 32 via a torque clutch 50 with torque limiter for limiting the winding torque. The torque clutch 50 is designed to force the knob 36 , 38 to idle when the knob 36 , 38 is rotated in the belt winding direction after the lap belt 1 a or the shoulder belt 1 b is sufficiently wound around the wind-up shaft 24 and the preset tension has been exerted on the belt 1 a , 1 b , thereby preventing winding torque from being further applied to the wind-up shaft 24 .
The structures of the knob 36 , 38 and the torque clutch 50 will now be described with reference to FIGS. 10 - 15 ( c ).
The knob 36 comprises a knob casing 36 a having a substantial cylindrical container of which the back side is an open end face; a cover 36 b attached to the open end face of the knob casing 36 a ; and an arm 36 c for supporting the finger grip 40 , which is disposed on a front end face of the knob casing 36 a . The torque clutch 50 is accommodated within the knob casing 36 a . The worm shaft 32 is inserted into the knob casing 36 a through an aperture 36 d of the cover 36 b.
The knob casing 36 a has a groove 36 e formed in the front end face thereof such that the arm 36 c can be fitted in the groove 36 a in the diametrical direction of the knob casing 36 a when the longitudinal direction of the arm 36 c is equal to the diametrical direction of the knob casing 36 a . One end of the groove 36 e is exposed to a grip accommodating space 36 f which is formed by cutting a portion of the periphery of the knob casing 36 a.
The arm 36 c has a length substantially equal to the radius of the end face of the knob casing 36 a . An end (proximal end) of the arm 36 c is pivotally supported within the groove 36 e at about the center of the end face of the knob casing 36 a . As shown in FIGS. 10-11 , the arm 36 c is pivotable about its proximal end so that the arm 36 c can be selectively fitted in either of halves of the groove 36 e . The finger grip 40 is rotatably attached to the other end (distal end) of the arm 36 c such that the finger grip 40 is accommodated in the grip accommodating space 36 f when the distal end of the arm 36 c is fitted in the groove 36 e to face the grip accommodating space 36 f.
In FIGS. 10-11 , numeral 36 g designates pairs for retaining members for retaining the arm 36 c in the groove 36 e in a state that the finger grip 40 is accommodated in the accommodating space 36 f and in a state that the finger grip 40 is taken out from the accommodating space 36 f and is in usable condition. In FIG. 12 , numeral 40 a designates a bolt for rotatably attaching the finger grip 40 to the arm 36 c and numeral 36 h designates vises for fixing the cover 36 b to the knob casing 36 a.
The torque clutch 50 comprises a first clutch disc 52 fixed at the end of the worm shaft 32 , a second clutch disc 54 disposed facing the first clutch disc 52 , and a clutch spring 56 for pressing the second clutch disc 54 against the first clutch disc 52 . The first clutch disc 52 and the second clutch disc 54 have serrations 52 a , 54 a , composed of triangle convexities and engageable with each other, on the respective opposed surfaces thereof. The serrations 52 a , 54 a are arranged on the surfaces of the clutch discs 52 , 54 to form circles having the same radius coaxially with the worm shaft 32 .
The first clutch disc 52 is held in a first clutch disc holding space 36 j formed in the interior side surface of the cover 36 b . The second clutch disc 54 is held in a second clutch disc holding space 36 k formed in the knob casing 36 a.
The second clutch disc holding space 36 k is provided with projections 361 for guiding the second clutch disc 54 in a direction closer to and apart from the first clutch disc 52 and for coupling the second clutch disc 54 and the knob casing 36 a to rotate together. The projections 361 are slidably engaged with guide grooves 54 b formed in the periphery of the second clutch disc 54 .
The clutch spring 56 is compressed and disposed between the second clutch disc 54 and the bottom surface of the second clutch disc holding space 36 k . As the knob casing 36 a is rotated, the second clutch disc 54 is rotated together. Though the serrations 54 a of the second clutch disc 54 tend to cross over the serrations 52 a of the first clutch disc 52 so that the second clutch disc 54 tends to come off the first clutch disc 52 , the clutch spring 56 has such a biasing force (spring constant) as to press the second clutch disc 54 not to come off the first clutch disc 52 so as to prevent the serration 54 a from crossing over the serrations 52 a until rotational torque exceeding a preset value (for example, 10 kgf-cm) is applied to the knob 36 .
In the torque clutch 50 having the aforementioned structure, when the rotational torque applied to the knob 36 is equal to the preset value or less, the serrations 54 a do not cross over the serrations 52 a so as to keep the engagement between the first clutch disc 52 and the second clutch disc 54 because of the biasing force of the clutch spring as shown in FIGS. 14 ( b )- 14 ( c ). Therefore, the first clutch disc 52 and the second clutch disc 54 are rotated together so that the rotational torque applied to the knob 36 is transmitted to the worm shaft 32 , whereby the worm shaft 32 is rotated.
When the rotational torque applied to the knob 36 exceeds the preset value, the second clutch disc 54 comes off the first clutch disc 52 while the serrations 54 a cross over the serrations 52 a against the biasing force of the clutch spring 56 as shown in FIGS. 15 ( b )- 15 ( c ). Therefore, the knob 36 idles so as to prevent the rotational torque applied to the knob 36 from being transmitted to the worm shaft 32 .
The steps of installing the child seat 10 according to an embodiment of the present invention to a vehicle seat will now be described.
In case using an adult seat belt 1 composed of only a lap belt 1 a , i.e., a so-called two-point seat belt, the child seat 10 is put on the vehicle seat. After that, the lap belt 1 a is threaded through one of the seat belt through apertures 20 , 22 (in FIG. 7 , the through aperture 22 ) and is threaded through the other through aperture 22 or 20 (in FIG. 7 , the through aperture 20 ) so as to extend between the through apertures 20 and 22 as shown in FIG. 7. A tongue connected to the end of the lap belt 1 a is then latched into a buckle. After that, the halfway of the lap belt 1 b extending between the through apertures 20 and 22 is inserted into the lap belt slit 24 a through the belt inlet 24 c.
After that, either of the knobs 36 , 38 is turned to rotate the wind-up shaft 24 so that the lap belt 1 a is wound around the wind-up shaft 24 until sufficient tension is applied to the lap belt 1 a , thereby firmly securing the child seat 10 to the vehicle seat with the lap belt 1 a.
In case using an adult seat belt 1 composed of a lap belt 1 a and a shoulder belt 1 b , i.e., a so-called three-point seat belt, the child seat 10 is put on the vehicle seat. After that, the lap belt 1 a and the shoulder belt 1 b are threaded through one of the seat belt through apertures 20 , 22 (in FIG. 6 , the through aperture 22 ) and are threaded through the other through aperture 22 or 20 (in FIG. 6 , the through aperture 20 ) so as to extend between the through apertures 20 and 22 as shown in FIG. 6. A tongue is then latched into a buckle. After that, the halfway of the shoulder belt 1 b extending between the through apertures 20 and 22 is inserted into the shoulder belt slit 24 b . In this case, the lap belt 1 a is not inserted into the lap belt slit 24 a.
After that, either of the knobs 36 , 38 is turned to rotate the wind-up shaft 24 so that the shoulder belt 1 b is wound around the wind-up shaft 24 until sufficient tension is applied to the lap belt 1 a and the shoulder belt 1 b , thereby firmly securing the child seat 10 to the vehicle seat with the lap belt 1 a and the shoulder belt 1 b.
In the child seat 10 in this embodiment, the wind-up shaft 24 extends in a vertical direction and is provided with the lap belt slit 24 a at such a level that the lap belt 1 a can be inserted into the lap belt slit 24 a while the lap belt 1 a extends in substantially parallel with the seat squab of the vehicle between the seat belt through apertures 20 and 22 and further provided with the shoulder belt slit 24 b at such a level that the shoulder belt 1 b can be inserted into the shoulder belt slit 24 b while the shoulder belt 1 b threaded through the seat belt through apertures 20 and 22 extends substantially straight from the deflection fitting to the tongue.
Since the shoulder belt 1 b thus extends substantially linearly from the deflection fitting to the tongue after the shoulder belt 1 b is inserted into the shoulder belt slit 24 b and wound around the wind-up shaft 24 , the shoulder belt 1 b never applies a lifting force to the child seat 10 , thereby stabilizing the attitude of the child seat 10 .
In this embodiment, the lap belt slit 24 a and the shoulder belt slit 24 b are formed to continue in a vertical direction into each other via the common belt inlet 24 c . Therefore, even when the lap belt 1 a is inserted into the shoulder belt slit 24 b , the lap belt 1 a moves into the lap belt slit 24 a because of the tension by the seat belt retractor. Similarly, even when the shoulder belt 1 b is inserted into the lap belt slit 24 a , the shoulder belt 1 b moves into the shoulder belt slit 24 b because of the tension by the seat belt retractor. After that, the lap belt 1 a or the shoulder belt 1 b can be smoothly wound.
In this embodiment, the knobs 36 , 38 are connected to the worm shaft 32 via the torque clutches 50 so that the knobs 36 , 38 are adapted to idle after the lap belt 1 a or the shoulder belt 1 b is wound around the wind-up shaft 24 enough and the preset tension has been applied to the lap belt 1 a and the shoulder belt 1 b , thereby preventing excessive winding torque from being exerted on the wind-up shaft 24 .
Since the torque clutches 50 are installed in the knobs 36 , 38 , respectively, the operator can easily recognize from vibration and sound generated by idling of the knob 36 , 38 that the belt 1 a , 1 b has been wound to obtain the preset tension.
As the aforementioned embodiment is an example of the present invention, it is to be understood that the invention is not limited to the aforementioned embodiment thereof. For example, the torque limiter for limiting the winding torque may be of a type besides such a type as the torque clutches 50 that physically stops the further winding of the seat belt when the tension on the seat belt reaches the preset value. For instance, a torque sensor (strain gauge) is provided for detecting the winding torque exerted on the wind-up shaft, and an indicator is provided which emits light when the torque detected by the torque sensor reaches to a preset value or a monitor is provided which indicates numerically the torque detected by the torque sensor to let the operator know the completion of the winding of the seat belt. In addition, a means for changing the preset value may be provided.
As described in the above, a child seat according to an embodiment of the present invention can be firmly secured to a vehicle seat even with a shoulder belt of a three-point seat belt.
In addition, with a child seat according an another embodiment of the present invention, the seat belt can be wound up to securely apply a predetermined tension to the seat belt.
The priority documents, Japanese Patent Application No. 2002-299201, filed Oct. 11, 2002, and Provisional Application No. 60/430,439, filed Dec. 3, 2002, are hereby incorporated by reference.
Given the disclosure of the present invention, one versed in the art would appreciate that there may be other embodiments and modifications within the scope and spirit of the invention. Accordingly, all modifications attainable by one versed in the art from the present disclosure within the scope and spirit of the present invention are to be included as further embodiments of the present invention. The scope of the present invention is to be defined as set forth in the following claims.
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A child seat for a vehicle which can be firmly secured to a vehicle seat even with a shoulder belt of a three-point seat belt and which can wind up the seat belt to securely apply a predetermined tension to the seat belt. The child seat includes a child seat and a shaft attached to the child seat. The shaft is rotatable about an axis of the shaft. Additionally, a first end of the shaft is disposed at a higher elevation than a second end of the shaft. The shaft further includes at least one slit configured to accept a seat belt.
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REFERENCES CITED
[0001]
[0000]
U.S. Patent Documents
Patent No.
Issue Date
Author
Comments
7,126,024
Oct. 24, 2006
D A Morgenstern,
Catalytic conversion of alkaline alcohols to carboxylic acid
J P Coleman,
salts using a Fe/Ni/Cu dehydrogenation catalyst.
J M Allman
5,268,509
Dec. 7, 1993
O Immel, D Liebsch,
Catalytic hydrogenation of nitriles to form primary amines
H-H Schwarz, S Wendel,
using an iron catalyst with ammonia at 80 C. to 180 C. and
P Fischer
20 to 400 atmospheres pressure.
4,994,428
Feb. 19, 1991
W K Bell, W O Haag
Fischer-Tropsch conversion of wet syngas to liquid
hydrocarbons on a promoted iron catalyst at 160 C. to 350 C.
4,532,209
Jul. 30, 1985
S Hagedorn
Cresol from chemical conversion in acidic medium of
4-methylcyclohexa-3,5-diene-1,2-diol-1-carboxylic acid.
4,465,872
Aug. 14, 1984
T Suzuki, S Hashimoto,
Peroxide oxidation of p-tolualdehyde to p-cresol in
M Orisaku & R Nakno
aqueous formic acid at 50 C. to 150 C.
4,301,308
Nov. 17, 1981
R Canavesi, F Ligorati,
o-Cresol is prepared from gaseous methanol + phenol at
& G Aglietti
200 C. to 400 C. over alumina particles.
BACKGROUND
[0002] 1. Field of Invention
[0003] Renewable resources including bagasse, corn stover, wood sawdust, switch grass, recycled cellulose and starch materials are subject to direct catalytic conversion or bio-fermentation processes producing ethanol and organic by products leaving complex lignin compounds as waste for disposal. Chemical conversion of lignin compounds to aromatic lignin acids followed by reductive hydrogenation to cresol and substituted creosol compounds prepares these natural resources for chemical conversion to a form of gasoline and industrial compounds. The process disclosed herein is also applicable to organic carboxylic acid compounds such as natural oils producing valued organic products and hydrocarbon fuels.
[0004] Catalytic reactions are taught for reductive chemical hydrogenation of lignin acids comprising 4-hydroxy-3,5-dimethoxybenzoic acid, 4,5-dihydroxy-3-methoxybenzoic acid, 4-hydroxy-3-methoxybenzoic acid, 4-hydroxybenzoic acid and substituted aliphatic carboxylic acid comprising citric and oleic acid compounds in contact with an iron or steel metal catalyst, a promoter comprising an alkali metal sulfate and a catalyst comprising Co(II)—Co(III), Mn(II)—Co(III) or V(II)—Co(III) compound using hydrogen gas at ambient to 10 atmospheres pressure.
[0005] 2. Description of Prior Art
[0006] The chemical process industry has grown to maturity based on petroleum feed stocks. Petroleum is a non-renewable resource that may become unavailable in the next 100 years. This planet Earth fosters continual growth of numerous carbohydrate based plants including fruits, vegetables and grain food sources plus their supporting plant stalks and related cellulose materials. Grains, corn cobs, the support plant stalks and certain grasses are subject to direct catalytic conversion and bio-fermentation processes producing ethanol and organic by products leaving complex lignin compounds as waste for disposal. Chemical conversion of lignin compounds to aromatic lignin acids followed by reductive hydrogenation to cresol and substituted creosol compounds prepares these natural resources for chemical conversion to a form of gasoline. A major industry is blooming in ethanol production but the published conversion efficiencies based on total cellulose starting material are low. These conversion efficiencies can be improved substantially by complete utilization of waste lignins. Ethanol is becoming more available as a renewable resource and this application teaches catalytic hydrogenation of lignin acids and non-lignin acids to valued cresols, substituted creosols and related hydrocarbons in preparation for production of a form of gasoline and chemical intermediates for use in the chemical process industry.
[0007] Prior art discloses conversion of chemical compounds derived from petroleum processes to cresols by oxidation, reactive combination or reactive ring closure but none of these reactions teach conversion of lignin acids or non-lignin acid organic compounds to cresols or aliphatic hydrocarbons respectively. U.S. Pat. No. 4,301,308, issued Nov. 17, 1981, introduced a process for preparation of o-cresol by reacting methanol with vaporized phenol at temperatures in the range of 200° C. to 400° C. over alumina particles. U.S. Pat. No. 4,465,872, issued Aug. 14, 1984, teaches a process for peroxide chemical oxidation of p-tolualdehyde to p-cresol in aqueous formic acid at temperatures in the range of 50° C. to 150° C. U.S. Pat. No. 4,532,209, issued Jul. 30, 1985, discloses a process for a reactive ring closure of 4-methylcyclohexa-3,5-diene-1,2-diol-1-carboxylic acid to cresol in an acidic medium.
[0008] Iron materials have been employed in chemical conversion processes at times as a co-reactant to consume oxygen byproducts and as catalysts. Catalytic chemical conversion of alkaline alcohols, alcohol amines or alcohols in the presence of amines, to carboxylic acid salts using a Fe/Ni/Cu dehydrogenation catalyst as taught in U.S. Pat. No. 7,126,024, issued Oct. 24, 2006. This is chemically similar to an oxidation reaction. Nitrile compounds have been reduced to amines with hydrogen and ammonia gases on an iron catalyst at 80° C. to 180° C. and 20 to 400 atmospheres pressure as disclosed in U.S. Pat. No. 5,268,509, issued Dec. 7, 1993. Iron has been employed as the primary reaction conversion catalyst for Fischer-Tropsch reactions. For example, chemical conversion of wet syngas to hydrocarbons containing liquids has been conducted on a promoted iron catalyst at 160° C. to 350° C. in U.S. Pat. No. 4,994,428, issued Feb. 19, 1991. While these are all productive uses of iron catalysts none of these disclosures teach use of iron or steel catalysts for chemical reduction of carboxylic acids to methyl substituted compounds as cresols, substituted creosols, alcohols or hydrocarbon compounds.
[0009] The above reported chemical processes have been conducted using available petroleum derived chemical compounds and are, therefore, distinctly different from catalytic reductive hydrogenation of renewable resources, specifically lignin acid compounds, to valued cresol and substituted creosol products. The process disclosed herein is also applicable to organic carboxylic acid compounds known as natural fats and oils producing valued liquid hydrocarbon fuels.
SUMMARY OF THE INVENTION
[0010] This invention describes chemical methods using selected transition metal catalysts for reductive hydrogenation of lignin acids and non-lignin acid organic carboxylic acid compounds to cresols, substituted creosols and hydrocarbon products. This process has been shown to be effective for reductive conversion of lignin acids comprising 3,4-dihydroxy-5-methoxybenzoic acid, 3-hydroxy-4-methoxybenzoic acid and 4-hydroxybenzoic acid as well as for aliphatic carboxylic acid compounds comprising oleic acid over zero valent transition metals comprising iron and steel to cresols, substituted creosols and aliphatic hydrocarbons.
[0011] It is an object of this invention, therefore, to provide a catalytic process facilitating reductive conversion of lignin acids to cresols and creosols. It is another object of this invention to catalytically reduce non-lignin acid organic carboxylic acid compounds to hydrocarbons. Other objects of this invention will be apparent from the detailed description thereof which follows, and from the claims.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Catalytic hydrogenation of aromatic lignin acids to cresol, creosol and substituted creosol compounds prepares these valuable derivatives of natural resources for chemical conversion to a form of gasoline and valued industrial compounds. The process is also applicable to aliphatic carboxylic acid compounds such as natural oils producing valued liquid hydrocarbon fuels. Specifically catalytic reactions are taught for reductive chemical hydrogenation of lignin acids comprising 4-hydroxy-3,5-dimethoxybenzoic acid, 4,5-dihydroxy-3-methoxybenzoic acid, 4-hydroxy-3-methoxybenzoic acid, 4-hydroxybenzoic acid to cresol, creosol and substituted creosols, and substituted aliphatic carboxylic acid comprising citric and oleic acid compounds are reduced to hexanol and C 18 hydrocarbons respectively. These reductions take place with lignin acids or aliphatic carboxylic acid compounds in contact with an iron or steel metal surface, a promoter comprising an alkali metal sulfate and a catalyst comprising Co(II)—Co(III) or Mn(II)—Co(III) using hydrogen gas at ambient to 10 atmospheres pressure.
[0013] This process employs transition metal catalysts for which the transition metals and directly attached atoms possess C 4v , D 4h or D 2d point group symmetry. The catalysts have been designed based on a formal theory of catalysis, and the catalysts have been produced, and tested without pre-conditioning to prove their activity as prepared. The theory of catalysis rests upon a requirement that a catalyst possess a molecular string such that transitions from one molecular electronic configuration to another be barrier free so reactants may proceed freely to products as driven by thermodynamic considerations. Catalysts effective for stated chemical conversions to products can be made from bi-metal, tri-metal and/or poly-metal backbone or molecular string type compounds of mixed valence form the transition metals comprising titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zirconium, niobium, molybdenum, ruthenium, rhodium, palladium, silver, hafnium, tantalum, tungsten, rhenium, osmium, iridium, platinum, gold or combinations thereof. These catalysts are made in the absence of oxygen so as to produce compounds wherein the oxidation state of the transition metal is low, typically divalent and trivalent metals. Mixed transition metal compounds have also been found to be effective catalysts for non-oxidative chemical conversions.
[0014] Iron and steel surfaces are the sites of hydrogenation but a promoter and a catalyst are required to enable the reductive chemistry. It is believed that the catalyst assists in bond opening and the promoter functions to assist in hydrogenation of the metallic surface. It is also apparent that water vapor, a byproduct of the reduction reaction, inhibits the rate of the reaction. Thus, by instituting a pulsed hydrogen gas flow, reaction products can be swept from the metallic surface with the byproduct water vapor. For example, reduction of 4-hydroxybenzoic acid with a steady gas flow produced approximately 25 percent product while the pulsed flow process produced nearly 100 percent conversion.
[0015] Thermodynamic considerations determine which chemical compounds are reduced, however reduction becomes increasingly favored as hydrogen pressure is increased. For example, 4-hydroxybenzoic acid was converted to 13 percent product at ambient hydrogen pressure while the reduction process produced nearly 100 percent product at 30 psig. Similar relative pressure related conversion efficiencies were observed for oleic acid. Thus, reductive chemical conversion of carboxylic acid compounds, activated by the selected catalysts and a promoter on iron or steel surfaces, are taught herein producing methyl substituted analogs of the original compounds.
Catalyst Preparation
Example 1
Preparation of the Co(Ii)—Co(III) and the Mn(II)—Co(III) Catalysts were Conducted in a Short Time Sequence Preferably in an Inert Gas Environment
[0016] Glass vial a—To 0.0115 g tetrachlorocatechol add 0.0025 g Na 2 CO 3 in 1 g water, heat and stir until dissolved. Immediately add 0.0110 g CoCl 2 -6H 2 O and stir to form product A. Heat at 160° C. for approximately 2 minutes to form product. Glass vial b—To 0.0115 g tetrachlorocatechol add 0.0025 g Na 2 CO 3 in 1 g water, heat and stir as before until dissolved. Add 0.0124 g Co(NH 3 ) 6 Cl 3 and stir to form the product. Heat the vial at 160° C. for approximately 2 minutes to form product. Mix product a and product b together, add an additional 1 g water and add 0.0115 g tetrachlorocatechol, heat as before and stir until a dark color product forms.
Example 2
[0017] Glass vial a—To 0.0229 g tetrachlorocatechol add 0.0049 g Na 2 CO 3 in 1 g water, heat and stir until dissolved. Immediately add 0.0183 g MnCl 2 -4H 2 O and stir to form product A. Heat at 160° C. for approximately 2 minutes. Glass vial b—To 0.0229 g tetrachlorocatechol add 0.0049 g Na 2 CO 3 in 1 g water, heat and stir as before until dissolved. Add 0.0247 g Co(6NH 3 )Cl 3 and stir to form the product. Mix products a and b together, add an additional 1 g water and add 0.0229 g tetrachlorocatechol, heat as before and stir until a dark color product forms.
Examples of Catalytic Chemical Conversion
[0018] Specific examples of the conditions of catalytic reductive chemical conversion to products are provided here.
Example A
p-Cresol Formation
[0019] The reaction equipment consisted of a 250 mL three neck round bottom pyrex glass flask fit with a thermocouple, a one eighth inch diameter stainless steel line for hydrogen gas introduction, a one quarter inch line for product vapor removal in series with a gas vent line. The reactor was wrapped with a thick layer of fiber mat insulation to maintain a uniform temperature throughout the reaction chamber. Two pieces of carbon steel, each 2″×¾″×0.032″ were placed in the bottom of the flask. The reactants, 4.0 g of
[0000] 4-hydroxy benzoic acid plus 0.022 g Co(II, III) tetrachlorocatechol catalyst plus 0.405 g Na 2 SO 4 , were ground together in a mortar and pestle and placed in the flask on top of the steel strips. Hydrogen gas was introduced into the bottom of the flask at a flow rate of 10 mL/minute to flush air from the reactor. After flushing the reactor was heated to 285° C. to 288° C. for a period of one hour with ambient pressure hydrogen gas flowing to form 0.41 gram (13 percent) p-cresol product (verified by boiling point).
Example B
p-Cresol Formation
[0020] The reaction equipment consisted of a 6″ long×2″ diameter steel reactor fit with a thermocouple, a one eighth inch diameter stainless steel line for hydrogen gas introduction, a one eighth inch line for product vapor removal in series with a gas vent line. The reactor was wrapped with a thick layer of fiber mat insulation to maintain a uniform temperature throughout the reaction chamber. One piece of carbon steel, each 2″×¾″×0.032″ plus the ground reactants, 3.246 g of 4-hydroxy benzoic acid plus 0.0108 g Co(II, III) tetrachlorocatechol catalyst plus 0.304 g Na 2 SO 4 , were placed in a 30 mL glass vial that was set into the vertical reactor and the reactor top was sealed closed. Hydrogen gas was introduced into the reactor at a flow rate of 10 mL/minute to flush air from the reactor. After flushing the reactor was pressurized to 30 psig with hydrogen gas heated to 288° C. to 290° C. for a period of three hours and forty minutes. The reactor was flushed with a short burst of hydrogen, by sharp pressure drops followed by re-pressurization, every 5 to 10 minutes to sweep out water vapor. Once the reactor was cool it was opened and 2.301 g (95.7%) crude liquid p-cresol was recovered.
Example C
Methoxy Cresol Formation
[0021] The reaction equipment consisted of a 6″ long×2″ diameter steel reactor fit with a thermocouple, a one eighth inch diameter stainless steel line for hydrogen gas introduction, a one eighth inch line for product vapor removal in series with a gas vent line. The reactor was wrapped with a thick layer of fiber mat insulation to maintain a uniform temperature throughout the reaction chamber. One piece of carbon steel, each 2″×¾″×0.032″ plus the ground reactants, 2.853 g of 4-hydroxy-3-methoxybenzoic acid plus 0.0158 g Co(II, III) tetrachlorocatechol catalyst plus 0.315 g Na 2 SO 4 , were placed in a 30 mL glass vial that was set into the vertical reactor and the reactor top was sealed closed. Hydrogen gas was introduced into the reactor at a flow rate of 10 mL/minute to flush air from the reactor. After flushing the reactor was pressurized to 30 psig with hydrogen gas heated to 315° C. to 330° C. for a period of two hours and fifteen minutes. The reactor was flushed with a short burst of hydrogen, by sharp pressure drops followed by re-pressurization, every 5 to 10 minutes to sweep out water vapor. Once the reactor was cool it was opened and 1.31 g (57%) crude liquid methoxy cresol was recovered.
Example D
Dimethoxy Cresol Formation
[0022] The reaction equipment consisted of a 6″ long×2″ diameter steel reactor fit with a thermocouple, a one eighth inch diameter stainless steel line for hydrogen gas introduction, a one eighth inch line for product vapor removal in series with a gas vent line. The reactor was wrapped with a thick layer of fiber mat insulation to maintain a uniform temperature throughout the reaction chamber. One piece of carbon steel, each 2″×¾″×0.032″ plus the ground reactants, 3.013 g of syringic acid plus 0.0120 g Co(II, III) tetrachlorocatechol catalyst plus 0.356 g Na 2 SO 4 , were placed in a 30 mL glass vial that was set into the vertical reactor and the reactor top was sealed closed. Hydrogen gas was introduced into the reactor at a flow rate of 10 mL/minute to flush air from the reactor. After flushing the reactor was pressurized to 30 psig with hydrogen gas heated to 320° C. to 345° C. for a period of two hours and fifteen minutes. The reactor was flushed with a short burst of hydrogen, by sharp pressure drops followed by re-pressurization, every 5 to 10 minutes to sweep out water vapor. Once the reactor was cool it was opened and 1.334 g (53%) crude liquid dimethoxy cresol was recovered.
Example E
Hexanol Formation
[0023] The reaction equipment consisted of a 6″ long×2″ diameter steel reactor fit with a thermocouple, a one eighth inch diameter stainless steel line for hydrogen gas introduction, a one eighth inch line for product vapor removal in series with a gas vent line. The reactor was wrapped with a thick layer of fiber mat insulation to maintain a uniform temperature throughout the reaction chamber. One piece of carbon steel, each 2″×¾″×0.032″ plus the ground reactants, 3.136 g of citric acid plus 0.0316 g Co(II, III) tetrachlorocatechol catalyst plus 0.377 g Na 2 SO 4 , were placed in a 30 mL glass vial that was set into the vertical reactor and the reactor top was sealed closed. Hydrogen gas was introduced into the reactor at a flow rate of 10 mL/minute to flush air from the reactor. After flushing the reactor was pressurized to 30 psig with hydrogen gas heated to 228° C. to 249° C. for a period of two hours. The reactor was flushed with a short burst of hydrogen, by sharp pressure drops followed by re-pressurization, every 5 to 10 minutes to sweep out water vapor. Once the reactor was cool it was opened and 0.644 g (39.5%) crude hexanol was recovered.
Example F
A C 18 Wax
[0024] The reaction equipment consisted of a 6″ long×2″ diameter steel reactor fit with a thermocouple, a one eighth inch diameter stainless steel line for hydrogen gas introduction, a one eighth inch line for product vapor removal in series with a gas vent line. The reactor was wrapped with a thick layer of fiber mat insulation to maintain a uniform temperature throughout the reaction chamber. One piece of carbon steel, each 2″×¾″×0.032″ plus the ground reactants, 5.0 g oleic acid liquid with 0.053 g Mn(II)—Co(III) tetrachlorocatechol catalyst plus 0.52 g Na 2 SO 4 , were placed in a 30 mL glass vial that was set into the vertical reactor and the reactor top was sealed closed. Hydrogen gas was introduced into the reactor at a flow rate of 10 mL/minute to flush air from the reactor. After flushing the reactor was pressurized to 30 psig with hydrogen gas heated to 228° C. to 249° C. for a period of two hours. The reactor was flushed with a short burst of hydrogen, by sharp pressure drops followed by re-pressurization, every 5 to 10 minutes to sweep out water vapor. Once the reactor was cool it was opened and 0.13 g brown wax, likely octadecane or octadecene, (10%) was recovered.
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Renewable resources comprising bagasse, corn stover, wood sawdust and switch grass are subject to direct catalytic conversion or bio-fermentation processes producing ethanol and organic by products leaving complex lignin compounds as waste for disposal. Chemical conversion of lignin compounds to aromatic lignin acids followed by reductive hydrogenation to cresol and substituted creosol compounds prepares these natural resources for chemical conversion to a form of gasoline and valued industrial compounds. The process disclosed herein is also applicable to organic carboxylic acid compounds such as natural oils producing valued liquid hydrocarbon fuels.
Specifically catalytic reactions are taught for reductive chemical hydrogenation of lignin acids comprising 4-hydroxy-3,5-dimethoxybenzoic acid, 4,5-dihydroxy-3-methoxybenzoic acid, 4-hydroxy-3-methoxybenzoic acid, 4-hydroxybenzoic acid and substituted aliphatic carboxylic acid comprising citric and oleic acid compounds in contact with an iron or steel metal surface, a promoter comprising an alkali metal sulfate and a catalyst comprising Co(II)—Co(III) or Mn(II)—Co(III) compound using hydrogen gas at ambient to 10 atmospheres pressure. This process readily forms valued organic compounds from waste natural materials thereby increasing their value.
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BACKGROUND OF INVENTION
In today's environment where consumers and companies are deluged with mail that includes bills, special offers, rebates, incentive programs, subscriptions, membership dues, charitable organizations, invitations, catalogs, coupons, and many other pieces, it has become more and more difficult to get responses from recipients. Additionally when recipients do respond it takes a longer time for them to perform a response. One common tactic that companies have used is prepaid postage or Business Reply Mail offered by the United States Postal Service. Business Reply Mail allows companies and individuals to pay the cost of delivery for responses that are received. Generally, prepaid postage effectuates greater response rates from recipients. With prepaid postage, recipients are saved the step of affixing postage to an envelope. But even with prepaid postage there is no urgency created and accordingly no guaranteed increase in actual response time. Prepaid postage does not engender a sense of urgency or action with the recipient. Recipients know that they can use the prepaid postage at any time, and respond at their leisure, and the postage will still be paid. Accordingly, prepaid postage merely facilitates action, but does not create or cause action.
Additionally in the case of Business Reply Mail, it has no expiration, and will be forwarded to the company at any location in the country as long as the Business has an active account with the Postal Service. Conceivably a company could offer a special unique promotion and receive a reply card or envelope 5 years later. The promotion may have been long over and no longer relevant, yet they would be obligated to receive said items and pay said postage.
With package delivery companies, such as FedEx, Airborne Express, UPS, and others, the method presently offered to prompt a quick response with customers is to schedule a pick-up for them. In these instances, for example, a customer may wish to return an item purchased. The customer contacts the company, who agrees to take the return, and the company in turn contacts the delivery company to schedule a pick-up. The delivery company then contacts the customer to schedule a pick-up. This requires many unnecessary steps for both the customer and the company. It requires the company to staff additional customer service representatives, it requires the delivery company to have additional customer service representatives, and it requires the customer to deal with all of them. It also does not effectuate any time controlled prepaid delivery with a predetermined effective expiration date.
Another instance where the system creates problems is in the case of prepaid returns by catalog companies. For example many catalog companies will agree to pay the delivery cost of returns. Accordingly they send the customer a prepaid delivery slip, and the customer then uses that slip to send off the package. The longer it takes the customer to send the item back to the company, the longer it takes to get that item back into circulation, and ultimately the longer it takes to make the sale. This is because prepaid delivery slips do not have any form of expiration date. These delivery slips are all open ended, and accordingly can be utilized by a customer at any time.
Companies and individuals will always need to improve customer's response times. With improved response times, companies and individuals can gauge effectiveness of advertising, the quality and appropriateness of a targeted demographic profile, improve cash flow, increase dialogue with the recipient, improve planning and preparation, facilitate company growth, etc. Clearly, increasing response rates of groups and individuals would provide enormous benefits to those groups issuing the item for response.
BRIEF DESCRIPTION OF FIGURES
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriate manner
FIG. 1 shows a representation of a proposed “Urgent Reply Mail” envelope with a predetermined effective expiration date. “Urgent Reply Mail” is a term created for descriptive and clarification of this method. Said representation could also be used for a card as well.
FIG. 2 shows a representation of a Stamp/postage with a predetermined effective expiration date. Said stamp could be affixed on an envelope, card, box, tube, pak, or other method of delivery.
FIG. 3 shows a representation of a shipping label used by a Delivery company with a predetermined effective expiration date. Said label could be affixed on an envelope, card, box, tube, pak, or other method of delivery.
FIG. 4 shows a representation of a “Date Sensitive Mail” envelope with a predetermined effective start date and a predetermined effective expiration date.
DETAILED DESCRIPTION OF INVENTION
In order to solve the above referenced and related problems, I have proposed to create a method of prepaid postage/delivery with an expiration date. This expiration date would prove an important incentive to facilitate and increase a Recipient's rate of response. Time Controlled Prepaid Delivery with an issuer defined predetermined effective expiration date will provide many benefits to Issuers. It will improve customer response time, company cash flow, and the general likelihood of a recipient's response. It will also be perceived by the Recipient as a benefit and convenient service.
The most commonly used prepaid delivery system currently in use is Business Reply Mail offered by the United States Postal Service. As discussed earlier there is no expiration date for Business Reply Mail, accordingly there is no cost benefit for many Companies to provide this particular service to their regular bill paying customers. These customers are already obligated to pay their monthly bills to these companies. Accordingly, for companies to provide Business Reply Mail in its current form to customers would only add additional cost to the company's bottom line.
With the Time Controlled Prepaid Delivery service that I propose, companies could choose based upon a cost-benefit analysis, whether of not to offer the benefit of time controlled prepaid postage/delivery to their customers. For companies that provide such service, their customers could choose whether or not to take advantage of prepaid postage and send an item prior to its postage's predetermined expiration date or to send the item after the predetermined effective expiration date and pay for postage themselves.
By providing this service to its customers, companies would not only be providing additional benefit to its customers, but would receive substantial financial benefits as well. By example, the following chart shows increased revenue for a number of large potential Issuers. These calculations are based upon a rate to Issuer of $0.35 per envelope, which is consistent with the USPS charge for Qualified Business Reply Mail. The chart shows the Increased revenue based upon specific Issuers, number of customers, average daily balance, number of yearly payments, improved payment time, and value of money.
# of
Avg. Balance
# of
Improved
Annual
customers/
due by
payments
payment
Value of
increased
Issuer
members
customer
in a year
time
money
revenue
Credit Card Company
500,000
$400.00
12
7 days
8%
$1,580,880.00
Auto Finance Co.
350,000
$450.00
12
7 days
8%
$1,428,693.00
Insurance Company
750,000
$500.00
2
7 days
8%
$625,275.00
Auto Insurance
800,000
$375.00
2
10 days
8%
$754,600.00
Mortgage Company
600,000
$1,000.00
12
7 days
8%
$8,522,640.00
Membership
50,000
$750.00
1
15 days
8%
$105,743.75
organization
Telephone Company
250,000
$200.00
12
10 days
8%
$264,600.00
It should be clearly noted that the vast majority of companies that would benefit from Time Controlled Prepaid Delivery do not currently provide customers with any form of prepaid Business Reply Mail. Specific examples include Credit Card companies, Finance companies, mortgage companies, utility companies, insurance companies, professional services, membership groups, service companies, and others. Accordingly, there is a tremendous untapped market of revenue for the US Postal Service. At current rates charged for the most comprehensive service, Qualified Business Reply Mail, the USPS could be increasing revenues by $0.02 per item delivered via this method, and by as much as $0.30 per letter for Basic Business Reply mail.
As stated earlier, many companies do not utilize Business Reply Mail because of its lack of timeliness, effectiveness, and unending potential charges, but would likely use a Time Controlled Prepaid Delivery service. These instances would include; Credit Card bills, Credit Card solicitations, Subscription services, Contests, Sweepstakes, Special offers, Coupons, Charitable Organizations, Membership groups, Finance companies, Banks, Professional companies (ie. Doctors, Lawyers, Accountants), Service Companies (ie. Plumbers, Electricians, Home Improvement Companies), etc. Time Controlled Prepaid Delivery Service would be a valuable and useful service to any company or individual that wishes to improve cash flow, speed of response, and effectiveness of advertising
Time Controlled Prepaid Delivery could be issued as a 1-day service, 2-day service, 3-day service, 4-day service, 5-day service, 6-day service, 7-day service, 8-day service, 9-day service, 10-day service, 11-day service, 12-day service, 13-day service, 14-day service, 15-day service, 16-day service, 17-day service, 18-day service, 19-day service, 20-day service, 21-day service, 22-day service, 23-day service, 24-day service, 25-day service, 26-day service, 27-day service, 28-day service, 29-day service, 30-day service. It could be issued as a 1 month service, 2 month service, 3 month service, 4 month service, 5 month service, 6 month service, 7 month service, 8 month service, 9 month service, 10 month service, 11 month service, and 12 month service. It could also be issued in any combination of the above referenced or longer.
Time Controlled Prepaid Delivery could also be offered on a graduated reduction scale in any chosen combination of payment. Wherein for example a Company could agree to pay the full postage up until a predetermined date and half the postage until a predetermined date, a quarter of the postage up until a predetermined date, and none of the postage after a predetermined date. A clear example of this may be a company that has delivered a very expensive item to deliver. For instance it may cost a company $2,000.00 to deliver an expensive motorcycle. They could agree to pay the full $2,000 return delivery charges for 10 days following receipt. After 17 days they could offer to pay half of the return delivery charges, after 25 days they could offer to pay a quarter of the return delivery charges, and after 30 days they could offer to pay none of the delivery charges.
There also could be a variation wherein a company pays the entire amount regardless of when the item delivers, but charges back the customer's account based upon the date of delivery.
By example a Plumber could utilize a Time controlled prepaid delivery as follows. He could check his records and determine that on average his customers pay their bills 15 days following their receipt of a bill. With Time Controlled Prepaid Delivery, that plumber could offer his customers prepaid postage if they pay their bills 7 days following receipt. The plumber would go to the post office, or apply through some other method as offered by the post office at that time (ie. Internet, 1-800 number), and get an annual, or monthly, or daily “Urgent Reply Mail” permit (or some other name for Time Controlled Prepaid Delivery as determined by the Post Office). Once the account was opened with the Post Office, the plumber could preprint envelopes through a company or use an in-house computer program or other method to preprint envelopes. These envelopes would include his permit number, postage paid line, Postnet Bar code, Postage Endorsement Indicia, Facing Identification Mark, Horizontal Bars, mailing address, and other information, as required by the Post office at that time. He would send the preprinted envelopes to his customers with the chosen predetermined effective expiration date prominently printed on them. He would print this expiration date with a computer, or use a special date stamp, or through some other method. The date would also likely be encoded in a barcode on the envelope, so that it would automatically be read by the Post Office's mail processing machines and automatically charged to his account. Then, when the customers receive their bills, they could choose to either send their payment in the mail prior to the predetermined effective expiration date, or they could affix a stamp to the envelope and pay for it themselves after the predetermined effective expiration date. The Post office would bill the plumber's account for every envelope that was mailed prior to the predetermined effective expiration date. The post office may offer, at the plumber's option, the ability to pay for all postage of items sent without postage regardless of the date stamped on the mail. This would be encoded in the barcode, but would not be evident to the consumer. The reason the plumber may choose this option is to encourage a faster response, yet ensure the delivery for items mailed after the predetermined effective expiration date and without proper postage affixed. The plumber may even send a charge-back to the customer for the cost of postage if an item was sent after the predetermined effective expiration date without postage affixed. The use of the Time Controlled Prepaid Delivery system would provide the plumber with a method to expedite payments, improve company cash flow, and in most cases would not cost the plumber in instances where customers chose to pay after the prepaid postage offer.
Another example may include a Landlord or Mortgage company. Many states allow tenants and Mortgagees to make rent and Mortgage payments as late as the tenth day of each month without a penalty. A Landlord or Mortgage company could determine that it would be beneficial to pay for its customers postage on monthly payments that were mailed within the first 6 days of each month. Since their customers make payments every month, the companies could either send to their customers a bill each month with a preprinted prepaid envelope, or provide their customers with 12 preprinted envelopes for the year in a coupon book like format. In the coupon book like format, there may be a bill for each month and there would be an envelope for each month that would have a predetermined effective start date at the beginning of a month and a predetermined effective expiration date of 6 days later. For example there would be an envelope that had a predetermined effective start date of Jan. 1, 2001 and a predetermined effective expiration date of Jan. 6, 2001. The next envelope would have a predetermined effective start date of Feb. 1, 2001 and a predetermined effective expiration date of Feb. 6, 2001. The next envelope would have a predetermined effective start date of Mar. 1, 2001 and a predetermined effective expiration date of Mar. 6, 2001, and so on. By having a predetermined effective start date, customers could not merely use a later envelope when mailing a payment after the 5th day of the month. The companies would follow the same steps as the plumber listed above for getting such a permit from the Post Office. After getting this special permit, and using it on said envelopes, the company would only be billed for envelopes that were mailed following the predetermined effective start date and prior to the predetermined effective expiration date, unless they chose otherwise.
Another example may include a Credit Card Company. Using the example shown in the chart above, a credit card company could check their records for customers that have an average balance of over $400.00 per month, pay their bills in full every month, and after 15 days. Since the credit card company is not making any money on finance charges with these customers, and they are effectively extending an additional 15 days of credit, they could encourage these customers to send their payment 8 days earlier with Time Controlled Prepaid Delivery. By providing prepaid postage with a predetermined effective expiration date of 7 days after receiving the bill, customers would be required to pay their bills 8 days earlier to take advantage of free postage. For those customers that choose not to take advantage of free postage, the customer would have to affix postage, and there would be no charge to the Credit Card Company, other than the cost of printing the envelopes. Depending upon the interest rate, this earlier receipt of payment may only be worth 50 cents per customer to the credit card company, but multiplied by 12 months and several hundred thousand customers, and the value quickly adds up.
Time Controlled Prepaid Delivery could also be extremely beneficial for companies running special limited time offers. This may include special credit card offers, subscription services, discounts, coupons, and any kind of date sensitive, limited time offer. By including a predetermined effective expiration date, these companies would eliminate the chance of receiving responses to their offer months or years after the promotion has expired. By example EZ Credit Card company is offering a fixed 2.9% interest rate credit card. The special offer is only good for 60 days, to allow for potential changes in the Prime Lending Rate. EZ Credit Card usually would send out a mass mailer with Business Reply Mail envelopes inside. They found that they would get responses on average within 30 days, and as late as 2 years after the promotion would be offered. Unfortunately they were still obligated to pay the Post Office for delivery of these worthless responses. With the proposed “Urgent Mail” or Time Controlled Prepaid Delivery they could encourage customers to respond within 15 days cutting their response time in half, and not have to worry about responses after the 15 day deadline.
Time Controlled Prepaid Delivery could also be extremely beneficial to a membership organizations. Membership organizations often have difficulties receiving timely membership payments. With Time Controlled Prepaid Delivery, membership organizations could provide customers with prepaid predetermined effective expiration dated envelopes. They may offer their members to pay their membership within 15 days and receive free postage. These envelopes could be enough of an incentive for some members to pay dues and other fees sooner to these organizations. In the event customers do not make payments sooner, there would be no charge to the membership organization for offering this benefit to members.
Another example may be a Homeowners Association. Many Homeowners associations require its members to vote on different issues affecting the community. Generally these associations require a certain number of members to send in their votes to have a “quorum”. As a result they are often required to send their members self addressed stamped envelopes or utilize some form of business reply mail. In these instances votes must be received prior to a chosen end date. With business reply mail the Homeowners Association is obligated to pay the postage for these envelopes or reply cards as long as they have an account open with the Post office. With stamped envelopes, they have to make an upfront payment regardless of whether or not members send in their votes. The best solution to this problem is Time controlled prepaid delivery. With Time Controlled Prepaid Delivery, the association could send out vote cards that would expire after a certain date. This would save them the cost of wasted postage, and save them the risk of paying for delivery after an appropriate date.
As stated earlier, Private delivery services, such as Fed-ex, Airborne, UPS, etc., currently have no method or system for consumers or companies to prepay delivery with a predetermined effective expiration date. This could be extremely useful in a number of cases. For companies that offer “no hassle returns” within 30 days, they could provide a prepaid delivery label to customers with a 30 day effective expiration date in order to effectuate a return by that date. This could also apply when customers request a return, and the company agrees to pay the delivery fees for it as long as the delivery is performed prior to a certain date. Companies would set up an account with their delivery company and would only be charged for deliveries that occurred prior to the effective expiration date. Companies may also choose to offer the customers the flexibility of a return within 30 days, but only provide prepaid delivery for 15 days. This would effectuate a quicker response time, which would allow the company to ultimately sell the item quicker.
Another example may be a Compact Disc club that offers a Compact Disc of the month with a 30 day free trial inspection. They may choose to provide their customers the convenience of a prepaid delivery label for returns within 15 days. The reason they may choose 15 days is because they will still be offering the 30 day free trial inspection, but if they can encourage returns to occur earlier, they can then send the Compact Disc back into circulation quicker and ultimately sell it quicker.
Another example may be a Catalog company that already offers free shipping on returns for all items. They can include a pre-addressed prepaid label within the delivery. This would be perceived by customers as above average customer service, and would eliminate excess administration needed to process returns. And by providing a predetermined effective expiration dated delivery to its customers, it controls when the returns take place, and encourage those returns earlier. Encouraging quicker returns, improves merchandise circulation and ultimately improves the sales cycle.
Ultimately it becomes a cost calculation per Issuer as to what instances prepaying postage/delivery is valuable. This new method that I propose, when utilized to its full potential, will have a tremendous impact on companies of all sizes and industries. It will positively effect the United States economy by improving response times, making companies more profitable, lower prices, and improve customers experiences. It may likely prove to be one of the most important new methods to improve delivery and mail services in the United States and the World.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, and representative devices, shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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A method for generating, providing, and utilizing time controlled date sensitive pre-paid postage on an item to be delivered, including a desired delivery amount and personalized postage mark, with the intention of causing action prior to a chosen date. An Issuer would send prepaid postage to a Recipient with a chosen effective date and a chosen expiration date. Said effective date and expiration date would allow Issuer to encourage Recipients to initiate action within a predetermined time window. After effective expiration date, postage would expire requiring new postage/delivery fees to be added to the item for it to be mailed/delivered.
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STATEMENT OF GOVERNMENT INTEREST
The invention described was made in the performance of official duties by one or more employees of the Department of the Navy, and thus, the invention herein may be manufactured, used or licensed by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.
CROSS REFERENCE TO RELATED APPLICATION
The invention is related to and incorporates by reference in its entirety an application for U.S. Patent titled “Slider-Hinge Door” and assigned application Ser. No. 13/068,908.
BACKGROUND
The invention relates generally to slider-hinge doors/ship-board magazines that contain ammunition. In particular, this invention relates to a ready service magazine that facilitates proximate access to ammunition while complying with relevant safety requirements.
The United States Navy has commissioned two class prototypes for a Littoral Combat Ship (LCS) intended for close shore fire support. In particular, the lead ships for these classes are the steel planing monohull U.S.S. Freedom (LCS-1) designed by Lockheed Martin, and the aluminum trimaran U.S.S. Independence (LCS-2) designed by General Dynamics. Both classes can be reconfigured with interchangeable weapons modules for select plug-and-fight missions. Follow-on ships in the Freedom class include U.S.S. Fort Worth (LCS-3), U.S.S. Milwaukee (LCS-5) and U.S.S. Detroit (LCS-7). Follow-on ships in the Independence class include U.S.S. Coronado (LCS-4), U.S.S. Jackson (LCS-6) and U.S.S. Montgomery (LCS-8).
The Gun Mission Module (GMM) as an example for the surface warfare module package includes two turret-mounted, axis-stabilized chain guns that can fire up to 200 rounds per minute of 30×173 mm ammunition, and can hold 800 rounds. Uniformed Navy personnel operate in highly confined spaces, including below deck. The GMM chain gun protrudes above deck from a module cover, below which personnel can supply ammunition from storage containers. Conventionally, such containers are disposed in a location requiring such ammunition either to be linked together absent adequate platform and/or to be carried to the combat firing platform some significant distance from its stowage location.
SUMMARY
Conventional ammunition stowage magazines yield disadvantages addressed by various exemplary embodiments of the present invention. In particular, these embodiments provide a stowage magazine for securing a can of ammunition rounds.
The magazine includes a frame having lateral sides that define a space for the can; a hinge mechanism connecting to the lateral sides; and a door connecting to the mechanism. The door provides and restricts access to the space in respective open and closed positions. The door is openable along an axial direction to provide an operational surface. The mechanism avoids lateral obstruction beyond the door's surface. The frame can suspend lanyards to restrain the can even with the door in open position.
BRIEF DESCRIPTION OF THE DRAWINGS
These and various other features and aspects of various exemplary embodiments will be readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings, in which like or similar numbers are used throughout, and in which:
FIGS. 1A and 1B are isometric assembly views of an ammunition magazine module;
FIG. 2A is an isometric exploded view of components for the ammunition magazine module;
FIG. 2B is an isometric component view of a door panel;
FIGS. 3A and 3B are respective isometric views of a magazine frame and an ammunition can;
FIGS. 4A and 4B are respectively isometric and plan assembly views of a ready service magazine;
FIG. 5 is an elevation assembly view of the ready service magazine;
FIGS. 6A and 6B are elevation detail views of components of the ready service magazine;
FIGS. 7A and 7B are respectively isometric and elevation assembly views of the ready service magazine;
FIG. 8 is an isometric assembly view of an LCS GMM stowage frame; and
FIGS. 9A and 9B are isometric assembly and exploded views of the LCS GMM.
DETAILED DESCRIPTION
In the following detailed description of exemplary embodiments of the invention, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific exemplary embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be utilized, and logical, mechanical, and other changes may be made without departing from the spirit or scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.
FIG. 1A shows an isometric assembly view 100 of an ammunition magazine module in closed configuration. For orientation convention, depth, width and height can be denoted by arrows for axial 110 (aft-to-fore), lateral 120 (port-to-starboard) and vertical 130 (bottom-to-top) directions. The magazine 140 includes a rectangular container 150 flanked by a hinge-rail assembly 160 and accessible by a hatch or door 170 accessible by a handle 175 . FIG. 1B shows an isometric assembly view 180 of the modular ammunition magazine 140 in open configuration as indicated with the door 170 pulled down by the handle 175 to reveal an internal storage chamber 190 .
The door 170 represents a front-load configuration that travels axially fore and aft. Artisans of ordinary skill will recognize that this movement can also apply to a top-load configuration for a door that travels vertically up and down. Depending on orientation, the terms “fore” and “aft” can be interpreted as directions of door's motion for either opening configuration that are substantially parallel to the sides of the container 150 .
FIG. 2A shows an isometric exploded view 200 of components for the magazine module 140 . The hinge-rail assembly 160 comprises armature components 210 mounted to the external port and starboard sides of the container 150 . The components 210 include an elbow bar 220 , a slider 230 , a slide rail 240 , a first three-point hinge 250 , and a second two-point hinge 260 . Button pins 270 protrude laterally from the container 150 on which the first hinge 250 and second 260 hinge pivot. The elbow bar 220 attaches to the slider 230 to traverse fore and aft along the slide rail 240 . Button pins 275 and protruding flanges 280 extend from the lateral ends of the door 170 . FIG. 2B shows an isometric view 290 of the door 170 . The upper and lower pins 270 insert into ends of the respective second and first hinges 260 and 250 . The upper and lower pins 275 insert into ends of the respective first and second hinges 250 and 260 .
FIG. 3A shows an isometric view 300 of the magazine's framework, and FIG. 3B shows an isometric view 310 of an ammunition can for 30 mm rounds. The magazine includes a steel container frame 320 comprising a stack pair of containers 150 mounted on a floor base 330 shown within substantially the same directional orientation as container assembly view 100 . The frame 320 defines interior spaces 340 separated by dividers 350 and 360 . A strut 370 attaching to the lateral sides of the frame 320 provide mounts for the rail 240 .
A typical 30 mm ammunition can 380 slides into one space 340 for stowage. For the container frame shown 320 , the spaces 340 can hold a total of eight cans 380 . Each can 380 holds two belts of fifteen linked 30 mm rounds and weighs about 80 pounds-mass. Alternate designs can provide for more or fewer ammunition containers of sundry dimensions.
FIGS. 4A and 4B respectively show an isometric assembly view 400 and a plan assembly view 410 of a modular Ready Service Magazine 420 for ammunition stowage. A pair of upper and lower containers 150 stacks vertically together as the frame 320 onto and above the base 330 . A security bar 430 locks the doors 170 in the closed position when not in use to inhibit unauthorized opening, particularly from sudden lateral ship movement.
Typical dimensions for the magazine 420 include length (along the lateral direction 120 ) of 44.0 inches, height (vertical direction 130 ) of 37.0 inches and width (axial direction 110 ) of 20.0 inches. The door 170 has corresponding length, width and thickness of 42.75 inches, 15.75 inches and ⅞ inch with a weight of 44 pounds-mass. The door's steel panel surface incorporates a perpendicular mesh of steel strips for structural support of ammunition disposed thereon. Artisans of ordinary skill will recognize that these dimensions are exemplary only and not limiting.
A thermometer 440 above the upper container 150 monitors temperature of the magazine's environment within the spaces 340 . A label plate 450 provides appropriate identification of the magazine 320 and its contents. The magazine 420 incorporates features suitable for both an ammunition magazine (e.g., provisions for accessible workspace, thermal insulation, ventilation, and a sprinkling system) and a storage locker (e.g., possession of minimal footprint, and securable access doors).
FIG. 5 shows an elevation assembly view 500 of the magazine 420 from the fore end with the doors 170 removed. Each container 150 includes a hanger guide 510 and a hook eyelet 520 to secure outer and inner retaining lanyards 530 , 540 . The eyelet 520 includes a detail view 550 described below. The lanyards 530 , 540 provide restraints for the can 380 from crashing or slamming into the operating sailor as the ship rolls or pitches at sea while the door 170 remains open. A sprinkler-valve 560 supported by a column 570 attaches to the top of the magazine 420 for supplying fire retardant (e.g., water) in response to combustion, or else ventilation in the event of pressure from gas accumulation. The magazine 420 may also be equipped with sprinklers or alternate fire suppressant systems to retard blazes therein.
FIGS. 6A and 6B show elevation detail views 600 and 610 of components related to the hinge components 210 and the eyelet 520 . The view 600 shows a lateral side of the magazine 420 from starboard looking port. The view 610 shows the front of the magazine 320 from the front looking aft. In particular, the first hinge 250 features a pivot joint 620 connecting the first hinge 250 to the door 170 at the upper button pin 275 . Rollers on the slider 230 enable the elbow 220 to axially translate along the rail 240 . These motions open the door 170 from its closed position against the container.
A detail features a dog bolt assembly 630 including a rotatable handle 640 that can pivots on a swing hinge 650 attached to either side of each container 150 . With the door 170 closed, the handle 640 latches between the flanges 280 to preclude opening, being further secured by the security bar 430 . Note that the handle 640 can rotate on either or both longitudinal and hinge axes for quick release or engagement. The dog-latch assembly 630 latches the flanges 280 on the door 170 . The swing hinge 650 enables the handle 640 to be swung laterally away from the flanges 280 to release the door 170 for opening. The elbow bar 220 features an end cap 660 . A grounding boss 670 provides an attachment to electrically ground each module 140 . The eyelet 520 connects the inner lanyards 540 connected by the lanyard end retainers 680 .
Conventional techniques for supporting a drop-door involve top surface hinges or cables as commonly used in hatches for ovens or troop trans-ports to augment hinges that may support the door as a resting surface. Other conventional techniques involve manually pulling out a slider to support the drop door. Typically, these flanking sliders and cables impede lateral access beyond the door's opened surface, thereby blocking transport of items, such as ammunition rounds.
In various exemplary embodiments, the door 170 attaches at the lower and upper button pins 275 respectively to the second hinge 260 and the first hinge 250 , the latter demarcated as the joint 620 . Both hinges 260 and 250 connect to the container 150 respectively at the upper and lower button pins 270 to form a four-bar linkage assembly on each of the port and starboard sides. The slide rail 240 attaches to the container 150 , which houses the slider 230 . The elbow bar 220 attaches to the slider 230 .
The top of the first hinge 250 is equipped with a roller caster that rides inside a vertical slot of the elbow bar 220 forms a scotch yoke between the slide rail 240 , the elbow bar 220 and the slider 230 . The hinge-rail assembly 160 provides the advantages of providing a work surface that can be completely unobtrusive on both the top and at the port and starboard sides. The hinge-rail assembly 160 also enables the automatic reposition of the sliders 230 based purely on motion of the door 170 , such as by a scotch yoke (for converting between circular and linear motions), without the use of cables or gears.
FIGS. 7A and 7B respectively show an isometric assembly view 700 and an elevation assembly view 710 of the magazine 420 illustrated with the doors 170 hinged open to reveal the cans 380 restrained by the lanyards 530 and 540 . The flanges 280 on each door 170 rest on the elbow bars 220 to provide a flat table work surface 720 in front of the magazine 420 . The door's surface 720 supports 30 mm ammunition rounds 730 concatenated together for feeding into the chain gun by metal links 740 that may be assembled by sailors. For the configuration produced, the door 170 supported by the elbow 120 can support a load exceeding 80 pounds-mass.
FIG. 8 shows an isometric assembly view 800 of a pair of magazines 420 within a ship hold for containing the Gun Mission Module (GMM). The magazines 420 are contained within and covered by a storage frame 810 that includes a cutout region 820 for the gun platform, as well as an ammunition feed chute 830 to receive rounds 730 stored in the cans 380 within the spaces 310 . FIGS. 9A and 9B respectively show an isometric assembly view 900 and an isometric exploded view 910 of a GMM 920 installed in a ship hold 930 .
The GMM 920 includes a mid-foundation frame 940 and an upper mount frame 945 on which the turret 950 is disposed. The frames 940 and 945 are covered by a gun cover 960 connected to the hold 930 by a barbette 965 . The mid frame 940 rests on a foundation frame 970 . The storage frame 810 external to the mid frame 940 , as demarcated by the cutout 820 , contain magazines 420 on the foundation frame 970 .
Various exemplary embodiments of the ammunition magazine 420 can be employed as an LCS Gun Mission Module (GMM) Ready Service Magazine 420 in compliance with NAVSEA OP-4. The nature of the modular weapon system, such as the GMM, poses unique requirements on the ammo storage area, which must satisfy many requirements of both a traditional Ready Service Magazine and a Ready Service Locker. The exemplary Ready Service Magazine 420 combines elements of both the magazine and locker to provide a a working space, similar to a traditional magazine, in the form of fold down doors for linking and de-linking ammo, while maintaining a locker sized footprint located in proximity to the weapon platform to be served.
Some missile storage rooms containing automatic handling equipment also serve as conventional primary magazines. Such a magazine constitutes actually a walk-in chamber with many requirements that are non-applicable for a modular weapon system including such features such as thermal insulation.
Conventional lockers are often provided for stowage of special types of ammunition and ammunition components such as detonators, pyrotechnics, and chemicals. These are frequently located on the weather deck to be conveniently accessible for the weapon to be served. White sunshields may be required when such lockers face exposure to external elements. Various requirements may be imposed depending on usage: NAVSEASYSCOM Drawing 804-1360106 for topside lockers attached to a deck or bulkhead, NAVSHIPS Drawing 804-6397302 for stowage of thermite grenades.
Lockers for pyrotechnic and incendiary ammunition, such as parachute flares and thermite grenades, include manual jettison capability in case of fire in the vicinity. Being located below the weather deck, the exemplary Ready Service Magazine 420 does not require the sunshield.
A positive locking device, such as the security bar 430 can be provided to prevent inadvertent actuation of any jettison mechanism installed in the magazine 420 . The support arm for the armature components 210 enable avoidance of contact with intended contents when the doors 170 are closed.
The LCS GMM ready service magazine 420 , divided into upper and lower sections with each containing four ammunition cans 380 , can be operated as follows: An operator (e.g., sailor) unlocks the security bar 430 from the magazine 420 . The operator opens the door 170 by grasping the handle 175 to pull forward. The operator unlatches the retaining lanyards 530 and/or 540 for the compartment to be accessed. The operator pulls an ammunition can 380 forward onto the work surface 720 of the door 170 . The operator pulls the ammunition can 380 and connects rounds 730 together by associated links 740 on the door's work surface 720 . The magazine 420 has the advantage of providing an unobstructed working surface 720 and stowage spaces 340 in a small footprint necessary for a modular system.
While certain features of the embodiments of the invention have been illustrated as described herein, many modifications, substitutions, changes and equivalents will now occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the embodiments.
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A stowage magazine is provided for securing a can of ammunition rounds. The magazine includes a frame having lateral sides that define a space for the can; a hinge mechanism connecting to the lateral sides; and a door connecting to the mechanism. The door provides and restricts access to the space in respective open and closed positions. The door is openable along an axial direction to provide an operational surface. The mechanism avoids lateral obstruction beyond the door's surface.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent application Ser. No. 10/101,497 filed Mar. 19, 2002. U.S. patent application Ser. No. 10/101,497 claims priority to U.S. Provisional Application No. 60/277,439. U.S. patent application Ser. No. 10/101,497 is a continuation-in-part of U.S. patent application Ser. No. 09/355,439, filed Nov. 29, 1999, now U.S. Pat. No. 6,412,553. That application is entitled “Apparatus for Positioning a Tong, and Drilling Rig Provided with Such an Apparatus.” The parent application was the National Stage of International Application No. PCT/GB97/03174, filed Nov. 19, 1997 and published under PCT Article 21(2) in English, and claims priority of United Kingdom Application No. 9701790.9 filed on Jan. 29, 1997. Each of the aforementioned related patent applications is herein incorporated in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The present invention generally relates to plugging and abandonment of oil and gas wells. More particularly, the present invention relates to the removal of a tubular from a wellbore in order to satisfy various environmental regulations. More particularly still, the invention relates to severing nested strings of tubulars that are cemented together in order to more easily handle the tubulars as they are removed from a wellbore during or subsequent to a plugging and abandonment operation.
[0004] In the completion of oil and gas wells, boreholes are formed in the earth and thereafter are lined with steel pipe known as casing. An annular area formed between the outside of the casing and the wall of the borehole is typically filled with cement in order to secure the casing in the borehole and to facilitate the isolation of certain areas of the wellbore for the collection of hydrocarbons. In most instances, because of the depth of a wellbore, concentric strings of tubulars are disposed in the wellbore with each lower string of tubulars being necessarily smaller in diameter than the previous string. In some cases, especially in offshore oil and gas wells, the strings are run in a nested fashion from the surface of the well. In other words, a first string of casing is cemented into the wellbore and, subsequently, a second smaller string of casing is cemented into the first string to permit the borehole to be lined to a greater depth. This process is typically repeated with additional casing strings until the well has been drilled to total depth. In this manner, wells are typically formed with two or more strings of casing of an ever-decreasing diameter.
[0005] When a decision is made to no longer operate a hydrocarbon well, the wellbore is typically plugged to prevent formation fluids from migrating towards the surface of the well or into a different zone. Various environmental laws and regulations govern the plugging and abandonment of wellbores. These regulations typically require that the wellbore be filled with some amount of cement. In some instances, the cement must be squeezed into the annular area around the cemented casing in order to prevent fluids from migrating up towards the surface of the well on the outside of the casing through any cement gaps. In offshore wells, regulations typically require not only the foregoing steps, but also that a certain amount of wellbore casing be completely removed from the wellbore. For example, in some instances, the upper 1,000 feet of casing extending downward from the ocean floor into the wellbore must be removed to complete a plugging and abandonment operation.
[0006] Various methods and techniques have been developed and are currently utilized in order to remove casing from an offshore wellbore. Most often, some type of cutting device is run into the wellbore on a wireline or string of tubulars. The cutting device is actuated in order to sever the casing at a predetermined depth, creating separate upper and lower strings of casing. Thereafter, the upper string is pulled and brought to the surface.
[0007] Because of the great length and weight of the upper string of casing being removed, it is necessary to further sever the upper casing string as it is retrieved at the surface. Accordingly, the casing is further severed into predetermined lengths. This makes handling and disposal of the removed casing more efficient.
[0008] In some instances, the severed upper string of casing includes more than one set of tubulars. In other words, there is a first outer string of casing, and then a second smaller string of casing nested therein. In one example, the outer casing string is 13⅜ inches in diameter, and the smaller casing nested therein is 9⅝ inches in diameter. These two strings of severed casing will typically be joined by a layer of cement within the annular area. This cement layer adds to the weight of the severed casing string, making it even more desirable to cut the retrieved pipe into manageable sections.
[0009] A casing string is typically comprised of a series of joints that are 30 feet in length. The pipe joints are connected by threaded male-to-female connections. When retrieving a severed casing string during a plug and abandonment procedure, it is desirable to break the pipe string by unthreading the connected joints. However, this process is difficult where the severed string consists of outer and inner pipe strings cemented together. Further, there is little incentive to incur the time necessary to break the joints apart at the threads, as the pipe joints from an abandoned well will typically not be re-used. For these reasons, the severed casing is typically broken into smaller joints by cutting through the inner and outer strings at the surface of the well. The severed pipe sections are then recycled or otherwise disposed of.
[0010] In a conventional plug and abandonment operation, casing strings are severed generally as follows:
[0011] First, the casing string is severed within the wellbore. Typically, severance is accomplished at a depth of around 1,000 feet. Thereafter, the severed portion of casing is “jacked” out of the wellbore and raised to the surface of the rig platform using a platform-mounted elevator. As the upper end of the severed casing section reaches the floor of the platform, it is lifted to a predetermined height above a set of slips. The slips are then set, suspending the severed string of casing above the rig floor. A drilling machine then drills a hole completely through the casing, including any cement layer and smaller diameter casing which is cemented within the larger diameter casing. Thereafter, a pin or other retainer is inserted through the drilled hole to ensure that the smaller string of casing is anchored to the larger string. This method of drilling a hole through the casing and inserting a retainer pin is necessary to ensure that the smaller string of casing does not become dislodged from the larger string due to some failure of the cement layer there between.
[0012] After the inner casing string and cement there around is anchored to the larger outer string, a band saw is used to cut the severed tubular into a predetermined length. The band saw operates with coolant to avoid the use of high temperature cutters or the production of sparks. Typically, a length of between fifteen and thirty feet is selected, with the cut being made above the retention pin. The newly severed, ten-foot portion of string is then transported to a barge or other transportation means for disposal or salvage.
[0013] With the slips disengaged, the elevator then raises the severed string of casing another length of approximately ten feet. The slips are then re-engaged and the drilling, anchoring and cutting procedure takes place again.
[0014] While the foregoing apparatus and method are adequate to dispose of strings of concentrically cemented casing, the operation necessarily requires personnel to be at the drilling mechanism and the band saw during the operation. The presence of personnel on a platform inherently carries risk. The risk is magnified when the personnel must be in close contact with the operating machinery.
[0015] There is a need, therefore, for a method and apparatus of disposing of concentric strings of tubular during a plugging and abandonment operation which does not require personnel to be located directly at the machinery performing the cutting operations. There is a further need for a method and apparatus which can be operated remotely by well platform personnel. There is yet a further need for an apparatus and method that can more safely and effectively sever strings of casing at a well site.
SUMMARY OF THE INVENTION
[0016] The present invention generally provides an apparatus and method for severing predetermined lengths of nested casing above a drilling rig or workover rig platform. The apparatus includes a clamp assembly, a drill assembly and a cutting assembly. In one aspect, the clamp assembly, the drilling assembly and the cutting assembly are disposed at the end of a telescopic arm, and are remotely operated by personnel using a control panel. In accordance with the present invention, the clamp assembly is positioned adjacent a section of casing to be severed, and then clamped thereto. Thereafter, the drilling assembly is actuated so as to drill a hole completely through the casing strings. A retention pin is then inserted through the newly formed aperture. Finally, the cutting assembly, such as a band saw, is actuated so as to severe the casing above the pin. The newly severed portion of casing above the pin may then be disposed of.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] So that the manner in which the features of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0018] FIG. 1 is a perspective view of the tubular severing apparatus of the present invention, in one arrangement.
[0019] FIG. 2 is a side, schematic view of the tubular severing apparatus of FIG. 1 .
[0020] FIG. 3 is a perspective view of a cross-sectional cut of a casing section. The pipe section is comprised of an outer casing string, an inner casing string and a layer of cement there between.
[0021] FIG. 4 is a side view illustrating a drilling assembly of the present invention. The drilling assembly is shown drilling a hole through a casing section.
[0022] FIG. 5 a is a top view showing an alternate embodiment of a drill assembly of the present invention. FIG. 5 b presents a side view illustrating the drill assembly of FIG. 5 a.
[0023] FIG. 6 is a perspective view illustrating the tubular severing apparatus of FIG. 1 . In this view, the clamping assembly is more clearly seen. The clamping assembly is shown clamping a casing section. Also visible is the band saw being used to cut through the casing section.
[0024] FIG. 7 is also a perspective view illustrating the tubular severing apparatus of FIG. 1 . In this view, features of an exemplary band saw are more clearly. The band saw is again shown cutting a casing section.
[0025] FIG. 8 is an enlarged view of the band saw of FIG. 7 .
[0026] FIG. 9 is a perspective view of a control panel as might be used to control various portions of the severing apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] The present invention provides a method and apparatus for severing casing that has been removed from a wellbore.
[0028] FIG. 1 provides a perspective view of a novel tubular cutting apparatus 100 of the present invention, in one embodiment. The apparatus 100 comprises a clamp assembly 130 , a drill assembly 150 and a cutting assembly 120 . The apparatus 100 is selectively movable. In one aspect, the apparatus 100 is disposed at the end of an extendable structure. In FIG. 1 , the extendable structure is shown as a cantilevered arm 110 . The exemplary arm 110 defines an outer barrel 110 having at least one telescoping section 112 extending therefrom. An intermediate telescoping section (not shown) may also be incorporated. In such an arrangement, the end telescoping section 112 is slidably mounted in the intermediate telescoping section which is, in turn, slidably mounted in the outer barrel 110 .
[0029] The arm 110 is supported by a base 114 secured to the floor of a rig platform (not shown). The arm 110 is disposed along a vertical support beam 116 vertically extending above the base 114 . In the parent application, the outer barrel of the arm 110 is described as being attached to the support beam 116 by means of a clamp (not shown in FIG. 1 ) bolted to the top of the beam 116 . The clamp maintains the arm 110 in position with respect to the beam 116 . In one aspect, the arm 110 is pivotally attached to the support beam 11 '3 to permit the tubular severing apparatus 100 to pivot about a vertical axis and, alternatively or in addition, a horizontal axis. In one aspect, the clamp is releasably attached to the support beam 116 .
[0030] An additional feature of the arm 110 described more fully in the parent application is that the outer barrel 110 of the arm itself may be selectively moved with respect to the support beam 116 . This means that the entire arm 110 may be retracted away from the casing section 200 ′. When the telescoping sections 112 are fully contracted, the free end of the arm 110 lies closely adjacent the support beam 116 . This retracting feature is shown in FIG. 4 of the parent application with respect to a tong, but may also be employed in the present application with respect to a tubular severing assembly 100 .
[0031] In the arrangement of FIG. 1 , the apparatus 100 is further supported by an overhead hoisting system. Cables 160 from the hoisting system are visible in FIG. 1 . In one aspect, the hoisting system maneuvers the tubular severing apparatus 100 , with the telescoping section 112 of the arm 110 moving in response. In another aspect, the telescoping section 112 of the arm 110 is hydraulically powered, causing the apparatus 100 and the supporting cables 160 to advance and recede in response to movement of the arm 110 . Alternatively, the arm 110 and the hoisting system may be independently powered.
[0032] Further details concerning the operation of a suitable telescoping arm are found in the pending application entitled “Apparatus for Positioning a Tong.” Ser. No. 09/355,439, and was filed on Nov. 29, 1999, now U.S. Pat. No. 6,412,553. That application is incorporated by reference herein, in its entirety.
[0033] Also visible in FIG. 1 is a section of casing 200 ′. Casing section 200 ′ represents an upper, severed string of casing that is being retrieved from a wellbore (not shown in FIG. 1 ). The casing 200 ′ is being further severed into smaller portions for ease of manipulation and disposal. The exemplary casing string 200 ′ houses a smaller, inner string of casing 205 nested within an outer casing string 200 . The inner string 205 has been cemented into the outer string 200 in connection with earlier wellbore completion operations.
[0034] FIG. 2 is a schematic view of the apparatus 100 , adjacent a section of casing 200 ′. Visible again in FIG. 2 is the clamp assembly 130 , the drill assembly 150 and the cutting assembly 120 . In this arrangement, the assembly 100 is again disposed at the distal end of the telescopic arm 110 and is suspended from above with cables 160 . The telescopic arm 110 again has at least one telescoping section 112 .
[0035] In FIG. 2 , the clamp assembly 130 is radially disposed about the section of casing 200 ′ so as to secure the casing section 200 ′ for severing. The casing 200 ′ is shown in FIG. 2 in cross-section. Visible in this view are the outer casing string 200 , the inner casing string 205 and a matrix of cured cement 210 in the annular region between the two casing strings 200 , 205 .
[0036] FIG. 3 is a perspective view showing a cross-section of the casing 200 ′ after it has been severed using the apparatus 100 of FIG. 2 . As previously described, casing section 200 ′ defines an outer string of casing 200 which houses a smaller diameter casing 205 . A matrix of cement 210 is disposed in an annular area between the two casing strings 200 , 205 . In this view, inner casing string 205 is eccentric relative to the surrounding outer casing string 200 , as is typical in a completed wellbore.
[0037] Referring back to FIG. 2 , the tubular string 200 ′ is shown being held above a floor member 170 by a set of slips 172 . The slips 172 permit the tubular string 200 ′ to be raised from below the surface of the platform to some height. Typically, elevators (not shown) are provided on a rig for maneuvering pipe relative to the wellbore. The slips 172 hold the casing 200 ′ so that it can be clamped and severed by the apparatus 100 after positioning of the casing 200 ′ by the elevators.
[0038] As noted, the apparatus 100 includes a drill assembly 150 . The purpose of the drill assembly 150 is to form an aperture through the casing strings 200 , 205 for insertion of a retention member 165 . Preferably, the retention member 165 defines a pin configured to be received within the formed aperture. Various pin types may be used, including, for example, a cylindrical bar, a cotter pin, or a cotter and key. In FIG. 2 , a simple tubular pin is shown. The pin 165 serves to anchor any nested casing string 205 and cement 210 to the outer casing string 200 . Preferably, the aperture is formed completely through both the front and back walls of the outer casing string 200 , and the pin 165 is inserted completely through the outer casing string 200 .
[0039] In the arrangement of FIG. 2 , the drill assembly 150 is disposed below the band saw 120 . The drill assembly 150 is constructed and arranged to insert a rotating drill bit 151 essentially perpendicular to the longitudinal axis of the casing string 200 ′. In this way, a suitable aperture is formed. Any known drilling device may be employed for boring a through-opening into the casing section 200 ′. The drill assembly 150 of FIG. 2 utilizes a rotary motor (not shown) inside of a housing 153 to rotate a single drill bit 151 . A positioning device is further provided for selectively advancing the drill bit 151 towards and away from the casing section 200 . In one aspect, a hydraulic cylinder 156 is used to advance the drill bit 151 towards and away from the casing section 200 ′ by adjusting flow and pressure of hydraulic fluid.
[0040] An enlarged perspective view of a drill assembly 150 in operation is shown in FIG. 4 . The drill bit 151 can be more clearly seen penetrating the wall of the outer section of casing 200 . The drill assembly 150 typically operates with a source of coolant and advances forward towards the casing 200 by means of a telescoping positioning device, shown in FIG. 4 as a cylinder 156 . In one aspect, the drill assembly 150 is operated remotely from a control panel 125 as is shown in FIG. 2 . The remote control panel 125 will be more fully described, infra.
[0041] An alternative arrangement for a drill assembly is presented in FIGS. 5 a and 5 b . FIG. 5 a is a top view of an alternate embodiment of a drilling assembly for the present invention. FIG. 5 b is a side view thereof. In this arrangement, a pair of opposing boring devices 155 are urged inwardly towards the center of the casing section 200 ′. Again, it is within the spirit of the present invention to employ any drilling assembly 150 capable of boring an aperture through the casing section 200 ′ for insertion of an anchoring pin 165 .
[0042] Referring again to FIG. 2 , it can be seen that the drill assembly 150 has been actuated to form an aperture through both casings strings 200 , 205 . The pin 165 has been inserted through the formed aperture to anchor the inner casing 205 to the outer casing 200 .
[0043] FIG. 6 is a perspective view of the apparatus 100 of FIG. 1 . In this view, the clamp assembly 130 is more clearly seen. The clamp assembly 130 includes a frame 134 that selectively radially encompasses the casing section 200 ′ in order to secure the apparatus 100 to the casing section 200 ′. The clamp assembly 130 further comprises at least two clamp members 140 for frictionally engaging the casing 200 ′. In the arrangement of FIG. 6 , the clamp members 140 each define a pair of angled support blocks which are moved into contact with the casing 200 ′. However, other arrangements may be employed, such as a single block having a concave surface.
[0044] The clamp assembly 130 includes a gate member 135 that swivels about a hinge 133 mounted on the frame 134 . The hinge 133 permits the gate member 135 to be selectively opened and closed for receiving and for clamping the casing 200 ′. In the view of FIG. 6 , the gate member 135 is closed about the casing 200 ′ while the casing section 200 ′ is being severed. The gate member 135 includes at least one clamp member 140 for engaging the casing 200 ′ in its closed position. The gate 135 preferably operated with hydraulic power, and is remotely operated from control panel 125 . A hydraulic arm 136 is shown to aid in remotely opening and closing the gate 135 .
[0045] FIG. 7 presents the apparatus 100 of FIG. 1 in still greater detail. In this perspective view, the cutting assembly 120 is more clearly seen. The cutting assembly 120 is shown as a band saw. The band saw 120 first comprises a housing 122 . The housing 122 houses a pair of wheels (not seen in FIG. 7 ) about which a band saw blade 121 is tracked. The band saw blade 121 includes a plurality of teeth. The blade 121 is fed through pairs of roller members 123 which guide the blade 121 to cut in a direction substantially perpendicular to the longitudinal axis of the outer casing 200 . One pair of roller members 123 is preferably provided at the housing outlet for the blade 121 . In this respect, the blade 121 is fed through this first pair of roller members 123 . A second pair of roller members 123 is disposed at the opening in the housing 122 through which the blade 121 is received back into the housing 122 . The roller members 123 are more clearly seen in the enlarged view of FIG. 8 .
[0046] It is within the spirit of the present invention to utilize any cutting device 120 known for severing casing, so long as the cutting device 120 may be adapted to operate in conjunction with a clamp assembly 130 and a drill assembly 150 . In the exemplary arrangement for a cutting assembly 120 of FIG. 7 , the cutting assembly defines a band saw 120 . Further, the band saw 120 includes a housing 122 that is offset from the angle of cutting by the blade 121 . In other words, the angle of the housing 122 of the band saw 120 is offset from the angle at which the teeth of the blade 121 engage the outer casing 200 during the cutting operation. The angle shown is approximately 30 degrees, though other angles may be used. In addition, an enlarged spacing 129 is provided in the housing 122 between the wheels. These features accommodate placement of and access to the drill assembly 150 and clamp assembly 130 . The spacing 129 in the housing 122 is more importantly sized to receive the casing 200 ′ as the blade 121 of the saw 120 advances through the casing 200 ′ during a cutting operation.
[0047] In the drawings of FIG. 7 and FIG. 8 , the blade 121 of the band saw 120 has been actuated. In addition, the blade 121 is engaging the casing section 200 ′, and has advanced partway through the casing 200 ′ to form a cut that is substantially perpendicular to the longitudinal axis of the outer casing 200 .
[0048] Referring again to FIG. 2 , the band saw 120 , the clamp assembly 130 , and the drill assembly 150 are preferably controlled in an automated fashion from a control panel 125 . Control lines 126 are provided from the control panel 125 to control the assembly 100 , e.g., parts 120 , 130 , 150 , etc. FIG. 9 is a more detailed perspective view showing a typical control panel 125 to be utilized with a tubular severing apparatus 100 . The illustrated control panel 125 in one aspect includes separate controls to operate the clamp assembly 130 , the drilling assembly 150 , and the band saw 120 .
[0049] The band saw 120 and the drill assembly 150 are typically operated with similar controls. For example, the drill assembly 150 and saw 120 each require an on/off control and a rotational speed control to manipulate the rotation of the saw blade 121 or the drill bit 151 . Corresponding gauges illustrating the rotational movement of the drill bit 151 and the band saw 121 as shown in revolutions per minute may optionally be provided. In addition, a tool advancing control is provided to control the speed of advance of the drill bit 151 into the casing 200 ′ and the blade 121 of the band saw 120 into the casing 200 ′. Corresponding positioning devices 127 (shown in FIG. 1 ) and 156 (shown in FIG. 4 ) are provided for the band saw 121 and the drill assembly 150 . These positioning devices, 126 , 156 , in one aspect, represent telescoping hydraulic cylinders. These devices permit the drill bit 151 of the drill assembly 150 and the blade 121 of the band saw 120 to be independently, selectively advanced towards the casing 200 ′ during the respective drilling and cutting operations and then withdrawn.
[0050] In addition, both the band saw 120 and the drill assembly 150 optionally include pressure sensors to determine the amount of pressure placed upon the casing by the rotating drill bit 151 or the rotating saw blade 121 . Gauges may be provided at the control panel 125 indicating pressures on the drill bit 151 or the rotating saw blade 121 . For example, core heads and saw blades provided by Mirage Tool Co ltd. (U.K.) and core heads from Alf I Larsen (Norway) may be used.
[0051] The clamp assembly 130 also has controls that are located on the control panel 125 . For instance, the clamp assembly 130 includes a panel-mounted control which opens and closes the gate 135 located on the clamp assembly 130 . Optionally, a gauge indicating pressure between the casing 200 ′ and a clamp 140 may be provided and pressure of the clamps 140 . A corresponding sensor is positioned on at least one of the clamp members 140 for sensing pressure of the clamp member 140 against the casing 200 when the gate 135 is closed. Preferably, the sensor is placed on the clamp member 140 on the gate 135 .
[0052] In use, the severing apparatus of the present invention operates as follows:
[0053] First, a casing cutting means (not shown) is run into a wellbore. The cutting means is typically disposed on the end of a run-in string or wireline. The cutting means is placed in the wellbore at a predetermined depth, and then actuated. In this way, a selected length of casing is severed downhole. Thereafter, the severed portion of casing 200 is pulled or “jacked out” of the wellbore and lifted to the rig platform within an elevator.
[0054] A predetermined amount of the severed portion of casing 200 ′ is pulled upwards past the slip 172 located at the level of the platform floor. The casing 200 ′ is held in place by the slip 172 , exposing the upper portion of the casing 200 ′ above the platform floor. Thereafter, a tubular severing apparatus 100 of the present invention is moved towards the casing 200 ′ by the telescopic arm assembly 110 with its extending and retracting sections 112 . As the apparatus 100 reaches a location proximate to the casing 200 ′, the clamp assembly 130 is actuated to open the gate 135 and to receive the casing 200 ′. The gate 135 is then closed around the casing 200 ′, and the clamp assembly 130 is secured to the casing 200 ′ by the clamping members 140 . In this way, the severing apparatus 100 is properly positioned with respect to the casing 200 ′.
[0055] Thereafter, with the outer casing string 200 clamped in the apparatus 100 , the drill assembly 150 is operated. Preferably, remote actuation of the drill assembly 150 is conducted through the control panel 125 . The drill bit 151 disposed on the drill assembly 150 is rotated and advanced towards the casing 200 to form an aperture therein. The aperture is created through at least the front wall of the casing section 200 ′ at an angle substantially perpendicular to the longitudinal axis of the outer casing 200 . A retention mechanism such as a pin 165 is then inserted through the casing 200 ′ to ensure that any inner string of casing 205 is longitudinally fixed with respect to the outer string of casing 200 .
[0056] The next step involves actuation of the band saw 120 . Preferably, actuation of the band saw 120 is performed remotely via the control panel 125 . The blade 121 of the band saw 120 is actuated, and is advanced through the casing 200 ′ at a point above the pin 165 . The retention pin 165 anchors the smaller diameter casing 205 within the larger diameter casing 200 . In this manner, the inner 205 and outer 200 casing strings in the lower section 200 ″ are prevented from separating below the rig floor. The severed portion of the casing section 200 ′ is then lifted away, leaving an upper end of the lower portion of casing 200 ″ remaining within the clamping assembly 130 .
[0057] Once the severed piece of casing 200 ′ has been disposed of, an elevator or other lifting device works with the slips to lift the casing 200 ′ another predetermined distance upwards. The slips 172 are then used to re-grasp the casing 200 ′ for the operation to be repeated. Each time a severing operation is completed, the clamp assembly 130 is de-activated, and the gate 135 is reopened so that the apparatus 100 can move away from the severed piece of casing 200 ′. In addition, it is noted that the pin 165 may be retained in the newly lifted section of casing 200 ′ to be severed. A new pin 165 can then be inserted once a new aperture is formed within the casing 200 ′.
[0058] As demonstrated in the foregoing disclosure, the apparatus 100 of the present invention provides a safe and efficient means for severing casing during a plug and abandonment operation. In one aspect, the apparatus 100 is operated via a remotely located control panel 125 .
[0059] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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An apparatus and method for use in severing casing as it is pulled from a wellbore. An apparatus is first provided, comprising a clamping assembly, a drilling assembly and a cutting assembly. In one aspect, the apparatus is disposed at the end of a telescopic arm, with the components being remotely operated by personnel using a control panel. The apparatus can be positioned adjacent casing and clamped thereto. Thereafter, the apparatus can drill a hole completely through the casing for the insertion of a retention pin. The apparatus can then severe the casing into manageable lengths to facilitate disposal, such as during a plugging and abandonment procedure.
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FIELD OF THE INVENTION
This invention relates to a semiconductor device, and more particularly to, a semiconductor device which is used as an optical detector and which has a photodiode structure including a silicon-germanium epitaxial layer.
BACKGROUND OF THE INVENTION
Typically used as an optical detector in optical communication system is a photodiode which is composed of a III-V system compound, e.g., InGaAsP. On the other hand, from the point of well matching with the silicon processing, a photodiode in which silicon-germanium(hereinafter referred to as `SiGe`) is used as a light-absorbing layer has been developed.
The problem in SiGe growth onto a silicon(hereinafter referred to as `Si`) substrate is in that there occurs a crystal defect due to its high lattice mismatch. In this regard, U.S. Pat. No. 4,529,455 (J. C. Bean et al.) discloses a method for growing a BOX-type SiGe layer with a critical film thickness. As a solution of the above problem caused by thickening a SiGe layer as a light-absorbing layer, Japanese patent application laid-open No. 62-165980 (1987) (J. C. Bean et al.) discloses a photodiode technique in which a Si/SiGe superlattice layer alternately layered of Si layers and SiGe layers is employed. In this device, since the total film thickness of the light-absorbing layer of SiGe is increased by employing the superlattice structure, the photoelectric conversion efficiency can be enhanced. With regard to such SiGe growth method, Japanese patent application laid-open No. 1-144617 (1989) (K. J. Lindberg) discloses a continuous growth method of superlattice layer.
FIG. 1 is a cross sectional view showing the device composition of an optical detector grown by the method of J. C. Bean et al. In this device, a Si/SiGe superlattice layer 3 is grown on a P + -type silicon substrate 1, further growing a N + -type silicon contact layer, whereby a photodiode is formed. In this structure, the Si/SiGe superlattice layer 3 as light-absorbing layer is depleted by reversely applying an voltage, whereby incident light is converted into electricity. As shown in FIG. 1, a Ge concentration distribution in the superlattice layer 3 has a BOX type of profile. Since the total film thickness of the light-absorbing layer prepared by employing the superlattice structure is thicker than that in case of stacking with single layers, light-receiving area can be enlarged, thereby increasing the quantum efficiency.
FIG. 2 is a cross sectional view showing the device composition of an optical detector grown by the method of K. J. Lindberg et al. and a Ge concentration profile in a SiGe epitaxial layer 8. Since it has the concentration profile that periodically changes, as shown in FIG. 2, by varying a gas flow rate in an apparatus, a thicker SiGe layer can be grown.
However, in the above conventional photodiodes using the superlattice, there are some problems as described below.
The first problem is that the superlattice structure device produced by the method of J. C. Bean et al. has a low productivity due to a low growth rate of the Si/SiGe layer. This is because the Ge concentration profile in SiGe layer is of a BOX type and Si layers with a very low growth rate need to be grown between the SiGe layers. The second problem is that the superlattice structure device produced by the method of K. J. Lindberg et al. is likely to be highly affected by heat treatment after growth, thereby occurring a leakage current. This is because the crystal defect due to lattice mismatch may occur during the continuous growth of a thick SiGe layer.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide a semiconductor device with a good productivity.
It is a further object of the invention to provide a semiconductor device in which the occurrence of crystal defect can be suppressed.
According to the invention, a semiconductor device, which is used as an optical detector, comprises:
a photodiode section which is composed of a first silicon layer, a light-absorbing layer and a second silicon layer which are in turn layered on a silicon substrate;
wherein the light-absorbing layer is formed as a single silicon-germanium epitaxial layer and the single silicon-germanium epitaxial layer has a germanium concentration distribution which provides germanium concentrations of zero at its interfaces to the first silicon layer and the second silicon layer and provides a triangle-shaped concentration profile that a peak concentration value is provided in the middle of the single silicon-germanium epitaxial layer.
In the semiconductor device of the above-mentioned invention, since the SiGe epitaxial layer which composes the light-absorbing layer has a triangle-shaped Ge concentration distribution, a part with relatively low Ge concentration can absorb light to some degree and a part with relatively high Ge concentration can sufficiently absorb light. As a result, thickening of the SiGe epitaxial layer can be substantially achieved. Moreover, since the growth rate of forming the single SiGe epitaxial layer is higher than that of a Si epitaxial layer, the productivity can be enhanced.
According to another aspect of the invention, a semiconductor device, which is used as an optical detector, comprises:
a photodiode section which is composed of a first silicon layer, a light-absorbing layer and a second silicon layer which are in turn layered on a silicon substrate;
wherein the light-absorbing layer is formed as a silicon/silicon-germanium superlattice layer in which a silicon epitaxial layer and a silicon-germanium epitaxial layer are alternately layered and the silicon-germanium epitaxial layer of the silicon/silicon-germanium superlattice layer has a germanium concentration distribution which provides germanium concentrations of zero at its interface to the silicon epitaxial layer and provides a triangle-shaped concentration profile that a peak concentration value is provided in the middle of the silicon-germanium epitaxial layer.
In the semiconductor device of the above-mentioned invention, substantial thickening of the SiGe epitaxial layer can be achieved by employing the Si/SiGe superlattice layer. Moreover, since the Si epitaxial layer is always sandwiched between adjacent two Si epitaxial layers, occurrence of crystal defect due to thickening can be suppressed, thereby reducing a leakage current.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in more detail in conjunction with the appended drawings, wherein:
FIG. 1 is a cross sectional view showing a conventional optical detector,
FIG. 2 is a cross sectional view showing another conventional optical detector,
FIG. 3A is a cross sectional view showing a semiconductor device in a first preferred embodiment according to the invention,
FIG. 3B shows a relationship between a depth of light-absorbing layer and a Ge concentration in the semiconductor device in the first embodiment,
FIG. 4A and 4B are cross sectional views showing a production process of the semiconductor device in the first embodiment,
FIG. 5A shows a relationship between a refractive index and a distribution of optical intensity in an optical fiber,
FIG. 5B shows a relationship between a refractive index and a distribution of optical intensity in the semiconductor device in the first embodiment,
FIG. 6A is a cross sectional view showing a semiconductor device in a second preferred embodiment according to the invention,
FIG. 6B shows a relationship between a depth of light-absorbing layer and a Ge concentration in the semiconductor device in the second embodiment, and
FIG. 7A and 7B are cross sectional views showing a production process of the semiconductor device in the second embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A semiconductor device in the first preferred embodiment according to the invention will be explained in FIGS. 3A to 4B.
FIG. 3A is a cross sectional view of the semiconductor device 11 in the first embodiment, which is formed as an optical detector in which a photodiode section with a mesa structure is formed on a P + -type silicon substrate.
As shown in FIG. 3A, a lower silicon layer 13 (first silicon layer) is formed on a P + -type silicon substrate 12, and formed in sequence thereon are a SiGe epitaxial layer 14 (light-absorbing layer), an upper silicon layer 15(second silicon layer) and a N + -type silicon contact layer 16, wherein the N + -type silicon contact layer 16 to upper part of the lower silicon layer 13 are formed as a mesa structure. Then, these are covered with silicon dioxide film 17, boring a contact 18, forming an aluminum electrode 19 contacting the N + -type silicon contact layer 16. An end surface to which light is introduced is provided by a cleavage plane which is obtained by cleaving the silicon chip.
FIG. 3B shows a relationship between a depth of a light-absorbing layer in the photodiode section and a Ge concentration.
As shown, the semiconductor device 11 has a Ge concentration distribution in the SiGe epitaxial layer 14 that Ge concentrations at the interfaces to the upper silicon layer 15 and the lower silicon layer 13 are zero and there is a peak value of at the middle of the depth, thereby forming a triangle.
Next, a production process of the semiconductor device 11 in the first embodiment will be explained in FIGS. 4A and 4B. First, as shown in FIG. 4A, the lower silicon layer 13 is grown by around 1.0 μm on the P + -type silicon substrate 12, thereafter growing the SiGe epitaxial layer 14 up to, e.g., 1.0 μm thickness with monotonously increasing its Ge concentration and growing it from there to 2.0 μm thickness with monotonously decreasing its Ge concentration, whereby the triangle-shape concentration distribution as shown in FIG. 3B is obtained. Then, the upper silicon layer 15 is grown by around 1.0 μm thereon, thereafter growing the N + -type silicon contact layer 16.
Then, as shown in FIG. 4B, to leave a region for forming a photodiode, the mesa-etching from the surface of the N + -type silicon contact layer 16 up to the lower silicon layer 13 is conducted, thereafter covering the entire surface with the silicon dioxide film 17. Then, after the silicon dioxide film 17 on the N + -type silicon contact layer 16 is partially bored, the aluminum electrode 19 as an upper electrode is formed. Thereafter, a part of the photodiode section is cleaved to provide a light-receiving surface, whereby the semiconductor device as shown in FIG. 3A is obtained.
Meanwhile, as explained before, the greater the Ge concentration in a SiGe layer is, the higher the lattice mismatch with silicon is. Thereby, the crystal defect in the SiGe layer will be increased and its critical film thickness will be thinner. In the first embodiment, as shown in FIG. 3B, the Ge concentration is gradually increased in the direction from the interface of the SiGe epitaxial layer 14 and the lower silicon layer 13 or upper silicon layer to the middle part of the SiGe epitaxial layer 14. Therefore, the lattice mismatch at the interfaces to silicon can be significantly relaxed as compared to the case of BOX-type, thereby increasing its substantial SiGe film thickness. As a result, the sectional area of the light-receiving part can be increased and the photoelectric conversion efficiency can be enhanced. Moreover, since the growth rate of the SiGe epitaxial layer 14 is higher than that of the silicon layer, the productivity can be improved as compared to that in the conventional optical detector with BOX-type concentration distribution.
On the other hand, when light is transmitted through an optical fiber which is a light-introducing source, the light has a constant optical intensity distribution as shown in FIG. 5A.
This is because the light is confined due to the core having a refractive index higher than that of the cladding layer. Here, when there exists a triangle-shape Ge concentration distribution in the SiGe epitaxial layer 14 of the photodiode section as illustrated in the first embodiment, there is provided, as shown in FIG. 5B, a refractive index distribution that a refractive index n is given by n=3.5+0.38x, where x represents a Ge content ratio in the SiGe epitaxial layer. Thus, the semiconductor device in this embodiment has also a sufficient light confinement effect that light is confined with a peak at the highest refractive index, therefore providing a good matching with an optical fiber. If silicon layers with a low refractive index are grown just under and on the SiGe epitaxial layer 14, the light confinement effect becomes maximum. Furthermore, if the silicon layer 13, 15 just under and on the SiGe epitaxial layer 14 are so-called non-doped layers with no impurity implanted, the difference of refractive index is further increased and the light confinement effect is also enhanced.
In optical communication field, light with a wavelength of 0.98 μm, 1.3 μm or 1.55 μm is used depending on characteristics of optical fiber. In this connection, using the semiconductor device 11 in the first embodiment, the sensitivity of photodiode is assessed while a peak value of the Ge concentration in the SiGe epitaxial layer 14 is varied. As a result, it is proved that, to get the sensitivity of photodiode with a quantum efficiency more than 10% that satisfies a practical level, it is necessary for the peak value of Ge concentration to be at least more than 8 atomic weight %. Also, it is proved that, in case of using light with a greater wavelength, it is necessary for the peak value of Ge concentration to be higher.
A semiconductor device in the second preferred embodiment according to the invention will be explained in FIGS. 6A to 7B.
FIG. 6A shows a cross sectional view of the semiconductor device 20 in the second embodiment, wherein like parts are indicated by like reference numerals as used in FIG. 3A. The semiconductor device 20, similarly to the first embodiment, comprises a mesa structure photodiode, but it is different from the first embodiment in that a Si/SiGe superlattice layer is used as a light-absorbing layer instead of the SiGe epitaxial layer 14.
As shown in FIG. 6A, a lower silicon layer 13 is formed on a P + -type silicon substrate 12, and formed in sequence thereon are a Si/SiGe superlattice layer 21, an upper silicon layer 15 and a N + -type silicon contact layer 16, wherein the N + -type silicon contact layer 16 to upper part of the lower silicon layer 13 are formed as a mesa structure. Then, these are covered with silicon dioxide film 17, boring a contact 18, forming an aluminum electrode 19 contacting the N + -type silicon contact layer 16. An end surface to which light is introduced is provided by a cleavage plane which is obtained by cleaving the silicon chip.
FIG. 6B shows a relationship between a depth of a light-absorbing layer in the photodiode section and a Ge concentration. As shown, different from the first embodiment, the semiconductor device 20 has a Ge concentration distribution in the Si/SiGe superlattice layer 21 that Ge concentrations of the respective SiGe epitaxial layers at the interfaces to the lower and upper Si epitaxial layers with Ge concentrations of zero are zero and there are peak values of at the middle of the respective SiGe epitaxial layers, thereby forming triangles.
Next, a production process of the semiconductor device 20 in the second embodiment will be explained in FIGS. 7A and 7B. First, as shown in FIG. 7A, the lower silicon layer 13 is grown by around 1.0 μm on the P + -type silicon substrate 12, thereafter growing the SiGe epitaxial layer up to the middle of its film thickness with monotonously increasing its Ge concentration and growing it from there with monotonously decreasing its Ge concentration. Then, the SiGe epitaxial layer and Si epitaxial layer, each of which has a thickness of, e.g., 50 nm, are alternately grown to provide its total layer number of around 20 to 40, whereby the Si/SiGe superlattice layer 21 which has a thickness of around 1.0 to 2.0 μm and has the Ge concentration distribution as shown in FIG. 6B is obtained. Then, the upper silicon layer 15 is grown by around 1.0 μm thereon, thereafter growing the N + -type silicon contact layer 16.
Then, as shown in FIG. 7B, to leave a region for forming a photodiode, the mesa-etching from the surface of the N + -type silicon contact layer 16 up to the lower silicon layer 13 is conducted, thereafter covering the entire surface with the silicon dioxide film 17. Then, after the silicon dioxide film 17 on the N + -type silicon contact layer 16 is partially bored, the aluminum electrode 19 as an upper electrode is formed. Thereafter, a part of the photodiode section is cleaved to provide a light-receiving surface, whereby the semiconductor device as shown in FIG. 6A is obtained.
Also in the second embodiment, by providing the Si/SiGe superlattice layer 21, the Ge concentration is gradually increased in the direction from the interface of the Si epitaxial layer and the SiGe epitaxial layer to the middle part of the SiGe epitaxial layer. Therefore, the lattice mismatch at the interfaces of the Si epitaxial layer and the SiGe epitaxial layer can be significantly relaxed, thereby increasing its substantial SiGe film thickness. As a result, similarly to the first embodiment, the sectional area of the light-receiving part can be increased and the photoelectric conversion efficiency can be enhanced.
Next, its light confinement effect will be discussed below.
If the peak of Ge concentration in the semiconductor device 11 of the first embodiment as shown in FIG. 3B is equal to the peak of Ge concentration in the semiconductor device 20 of the second embodiment as shown in FIG. 6B, refractive index at the middle of the whole light-absorbing layer in the semiconductor device 20 of the second embodiment is lower on average since the semiconductor device 20 includes regions with a concentration of zero, therefore resulting in reducing the light confinement effect. However, in the second embodiment, the sectional area of the light-absorbing layer can be substantially enlarged by employing the Si/SiGe superlattice structure, thereby providing an optical detector advantageous to the case that an optical fiber with a large numerical aperture is connected.
Though the semiconductor devices 11 and 20 in the above embodiments have the photodiode sections with mesa structure, they may have a planar type of photodiode section. Further, the conductivity types of the substrate and silicon contact layer, which are P-type and N-type, respectively in the above embodiments, may be N-type and P-type, respectively.
Although the invention has been described with respect to specific embodiment for complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modification and alternative constructions that may be occurred to one skilled in the art which fairly fall within the basic teaching here is set forth.
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Disclosed is a semiconductor device, which is used as an optical detector and has: a photodiode section which has a first silicon layer, a light-absorbing layer and a second silicon layer which are in turn layered on a silicon substrate; wherein the light-absorbing layer is formed as a single silicon-germanium epitaxial layer and the single silicon-germanium epitaxial layer has a germanium concentration distribution which provides germanium concentrations of zero at its interfaces to the first silicon layer and the second silicon layer and provides a triangle-shaped concentration profile that a peak concentration value is provided in the middle of the single silicon-germanium epitaxial layer.
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This application is a continuation of application Ser. No. 08/654,048 filed May 28, 1996, now abandoned, which is a continuation of application Ser. No. 08/433,680 filed May 4, 1995, now abandoned, which is a continuation of application Ser. No. 07/892,503 filed Jun. 2, 1992, abandoned.
INTRODUCTION
This invention relates generally to braiding machines and, more particularly, to improvements in braiding machines so as to permit them to reliably braid materials having extremely small diameters at reasonable cost and at reasonably high speed production rates.
BACKGROUND OF THE INVENTION
Braiding machines have long been known in the art for braiding multiple strands of materials, e.g., synthetic plastics or metals, such as copper or stainless steel wire, at reasonably high production rates. One type of braiding machine, which is commonly referred to as an internal cam rotary braider, has been known to the art for many years, being generally designated as the Wardwell Rapid Braider, made and sold by Wardwell Braiding Machine Company of Central Falls, R.I. (the "Wardwell" machine). Wardwell rotary braiding machines have been available in various sizes, depending on the number of strands required in the final braided output, and have been in use for many decades since the first designs thereof were made available about the turn of the century. Their reliability and relatively high speed of operation have been well recognized and such machines have been used satisfactorily over the years, normally requiring only the replacement of parts, their structure and operation having essentially remained unchanged since their original design.
As it becomes desirable, or necessary, to braid strands or filaments of material, particularly very fine copper or stainless steel wire materials, having extremely small diameters, e.g., as small as 0.0005-0.0030 inches, or less, it has been found that the Wardwell machine becomes unreliable because the rotary technique used therein produces so much tension on very small diameter materials, particularly at one stage of the braiding process, that such extremely fine filaments tend to break relatively easily and quickly, thereby automatically stopping the machine.
In an effort to braid such extremely fine filaments without significant breakage thereof, those in the art have turned to the use of other types of braiding machines, such as machines often ref erred to as "maypole" braiding machines, sold by the New England Butt Division of Wardwell Braiding Machine Company and by Steeger U.S.A., Inc. of Spartanburg, N.C., as well as machines often referred to as external cam rotary braiding machines, such as sold, for example, by Hacoba Textile Machinery of Charlotte, N.C. While such other types of machines tend to operate with some degree of success when used with relatively small diameter strands, the initial purchase and installation costs, as well as the operating costs thereof, tend to be higher than those of internal cam Wardwell machines, and the speeds of operation and, hence, the production rates thereof are often significantly lower than those of internal cam Wardwell machines.
It would be desirable, therefore, if the art could take advantage of the lower cost and higher operating speeds of the Wardwell rotating braiding machines by appropriately adapting such machines in a manner which would permit them to braid extremely fine materials without encountering the significant breakage problems discussed above and without unduly raising the costs of purchasing and operating such machines.
BRIEF SUMMARY OF THE INVENTION
In accordance with the invention, such adaptation has been achieved by re-designing the conventionally used lower carrier members of a typical Wardwell rotary braiding machine so as to replace such members with a new design that provides a structure and operation which considerably reduces the unwanted stresses placed on a strand of material being handled thereby, particularly when using extremely fine copper or stainless steel wires or filaments, so that the tendency for such materials to break is effectively eliminated, even for materials having diameters down to as small as 0.0005 inches, or less.
In a particular embodiment thereof, a lower carrier member includes a plurality of oppositely disposed pulleys for conveying a strand of material from the supply bobbin upwardly to the region where the upper carrier members of the machine are located, the upwardly moving strand being suitably deflected to move over the upper carrier members so that the braiding thereof with the strands of material supplied by the upper carrier members can take place. The use of such a uniquely designed pulley arrangement considerably reduces the unwanted stresses which are normally imposed on the wire, particularly very small diameter wire, as it is being conveyed over a deflector element and thence as it drops off the trailing edge of the deflector during its upward movement. The spindle used for the supply bobbin on the lower carrier member has also been re-designed so as to be mounted in a manner which considerably reduces the normal movement, or "play", thereof during operation. By appropriately adjusting the tension on the pulley arrangement of the lower carrier member, the movement of the strand can be effectively controlled so as to maintain a desired tension for braiding purposes while reducing unwanted stresses placed on the strand during the braiding operation so as to permit the braiding of very small filamentary materials essentially without breakage.
DESCRIPTION OF THE INVENTION
The invention can be described in more detail with the help of the accompanying drawings wherein
FIG. 1 shows diagrammatically an arrangement of upper and lower bobbins which is helpful in describing the general operation of a prior art Wardwell machine;
FIG. 2 shows a perspective view of a typical lower carrier member as used in a prior art Wardwell machine;
FIG. 3 shows a perspective view of a lower carrier member in accordance with the invention;
FIG. 4 shows a perspective view from below of a portion of the lower carrier member of FIG. 3;
FIG. 5 shows a perspective view from below of a portion of the prior art lower carrier member of FIG. 2;
FIG. 6 shows the perspective view from below of another portion of the lower carrier member of FIG. 3;
FIG. 7 shows a view in section of the spindle and bobbin assembly used in the lower carrier member of FIG. 3; and
FIG. 8 shows a view in section of the spindle and bobbin assembly used in the prior art lower carrier member of FIG. 2.
The structure and operation of a typical Wardwell machine is well-known to the art and is described in the instruction manuals available with such machines, such manuals for a typical machine being normally designated as "Wardwell Instruction Manual, Rapid Braiders" as supplied by Wardwell Braiding Machine Co., Central Falls, R.I.
FIG. 1 is an illustration adapted from a typical manual, and depicts diagrammatically the operation of a typical well-known Wardwell machine as described therein and as would be well known to those in the art. As can be seen therein, a plurality of lower carrier members 10, shown only diagrammatically in FIG. 1 and in more structural detail in FIG. 2, move in the direction of arrows 11, while a plurality of upper carrier members 12 move past lower carrier members 10 in the opposite direction, as shown by arrows 13. A strand 14 of material is supplied from a bobbin 20 on each lower carrier for intertwining with strands (not shown) supplied from a bobbin 19 on each upper carrier member, a strand from the lower carrier, for example, passing over one upper carrier member, then under the next adjacent upper carrier member, then over the next adjacent upper carrier member, and so on, as the upper and lower carriers move past each other in opposite directions. The intertwined strands are supplied to a braiding guide 15 which produces the braided output 16 therefrom. As each strand from a lower carrier member encounters the leading edge of deflector 18, it is lifted up and over an upper carrier member as it moves along the deflector, the strand then dropping off the trailing edge of the deflector so as to pass under the next adjacent upper carrier member.
A more detailed illustration of a typical lower carrier member 10 as used in current Wardwell machines is shown in FIG. 2. As seen therein, a bobbin 20 is mounted on a suitable spindle 21 and is retained thereon by a safety pin 22. A lower tension lever 23, having a pulley 24 mounted on its horizontal arm, is spring mounted on a lower tension lever retainer 25. The lever 23 is mounted by a suitable spring arrangement on the lower tension lever retainer so that its vertical arm is rotatable about its vertical axis, substantially parallel to the axis of spindle 21, as shown by arrow 26, so that pulley 24 moves generally in a direction perpendicular to the axis of bobbin 20.
A strand of material, such as a copper wire 27, from a spool thereof on bobbin 20 is supplied therefrom via a first thread guide roller element 28, thence to and around pulley 24 to a second thread guide roller element 29, and thence upwardly to the upper carrier members 12 and braiding guide 15, as shown by arrow 30.
As a strand on lower carrier member 10 moves relative to the upper carriers, it encounters the leading edge of a deflector 18 and rides over the upper surface of the deflector so as to lift the strand up and over an upper carrier member. As the strand moves over deflector 18, the lower tension lever 23 is rotated under spring tension so as to move pulley 24 from an initial position inwardly toward bobbin 20. As best shown in FIG. 5, pulley 24 is in its initial position as it reaches the leading edge of a deflector and, when the strand reaches the highest region on the surface of the deflector, the lower tension lever 23 and pulley 24 move to their maximum spring-deflected position as shown by dashed line 23' and pulley 24'. When the strand drops off the trailing edge of the deflector so as to permit the strand to drop to a lower position so as to pass under the next adjacent upper carrier, the spring action causes the lower tension lever 23 to snap back and return very rapidly to its initial position. Such operation produces a sufficient unwanted stress, or force, on the strand such that very small diameter strands break relatively easily at such stage of the operation, particularly when using very fine metallic wire, such as copper wire or stainless steel wire, which wires tend to be somewhat brittle and less resilient to such a rapid increase in longitudinal tension placed thereon during the rapid return motion.
In order to avoid such breakage problems on a Wardwell type braiding machine, the invention utilizes a new design for the lower carrier members thereof, a preferred embodiment of which is illustrated with reference to FIGS. 3, 4, 6 and 7. As seen therein, a bobbin 30 is suitably positioned on a rotating spindle 31, the particular structure of which is improved over that conventionally used in such machines, as discussed in more detail below. Lower tension lever 33 has mounted on its horizontal arm at least two pulleys 34 and 35 and, in the particular embodiment depicted, an additional pulley 36. Two additional pulleys 37 and 38 are fixedly mounted on the lower carrier member via a suitable mounting block 39 suitably affixed to the frame thereof. Pulleys 37 and 38 are displaced from pulleys 34, 35 and 36 and are positioned near a first thread guide roller element 40 as shown. A second thread guide element 41 is fixedly attached, as shown, to block 39 and to the frame of the lower carrier member. A strand 42, e.g., of copper wire, is supplied from bobbin 30 around first thread guide roller element 40 and thence around pulley 36 in a counter-clockwise direction to the bottom of pulley 37, exiting therefrom and returning to and around pulley 35 in a counter-clockwise direction, thence to the bottom of pulley 38, exiting therefrom and returning to and around pulley 34 in a counter-clockwise direction, and thence to second thread guide element 41 and upwardly toward the upper carrier members, as shown by arrow 44. Thus, the wire leaves the upper tension lever at substantially the same height as in the prior used structure shown in FIG. 2.
Tension on the lower tension lever 33 is maintained by a tension spring 55 as shown in FIG. 6 which can be adjusted by tension adjustment arm 56 via linkage 57 in a manner which is well-known to those in the art having familiarity with Wardwell machines to provide a desired tension on the wire for the braiding operation.
Wire 42 encounters the leading edge of fixedly mounted deflector 18 as the lower carrier member moves in the direction of arrow 43. Wire 42 moves along the upper surface of deflector 18 to its highest deflection point and then along the rest of the deflector surface until it drops off the trailing edge thereof in substantially the same manner as discussed above with respect to the lower carrier member of FIG. 2.
As wire 42 moves to its highest point along the deflector, lower tension lever 33 rotates to its maximum deflection position as shown in dashed line 33' and pulley 34' in FIG. 4. As can be seen, the movement of lower tension lever 33 in FIG. 4 is much less when using the pulley arrangement of FIG. 3 than the movement of lower tension lever 23 in FIG. 5 which occurs when using the prior art design. Accordingly, as the wire 42 drops off the trailing edge of deflector 18, the distance and rate at which the lower tension lever 33 returns to its original position is reduced and the unwanted stresses placed on the wire 42 are considerably decreased. It has been found that, because of such improved operation, the tendency of wire 42 to break is effectively eliminated even when using wire having a diameter down to a value as small as 0.0005 inches, or less. It has been further found, for example, that when handling wire of such fine diameter, the machine can be run continuously for time periods as long as 40 hours, or more, for example, without breakage. In comparison, when such fine diameter wire is attempted to be braided using the conventional lower carrier member of FIG. 2, breakage usually occurs within less than a few minutes and, in many cases, within less than a minute.
With respect to another aspect of the invention, although not absolutely necessary, it has been found that further improvement in assuring the elimination of breakage can be achieved by improving the rigidity of the bobbin and spindle assembly of the lower carrier member. As can be seen in FIG. 8, the spindle 21 of the prior art assembly is inserted into a sleeve 45, the reduced diameter lower end 46 of the spindle being in turn fixedly attached to a ratchet element 47. As the ratchet element 47 is rotated through discrete positions, the spindle end 46 is rotated so as to feed wire discretely from bobbin 20, in a manner well-known to those in the art. However, because of the structure utilized for such overall assembly, both longitudinal and lateral motions of the sleeve, spindle and bobbin elements occur, i.e., there is relatively significant "play" for such elements during operation. Such movements tend to aggravate the breakage problem since the supply of wire cannot proceed in a smooth enough manner to avoid the abrupt and undesired stresses placed thereon due, in part, to such significant play.
A re-design of the bobbin and spindle assembly, as shown in FIG. 7, overcomes such added undesired stress problems and further assists in eliminating the breakage problem. As seen therein, a sleeve 31 is machined so that its lower end portion 48 is tapered outwardly as shown and is welded, or otherwise affixed, to the ratchet element 47. Spindle 49 is inserted in sleeve 31, and is then retained therein by means of a set screw 50 which is tightened on to a suitably flattened portion of spindle 49, the reduced diameter lower end 49' of spindle 49 being attached to ratchet 47. A threaded shaft element 51 is inserted into and threaded on to the upper end of sleeve 31 and a wing nut 52 is threaded thereon to rigidly retain the sleeve in the assembly. The lower surfaces of the wing nut 52 are tapered inwardly as shown so that when the bobbin is positioned on sleeve 31, it is retained thereon by the tapered portions of wing nut 52. The somewhat resilient central element 53 at the lower and upper ends of bobbin 30 are rigidly held in the assembly by the tapered portion 48 of sleeve 31 and the tapered portion of wing nut 52, respectively. Accordingly, substantially little or no relative movement of the bobbin, the spindle, and the sleeve occurs and the bobbin, spindle, sleeve, and ratchet elements are maintained as a substantially rigid assembly during operation of the machine. It is found that the use of such a rigid assembly further enhances the operation of the machine in a manner which assists in eliminating breakage of the material being braided, particularly for very fine diameter metal wire materials, as discussed above.
While the embodiment of the invention depicted in FIG. 3 shows the use of three movable pulleys at the lower tension lever 33 and two fixed pulleys used therewith, it has been found that two movable pulleys and a single fixed pulley are sufficient in many cases to adequately reduce the motion of the lower tension lever 33 and, hence, to reduce the unwanted stresses on the strand to be braided so as to prevent breakage thereof. It has been found that the greater the number of movable and fixed pulleys used, the less the motion of the lower tension lever 33 and the greater the assurance that undesired stresses will be reduced and breakage will not occur. Although even more pulleys than shown in FIG. 3 can be used, practical considerations indicate that arrangements using two movable pulleys and one fixed pulley or using three movable pulleys and two fixed pulleys are usually adequate for handling wires having diameters down to as low as 0.0003 inches or less. Additional pulleys can be used, however, if found helpful or necessary.
While the above description discloses preferred embodiments of the invention, modifications thereto may occur to those in the art within the spirit and scope of the invention and, hence, the invention is not to be construed as limited to the particular emboidments discussed above, except as defined by the appended claims.
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An improvement in internal cam rotary braiding machines wherein each lower carrier member thereof includes a plurality of oppositely disposed movably mounted and fixedly mounted pulleys used to convey a strand of material from a supply bobbin upwardly to the upper carrier members thereof, the pulleys being arranged to reduce the unwanted stresses which are normally imposed on the strand as it is conveyed upwardly over a deflector member and thence as it drops off the trailing edge of the deflector. Further structural improvements are made with respect to the spindle assembly used for the supply bobbin to reduce the normal movement, or "play," of the spindle assembly components during operation and, hence, to reduce further undesired stresses on the strand. The tension on the movably mounted pulleys can be adjusted to maintain a desired tension on the strand of material during the braiding operation to permit the braiding of very small filamentary materials with little or no breakage thereof during the braiding operation.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of International Patent Application Serial No. PCT/DE02/00160 filed Jan. 21, 2002, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
The present invention relates to a method for controlling and/or regulating an automated clutch in a vehicle, wherein a characteristic curve of the clutch is adapted by means of an electronic clutch management system (ECM).
Automated clutches belong to the known state of the art of automotive technology. They allow a complete automation of the drive train of a vehicle, in particular a motor vehicle. Also known is the use of automated clutches in connection with automatic transmissions. In particular, the process of moving the clutch into engagement during a gear-shifting process is automated by means of the electronic clutch management (ECM) system.
The known process allows an adaptation of the characteristic curve of the clutch. Thus, the characteristic curve of the automated clutch can be altered in a suitable manner, e.g., based on possible influence factors.
However, with the known process the adaptation is dependent on the occurrence of a predetermined stationary operating point. This operating point can be present for example when shifting into first gear while the engine is idling and the service brake or hand brake is applied. Depending on the habits of the driver of the vehicle, this stationary operating point may occur extremely rarely.
OBJECT AND SUMMARY OF THE INVENTION
The object of the invention is to provide a method of controlling and/or regulating an automated clutch that is improved in particular with respect to the adaptation possibilities.
In the inventive method for controlling and/or regulating an automated clutch, wherein a characteristic curve of the clutch is adapted by means of an electronic clutch management system (ECM), the adaptation is carried out when at least one appropriate set of operating conditions (referred to as operating point) is present. For example, it is possible for the characteristic curve of the clutch to be adapted during each start-up or shift process, so that the dependence on an operating condition that may occur only rarely is avoided with the method according to the invention.
Of course, the adaptation can also be carried out at other desired operating points besides the aforementioned examples. Thus the adaptation is improved overall with the method according to the invention.
According to an advantageous development of the invention, the adaptation can be carried out by using a suitable theoretical model. Thus a model-supported adaptation of the characteristic curve of the clutch can be carried out. Based on a model of the characteristic curve of the clutch it is possible to carry out an adaptation of the point of incipient frictional contact (also referred to as take-up point) and of the coefficient of friction and/or of the shape of the characteristic curve of the clutch. In principle, this adaptation can take place every time the clutch goes through a slipping phase. It is also possible that with certain operating conditions or operating points, suitable restrictions are imposed on the adaptation. For example, shortly after the engine has been started, the engine torque signal may have a reduced reliability. In this case it can be advantageous to provide for a temporary suppression of the adaptation.
In a further development of the invention, at least one input variable is taken into account in the adaptation of the characteristic curve of the clutch. Preferably the characteristic curve of the clutch can be adapted based primarily on predetermined signals, such as for example engine rpm-rate, effective engine torque, and/or clutch actuator position. Of course, it is also conceivable to use other signals as input quantities for the adaptation.
According to an advantageous development of the invention, at least one delay block is used in the adaptation of the characteristic curve of the clutch. Preferably delay blocks can be used, e.g., with the input quantities engine rpm-rate, engine torque, and/or clutch actuator position. These delay blocks serve to compensate for a possible time shift between the signals that can result, e.g., from the signal acquisition and/or the signal transmission, so that at the output end of the delay blocks, the respective signals of the input quantities correspond physically to the same point in time.
According to another development of the invention a suitable adaptation algorithm is integrated in the adaptation of the characteristic curve of the clutch. The clutch torque is first estimated from the current position of the clutch actuator by means of a characteristic curve model without the adaptation algorithm. Together with the engine torque, the estimate allows a determination of the rotary acceleration of the internal combustion engine, from which a theoretical engine rpm-rate can be calculated. Based on the discrepancy between the actually measured rpm-rate and the theoretical engine rpm-rate, it is possible to evaluate the quality of the model data based on the actual deriving experience and to gain information for adapting the model data to the physically accurate values.
As a means of performing this adaptation, it is particularly advantageous to use an adaptation algorithm. The adaptation algorithm can perform an adjustment of the signals and/or the parameters as a function of the current operating point or driving condition. For example, a slipping state of the clutch can be used as a basis for adapting the model. When using an adaptation algorithm, it is particularly advantageous to include a correction term for the engine acceleration. This can be accomplished, e.g., according to the principle of a status monitor, in order to avoid discrepancies between the model values and the actual values.
Moreover, the adaptation algorithm can also include a torque correction term. The torque correction term serves to take a constant or slowly variable error of the torque signal into account. Such errors, which originate from uncertainties in determining the engine torque and/or from unknown torque-consuming units such as, e.g., a generator, an air-conditioning compressor or other device, can usually be identified very readily as a non-zero amount of torque that is present while the clutch is disengaged and the engine is idling.
The adaptation algorithm can further include a correction term for the clutch actuator displacement. This correction term is synonymous with the so-called take-up-point adaptation or contact point adaptation.
It is also possible for a characteristic curve parameter to be used in the adaptation algorithm. This can be a signal vector that serves to adapt the coefficient of friction of the clutch. By adapting, e.g., several suitable characteristic curves, similar effects can be achieved as with a multi-stage adaptation of the friction coefficient.
According to a further developed embodiment of the invention, a variety of models can be used for the design of the adaptation algorithm. For example, one could use a parameter identification of a preferably nonlinear character. Of course, it is also possible to use a so-called extended Kalman filter (EKF). Moreover, it is also conceivable to use so-called neuro-fuzzy methods in the design of the adaptation algorithm. Of course, there are other suitable design options, including a suitable combination of the aforementioned design possibilities.
It is particularly advantageous, if the current driving status or operating point is taken into account in a suitable manner when designing the adaptation algorithm. Dependent on the physical situation, a difference between the measured and the theoretically predicted engine rpm-rates will in some cases affect predominantly one adaptation quantity and in other cases predominantly another adaptation quantity. For example, the torque correction term can be adapted when the clutch is out of engagement and when the clutch is applied lightly, e.g. when starting from rest or creeping. The characteristic curve parameters, on the other hand, are to be adjusted primarily at higher levels of clutch torque.
According to another advantageous concept concerning the adaptation of the clutch characteristic, a second adaptation can be superimposed on a first adaptation. For example, a first adaptation could consist of an adaptation of the coefficient of friction and/or the take-up point. In this first adaptation, a possible discrepancy in the applied torques is determined, e.g., by evaluating a dynamic torque equilibrium at the clutch, and an adjustment of the friction coefficient is made based on the torque discrepancy. A second adaptation, in which preferably the shape of the characteristic curve of the clutch is evaluated, can then be superimposed on the first adaptation.
For example, the shape of the characteristic curve of the clutch can in fact deviate from a predetermined nominal characteristic curve shape, due to manufacturing tolerances and/or aging of the clutch, for example due to settling of the lining cushion. With the adaptations described up to this point, correction terms are calculated for a certain characteristic curve position or a characteristic curve area. Thus the shape of the characteristic curve of the clutch can be determined after sufficient adaptation phases. Rapid changes in the friction coefficient may not be detected thereby under certain conditions. It is necessary to perform adaptations at all operating points so that the global change in the friction coefficient is detected over the entire characteristic curve of the clutch.
In the type of adaptation according to the following description, it is particularly advantageous that rapid changes in the friction coefficient are taken into account, and also that it is made possible to determine the shape of the characteristic curve of the clutch repeatedly.
In particular, this adaptation includes a test whether during a slipping phase of the clutch the torque that is called for by the control sweeps through a significant portion of the clutch characteristic, so that sufficient information can be gained about the shape of the clutch characteristic. During this slipping phase, the dynamic equilibrium at the clutch with respect to the engine torque, the acceleration portion, and/or the set clutch torque is evaluated for some predetermined points of the characteristic curve. The actual profile of the clutch characteristic is found from the difference between the actual and predicted torque values.
The invention further offers the possibility that in addition to the previously implemented friction coefficients, an additional correction characteristic of the clutch is taken into account which describes the discrepancies between the actual and the nominal clutch characteristics. The possibility of the superimposition of adaptations will be further described below through examples illustrated in flowcharts. Of course, other suitable adaptation processes are also conceivable within the scope of the inventive method.
According to another advantageous embodiment of the invention, the adaptation of the clutch characteristic is carried out, e.g., in the slip phase of the clutch and in the phase where the engine rpm-rate takes off when the clutch is taken out of engagement in preparation for a gear shift. With this kind of adaptation, the torque acting on the clutch as a result of the engine torque and the rotary acceleration of the engine is compared against the clutch characteristic that is stored in a memory of the control unit. Based on the comparison, an advantageously simple adaptation of the clutch characteristic is achieved. To implement this concept, it is possible, e.g., to evaluate the engine torque equilibrium at the clutch, using the assumption that the occurring errors are caused only by an imbalance of the clutch characteristic. The torque equilibrium at the clutch can be expressed by the equation:
J engine *dω engine /dt=M engine −M clutch
wherein J engine =moment of inertia of the engine
dω engine /dt=rotary acceleration of engine
M engine =engine torque
M clutch =clutch torque
This equation is satisfied for the torques and accelerations of the actual system. The assumption that the clutch torque in the actual system can be calculated from the torque value used in the clutch control and an error torque is expressed in the equation:
M clutch, control =M clutch +ΔM clutch ,
wherein
ΔM clutch =M clutch, control −( M engine −J engine *dω engine /dt )
M clutch, control =clutch torque value used in the control unit, and
ΔM clutch =error in clutch torque.
Thus, an error in the clutch torque can be determined from the current engine torque, the rotary acceleration of the engine, and the clutch torque determined in the control unit. As a function of this error, the characteristic curve of the clutch stored in the clutch control unit can be corrected.
The characteristic curve of the clutch can be corrected, e.g., by adjusting the quantities describing the characteristic curve of the clutch, such as, e.g., the coefficient of friction, the contact point of the clutch, or similar quantities. At sufficiently large clutch torques, the coefficient of friction can be adjusted with the quantities or parameters describing the characteristic curve of the clutch. According to the above equations, the coefficient of friction is reduced, e.g., in the presence of a positive torque error and increased, e.g., in the presence of a negative torque error. For example, a crankshaft torque that corresponds to the engine torque corrected by a dynamic torque contribution, can be about 50 Nm, and a clutch torque calculated in the control unit can be about 30 Nm. This indicates a torque error of −20 Nm, as the clutch transmits a torque of 50 Nm rather than the torque of 30 Nm calculated in the control unit. Based n this information, the coefficient of friction must be increased. These data are merely meant as one example and can be expanded if desired.
It is also conceivable to correct, e.g., the parameters for describing the characteristic curve of the clutch. For this, a table or a functional correlation between the control signal of the clutch actuators and the clutch torque is used.
Within the scope of the adaptation of the characteristic curve of the clutch, it is advisable that the corrections of the descriptive parameters or quantities be carried out incrementally. This means that the calculated torque error is not reduced in one correction step. As a result, the stability of the total system is considerably increased, as only small feedback effects, in the sense of a closed-loop regulation, are present. Of course, other suitable corrections are also possible in the method according to the invention.
According to another development of the invention, it is possible to use an integrating process in the adaptation to correct the clutch characteristic, as an alternative to the direct torque evaluation. According to this concept, the engine rpm-rate can be determined from the torque signals through an integration, so that a theoretical engine rpm-rate is determined according to the following equation.
ω engine , model = 1 J engine ∫ ( M clutch , control - M engine ) ⅆ t
wherein ω engine, model stands for the angular velocity of the engine that is calculated from the theoretical model.
A comparison of the theoretical engine rpm-rate with the actual engine rpm-rate can be used as a basis for adapting the clutch characteristic. If discrepancies are found between the actual engine rpm-rate and the theoretical engine rpm-rate after the evaluation of the above equation, the characteristic curve of the clutch or the descriptive quantities or parameters, such as e.g. the coefficient of friction, the clutch take-up point, or the like, can be changed suitably based on the deviations. For example, if at a positive engine torque the actual engine rpm-rate is found to be lower than the theoretical rpm-rate, the clutch torque actually applied is greater than the torque value used in the control device, and consequently the value for the coefficient of friction must be increased.
In the integrating method, the changes in the characteristic curve of the clutch are likewise made preferably in incremental steps in order to avoid unstable feedback in the sense of a closed-loop regulation. Stability problems can thus be avoided in the method according to the invention. Of course, other possibilities of changing the clutch characteristic are also conceivable.
According to another advantageous concept of the invention, a multi-stage adaptation can be performed for the coefficient of friction at predetermined constraint points for the friction characteristic, in particular when the clutch or the transmission are first put into operation. With a multi-stage adaptation of the friction coefficient, the constraint points for the adaptation are preferably in the range of high clutch torques. According to a development of the invention, it is particularly advantageous if the changes or adjustments that were made in the friction coefficient at high torque values are transferred to other selected constraint points of the friction characteristic. This can be accomplished during and/or after a full load cycle. This adaptation mode is preferably used when the clutch or transmission is first put into operation. It can be activated or deactivated, e.g., by way of external preset points together with the accelerated adaptation rate which allows greater adaptation increments.
Of course, the adaptation process can also be modified to work for constraint points of the friction characteristic that are not in the range of high clutch torques. In the transfer of the change or adjustment of the friction coefficient to other constraint points, any desired constraint point of the friction coefficient characteristic can be selected.
A predominant portion of the deviation between the pre-initialized clutch characteristic and the actual clutch characteristic consists of an offset of uniform magnitude for all constraint points. In comparison, the shape deviations will make up only a small portion. An approximate compensation of the offset can be achieved by transferring the result for the adaptation at a selected driving cycle to all constraint points of the friction characteristic.
With the inventive method according to the invention, by performing an adaptation cycle of the clutch characteristic when the vehicle is first put into operation and by transferring the changes that were made at the predetermined constraint points to other constraint points, uncomfortable shifts in subsequent normal driving can advantageously be avoided. Moreover, the method according to the invention avoids the problem of falsifying friction coefficient values at already adapted constraint points. Thus, the fine tuning of the clutch characteristic in subsequent driving can be completed earlier by using the inventive method, since essentially only the shape of the characteristic curve of the clutch still needs to be adjusted.
The method according to the invention can in principle be used as described in an electronic clutch management system (ECM) and also in an automated shift transmission. Moreover, it is also conceivable to use the method according to the invention in continuously variable transmissions (CVT).
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages and advantageous embodiments of the invention are presented below with references to the drawings, wherein:
FIG. 1 represents a block diagram of an embodiment of the inventive method with an adaptation of the clutch characteristic based on a theoretical model;
FIG. 2 represents a flowchart of another embodiment of the method according to the invention with a superimposed adaptation of the characteristic curve of the clutch;
FIG. 3 represents a flowchart of a further embodiment of the method according to the invention; and
FIG. 4 represents an illustration of the torque equilibrium in a clutch.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a block diagram of an adaptation of a clutch characteristic that is supported by a theoretical model. The engine rpm-rate n engine , the engine torque M engine , the position of the clutch actuator X clutch , and the current driving state or operating point are provided as input quantities. The adaptation of the characteristic curve of the clutch is based primarily on the above-named input quantities or, more specifically, the signals that represent them. With the aid of delay blocks, a possible time offset between the respective signals of the input variables can be compensated for so that at the output of the delay blocks, all the signals correspond physically to the same point in time. The possible time offset between the signals can occur, e.g., in the signal acquisition and/or the signal transmission.
The delay block T tn is provided for the engine rpm-rate n engine , the delay block T tM for the effective engine torque M engine , and the delay block T tC for the position X clutch of the clutch actuator.
Moreover, a suitable adaptation algorithm and a predetermined characteristic curve model are integrated in the model-based adaptation of the clutch characteristic. Without taking the adaptation algorithm and its output signals into account, the system functions as follows:
The clutch torque M clutch is estimated from the position of the clutch actuator X clutch by means of the characteristic curve model. The acceleration or inertial response of the internal combustion engine is determined from the clutch torque M clutch and the engine torque M engine . From this, the predicted engine rpm-rate n′ engine can then be calculated.
From the difference between the measured engine rpm-rate n engine and the predicted engine rpm-rate n′ engine , it is possible to determine the quality of the model data during operation of the vehicle and to gain information for adjusting the model data to the actual physical values.
To make the aforementioned adjustment, the method calls for an adaptation algorithm that performs the adaptation of signals or parameters as a function of the respective driving state, for example a slipping state of the clutch, as a basis for the model structure shown in FIG. 1 .
As a first output quantity, the adaptation algorithm provides a correction term for the engine acceleration. The correction term is used according to the principle of a status observer in order to prevent the model and reality from drifting apart.
As a second output term, the adaptation algorithm provides a torque correction term ΔM engine . The term ΔM engine corrects a constant error of the torque signal M engine or an error that varies slowly over time. Such errors, which originate from uncertainties in determining the engine torque and/or from unknown torque loads of consumer devices such as the generator or the air-conditioning compressor, can usually be identified very readily as a non-zero amount of torque that is present while the clutch is disengaged and the engine is idling.
Further, as a third output term, the adaptation algorithm provides a correction term Δ TuP of the clutch actuator displacement. The term Δ TuP is synonymous with a so-called take-up point adaptation or contact point adaptation.
A so-called CC parameter (characteristic curve parameter) is provided as a fourth output quantity of the adaptation algorithm. This quantity has vector character and serves to adapt the friction coefficient of the clutch. By simultaneously adjusting several predetermined points of a characteristic curve, it is possible to achieve similar effects as with a multi-stage adaptation of friction coefficients.
Various methods are available for the design of the adaptation algorithm. For example, a nonlinear parameter identification, an extended Kalman filter (EKF), a neuro-fuzzy method or similar concept can be used.
In principle, the current driving status or operating point should be weighted very strongly in the design of the adaptation algorithm. Dependent on the physical boundary conditions, a difference n engine −n′ engine between the measured and the theoretically predicted engine rpm-rates will in some cases affect predominantly one adaptation quantity and in other cases predominantly another adaptation quantity. For example, the torque correction term ΔM engine can be adapted when the clutch is out of engagement, and the correction term for the clutch actuator displacement Δ TuP can be adapted primarily when the clutch is applied lightly, while the characteristic curve parameters, on the other hand, are to be adjusted primarily at higher clutch torques.
The flowchart of FIG. 2 represents an example of how an adaptation process could be structured for correcting the shape of a clutch characteristic. The process begins at step 1 with the engagement of the clutch after a gear change or in a start-up phase of the vehicle.
In step 2 of the preferred embodiment of the method according to the invention, a next clutch torque threshold is determined for the evaluation of the dynamic equilibrium in the clutch.
This is followed by a yes/no test in step 3 , as to whether the clutch torque is equal to the clutch torque threshold. In the affirmative case, the method proceeds to step 4 .
In step 4 the current clutch torque error and the coefficient of friction are stored in memory.
This is followed by step 5 , a yes/no test as to whether all of the measurement points have been processed. In the negative case of step 5 , the process loops back to step 2 . In the affirmative case, the method proceeds to step 6 , a yes/no test whether the clutch is out of engagement (neutral position).
In the affirmative case of step 6 , the method proceeds to step 7 . In the negative case, the process is terminated.
In step 7 an average value is calculated from all of the torque deviations that have been measured.
In step 8 , the individual deviation of each torque deviation from the average value is determined.
In step 9 , the measured value with the largest deviation from the average value is determined.
In step 10 , the final step in this process, the shape correction characteristic is updated for the point where the largest deviation of the clutch torque error from the average value was found. This ends the process.
The flowchart of FIG. 3 illustrates a further embodiment of the method according to the invention.
In step 1 a current actuator position is entered as an input.
In step 2 a nominal clutch torque is determined from the characteristic curve with the current actuator position.
In step 3 the nominal clutch torque is corrected with the global coefficient of friction.
In step 4 , the nominal clutch torque is corrected with a correction value based on the characteristic curve for the shape correction.
In step 5 , the final step, an updated value for the clutch torque is obtained as the output of the process.
The above-named method can also be carried out inversely, i.e., a theoretical actuator position can be determined from a given clutch torque.
FIG. 4 schematically illustrates the torques acting on the clutch. The clutch torque M clutch , the engine torque M engine , the rotary acceleration dω engine /dt of the engine, and the engine moment of inertia J engine are indicated in FIG. 4 . The torque equilibrium at the clutch is determined from these quantities by means of the following equation:
J engine ·dω engine /dt=M engine −M clutch
Without further analysis, the foregoing will so fully reveal the essence of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting essential generic or specific features that set the present invention apart from the prior state of the art. Therefore, such adaptations should be understood to fall within the scope and range of equivalence of the appended claims.
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A method of controlling an automated clutch of a vehicle includes the step of adapting a characteristic curve of the clutch through an electronic clutch management system. The adaptation is performed under at least one set of operating conditions that are represented by an operating point.
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This is a Continuation of co-pending application Ser. No. 855,530, filed Nov. 28, 1977, and now withdrawn in favor of the present case now abandoned.
FIELD OF INVENTION
The present invention relates to transfer printing, and, more particularly, to printing inks useful in transfer printing.
BACKGROUND OF THE INVENTION
Under the conditions of thermo-printing or transfer printing, sublimable dyes are transferred through heating from an auxiliary image support to the substrate to be printed, and are then fixed on the substrate, e.g., a textile fabric made of synthetic resin fibers, the fixing being effected through diffusion or dissolving into the fibrous material, the dyes thereby producing the desired colored images on the textile. As textile materials suitable for transfer printing, there are commonly used synthetic fibrous materials such as polyamides, polyesters, polyacrylonitriles and also cellulose fibers finished with synthetic resin. As the auxiliary image support, one uses generally in this connection paper sheets or metal foil, such as aluminum foil, on which the printing inks are applied by means of intaglio printing. As printing-ink binders suitable for this kind of printing, one uses in particular the cellulose esters, e.g., ethyl cellulose, in which connection one must use organic solvents.
However, it is also known to prepare such thermo-printing transfer papers through offset or letter printing, which introduces known advantages in relation to intaglio printing. Smaller editions can thus be produced without difficulty by means of this printing technique. Besides, offset or letter printing exhibits the advantage of omitting volatile organic solvents in the printing pastes, which leads to an acceleration of the printing operation, and, beyond that, introduces economic advantages.
In order to allow faster processing of the oily moist transfer-printing papers initially obtained in connection with offset printing, the German disclosed specification DT-OS 24 08 900 indicates the addition of gelling agents, such as aluminum chelate, in the amounts of up to 2% by weight to the printing-ink masses. This indeed produces a print which solidifies very rapidly on the surface; however, it has been shown quite generally that difficulties in regard to the reproducibility of color tones and color intensity of the thermo-transfer prints occur in connection with color images printed in accordance with the offset procedure. This is based on the fact that standard preparations are employed as binders for the manufacture of the printing inks for the thermo-printing papers through offset printing, such preparations being obtained on the basis of drying oils, such as linseed oil and mineral oils, unsaturated alkyd resins, hard resins or the like. As is well known, such printing inks dry up only very slowly through oxidation and, under the effect of air oxygen, attain a more or less definitive final state of crosslinking and, therewith, drying and hardening or curing only after a number of days.
This fact plays only a subordinate role in ordinary offset printing and is compensated and masked by other advantages offered by offset printing. However, in the preparation of thermo-transfer printing papers, hereafter referred to as "heat-transfers", it has turned out that oxidative curing is of influence because it was shown that the dyes used for the thermo-transfer printing, e.g., the readily sublimable anthraquinone or diazo dyes, are also oxidized in part during the crosslinking and hardening by oxidation of the binders used in the offset printing paste. Thus, after only a short storage period, this leads to color tone changes, e.g., fading or loss of brilliance, etc., when the dyes are transferred to the textile. Both in the case where such sublimable dyes are used alone and, especially, also in the case of dye mixtures that are required for obtaining the desired richness of shade, distinct differences in regard to tones and effect of the color images obtained through the transfer printing of textiles result within the drying time and then also during storage.
For the manufacturer of heat-transfers, e.g., the printer, this makes it very difficult or even impossible to exercise a precise control of his dye composition and color in the printing ink in regard to the result on the textile to be later obtained through transfer printing. While it is true that the oxidizing hardening of the offset printing inks can be accelerated through catalysts or by heating, catalysts also promote the undesirable oxidation of the dyes, and heating is conceivable only with the use of dyes possessing a high temperature of sublimation. These methods thus cannot be used practically in the manufacture of heat-transfers, especially since one must here use dyes that should sublime on heating as quickly as possible and as completely as possible.
SUMMARY OF THE INVENTION
It has now been found that it is possible to manufacture heat-transfer even in accordance with the offset and letter-printing methods, which no longer exhibit the hitherto-existing disadvantages of the products produced with such printing methods, if there is used for the formulation of the sublimable dyes in the preparation of printing inks for the heat transfers, a binder system which immediately hardens through UV radiation. As suitable binders there may be mentioned ethylenically unsaturated monomers and prepolymers that can be polymerized through free radicals, e.g., the ester compounds of mono or di-acrylic acid, to which UV polymerization initiators are added.
DETAILED DESCRIPTION OF EMBODIMENTS
German Auslegeschrift 24 38 712 describes particularly useful radiation hardened printing-ink binders that can be used in accordance with the present invention for the preparation of heat-transfers. Beside such curable binders that contain polyfunctional arylate esters of polyhydric alcohols as polymerizable component, one can also use other polymerizable resin preparations having polymerizable ethylenic unsaturation in the novel offset printing inks for the transfer printing, which preparations can rapidly be hardened and cross-linked through UV-initiators and radiation, as known for a long time as coating materials used for a very great variety of purposes. These include, for example, trimethylolpropane triacrylate or methacrylate, glycol diacrylate, 2-hydroxypropyl acrylate, vinyl pyrrolidone, soybean oil expoxidized and then reacted with acrylic acid, the linseed-oil alkyd obtained through the use of trimethylol propane esters of isophthalic acid, cyclohexanone-formaldehyde resin, as well as the reaction product of bisphenol, epichlorhydrin and acrylic acid. By mixing several components, the normally skilled artisan can in a simple manner adjust the consistency and the hardening properties of the printing inks.
As UV-polymerization initiators for the printing inks of the invention, one can use any substances that possess a triplet energy between 42-85 kcal/mol. For example, benzoin ether, benzoin urethane derivatives, acetophenone, Michler's ketone, benzophenone as well as its derivatives, benzoyl-benzalchloride and especially benzildimethyl ketal have proven to be especially suitable.
It is unexpected that, in spite of the intensive hardening and crosslinking of the binder, especially on the surface of the dye coating on the heat transfer, the transfer of the sublimable dye is not affected during the later transfer printing, i.e. during the sublimation of the dyes from the heat transfer onto the textile material. Moreover, in spite of the relatively high concentration of sublimable dyes in such offset printing ink materials the UV initiators bring about a sufficient hardening of the oily, hydrophobic printing material on the heat transfers during the irradiation which lasts only fractions of a second.
Thus, when polymerizable binders and UV activators are of a suitable composition, radiation exposure times of 0.1-0.3 seconds can lead to the desired immediate hardening of the prints on the heat-transfer backing, so that the printer is then immediately ready to test the so obtained heat transfer to determine its transfer-printing properties without the need to fear that the color images would change after storage. Since the hardening of the binder is not brought about through oxidizing, time-dependent procedures, the dyes remain unchanged. Accordingly, the heat transfers obtained in accordance with the invention can thus be stored practically indefinitely. Since the radiation-crosslinking of the polymerizable vinyl-group containing binders effected through the exposure to the UV light takes place in a fraction of a second, the color layer printed in accordance with the offset procedure is available in its final hardness on the heat transfer backing immediately after leaving the printing machine or the exposure device associated therewith in close spatial proximity, so that the papers may immediately be inspected and even stacked and packaged.
In the printing inks of the invention for manufacturing thermo-printing papers, one can use the same sublimable dyes as in the hitherto-customary intaglio printing inks or offset printing inks and as disclosed, e.g., in Swiss Pat. Nos. 572,550 and 573,311, Austrian Pat. No. 327,959 and British Pat. No. 1,433,763. Such dyes are not affected by exposure to UV light even in the presence of very active polymerization initiators. Moreover, there is no reaction between the anthraquinone or diazo dyes and the reactive monomers during ordinary storage of the printing inks or during the intensive polymerization or curing reaction which takes plce suddenly through the UV radiation, so that any doubts possibly existing against the use of such long-known radiation-hardening binders is groundless. In addition to the UV sensitizers or initiators, the printing inks of the invention may still contain other customary additives which improve the properties of the ink material for the offset printing, as well as also stabilizers against premature polymerization or cross-linking, etc.
The invention is to be explained more in detail below in reference to a few illustrative examples of printing inks of the invention for the preparation of heat-transfers.
EXAMPLE 1
For the preparation of a transfer printing ink, the following components were mixed, in which connection the components were in part premixed as customary and the components were then ground on a roller mill and processed until a homogeneous ink paste was obtained:
20 parts anthraquinone dye, disperse blue 95
330 parts trimethylolpropane-triacylate
330 parts of the reaction product of 1 mol bisphenol,
2 mols epichlorhydrin and 2 mols acrylic acid
40 parts benzophenone
30 parts Michler's ketone.
In order to set the printing consistency, 160 parts of 1:1 mixture of the above-mentioned trimethylolpropane-triacrylate and the reaction product of bisphenol, epichlorohydrin and acrylic acid were admixed to the ink paste.
The desired printing pattern was applied with the obtained printing ink by means of the offset method on a heavy machine-coated paper. The print was immediately exposed to a UV lamp (mercury medium pressure arc with 80 watts per cm arc length) for 0.2 seconds and thus dried. At a transfer temperature of 200°-220° C., the printed image was transferred to polyester fabric with a very good degree of efficiency in regard to the dye. The obtained dyed fabric exhibited excellent properties in regard to brilliance and fastness.
A transfer printing operation repeated after four weeks produced the same quality of printing.
With the obtained thermo-printing paper it was possible to produce in the same manner color patterns through transfer printing on synthetic-resin finished cotton fabric and also on polyacrylonitrile fabric.
EXAMPLE 2
A printing paste was prepared as described in Example 1, using the following materials:
10 parts disperse yellow 54
1 part disperse blue 95
300 parts trimethylolpropane-trimethacrylate
400 parts of the reaction product of bisphenol, epichlorhydrin and acrylic acid
40 parts benzophenone
30 parts Michler's ketone.
Also here the consistency was set to the value desired for the offset printing, through the addition of a mixture of the polymerizable acrylate component. Since the trimethacrylate component exhibits a lesser rate of polymerization, a drying delay had to be accepted. The time of exposure was set at 0.4 second. The obtained heat transfer possessed the same technical peroperties in regard to use, in which connection a green print was obtained.
In constrast with the prints obtained through the use of the two dyes comprising the ordinary binders which dry through oxidation, the obtained printed image remained unchanged even after long periods of storage.
EXAMPLE 3
5 parts disperse yellow 54
7 parts disperse red 4 (C.I. No. 60755) and
18 parts disperse blue 95, together with
330 parts hexandiolacrylate and
330 parts of the reaction product from bisphenol, epichlorhydrin and acrylic acid,
40 parts benzophenone and
30 parts Michler's ketone were stirred into an ink paste and the consistency desired for the offset printing was then set as described above by using the mixture of acrylate monomers.
After an exposure to UV light of 0.2 seconds, there was obtained a heat transfer which produced an excellent black image on polyacrylonitrile fiber fabric.
EXAMPLE 4
100 parts disperse red 60
10 parts disperse blue 14 (C.I. No. 61500)
300 parts epoxidized, acrylated soybean oil and
200 parts pentaerythrol-triacrylate in the presence of
7 parts benzildimethyl ketal as UV initiator were ground on a roller mill into a homogeneous ink paste. One part of micronized polyethylene wax was then added and the paste was mixed with further 100 parts of the acrylated soybean oil and 60 parts pentaerythrol-triacrylate into a printable ink mass. The printed paper was exposed as indicated in Example 1.
The technical testing concerning the use of the heat transfer produced the same results immediately after the production and after several weeks of storage.
EXAMPLE 5
200 parts disperse red 60
150 parts of a low-viscosity linseed oil alkyd (reaction product of trimethylol-propane ester of isophthalic acid)
150 parts of an oil-soluble cyclohexanone formaldehyde resin,
200 parts trimethylolpropane-triacrylate and
40 parts benzoinethylether were ground in a roller mill until a homogeneous ink paste was obtained, which was mixed with 160 parts vinyl pyrrolidone, so that a printable ink was produced. The print was exposed for 0.3 seconds to a UV radiation device. A bright red printed image was obtained on transfer printing to a synthetic-resin finished cotton fabric.
The technical testing concerning the use was performed in accordance with Example 1 amd am equivalent result was obtained.
It will be obvious to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is described in the specification.
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Heat Transfer prints are made by offset printing using a UV curable ink containing subliminal dyes printed onto a heat transfer backing, followed by rapid curing using UV light. The heat transfer prints are then used for dying fabric by applying the heat transfer print to the fabric, heating the print and thereby causing the dyes to sublimate and thereby transfer from the heat transfer print to the fabric where dying of the fabric occurs.
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BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
The present invention relates, generally, to alkali silicate glasses which are used as the basic glasses for the manufacture of selective filter glasses. More particularly, the present invention relates to the manufacture of selective filter glasses, colored with Co 2+ or with Co 2+ and Ni 2+ , which have transmission ranges primarily in the ultraviolet and visible spectral region between 280 and 500 nanometers (nm). These ion-colored glasses are imbued with the characteristic absorption bands of Co 2+ and Co 2+ together with Ni 2+ and, therefore, depending upon the layer thickness, produce selective bell-shaped transmission ranges, each surrounded by two stop ranges.
The most important characteristics of these so-called band pass filters, when the layer thickness is known, are the maximum of spectral transmission in the transmission band, T max and the half-value wavelengths λ'1/2 and λ"1/2 with a spectral transmission of T max /2. The mid-point between the half-value wavelengths λ'1/2 and λ"1/2 is called the mean wavelength λ m ; the distance from λ'1/2 to λ"1/2 is known as the half-value width (HW). (See FIG. 1.)
In research, engineering and medicine, these glasses are used, for example, as conversion filters in a narrow spectral region and, more particularly, are used in the filtering of UV light sources in the emission range from 200 to 1100 nm, with particular significance as pass filters in the ultraviolet spectral region from 250 to 400 nm and as stop filters in the spectral region of approximately 420 to 680 nm. The glasses can readily have compositions that assure high chemical resistance to acids, alkalis and water.
2. Description of the Prior Art
Alkali silicate glasses colored with Co 2+ or with Co 2+ and Ni 2+ are available from the major manufacture of optical filter glass and, therefore, known to the art, e.g. U.S. Pat. No. 3,902,881. Examples include BG 3, FG 3, UG 1 (Schott catalogue), 1-61, 7-51 (Corning catalogue), BD 37-93 (VEB Jena catalogue) and others. A drawback experienced with these glasses is that if they are exposed to ultraviolet radiation for a relatively long duration, the spectral transmission of these glasses can change, predominantly in the ultraviolet spectral range. The absorption increases up to a certain saturation value. This undesirable phenomenon is called solarization. The aforementioned saturation value is attained at varying degrees of quickness, depending upon the duration and intensity of the irradiation and on the distance of the filter glass from the light source. The glass "ages" and then
is only conditionally usable for its intended purpose.
For ascertaining the solarization properties of filter glasses, the following testing procedure is typical and generally applicable:
thickness of sample: 1 mm
light source: low-pressure mercury lamp (maximum emission at 254 nm), type: "Sylvania Germicidal," G 15 T 8, sold by Philips (emission spectrum, see FIG. 2)
filtering of source: none
exposure time: 75 hours
sample-to-source distance:140 nm
measured variable: Δτ (transmission before and after UV exposure)
In FIGS. 3 and 4, transmission curves are plotted, from 200 to 850 nm for both before and after the above-described solarization testing procedure, taking a commercially available blue alkali silicate glass as an example (BG 3 made by Schott Glaswerke, Mainz, Federal Republic of Germany). The curves demonstrate the very severe change in filter properties in the transmission band from 260 to 520 nm.
DESCRIPTION OF THE INVENTION
An object of the present invention is to provide UV filters, made of alkali silicate glasses, having a high chemical stability to acids, alkalis and water and having a high solarization resistance when exposed to ultraviolet light for relatively long periods of time.
The foregoing and related objects are accomplished by the use of an alkali silicate glass, colored with Co 2+ or with Co 2+ and Ni 2+ , as an optical filter glass, which has the following composition:
SiO 2 : 52-71% by weight
PbO: 2.9-16.8% by weight
SnO 2 : 0.1-1.65% by weight
Na 2 O: 6.7-16.7% by weight
K 2 O: 0.5-9.9% by weight
Na 2 O+K 2 O: 13.3-18.3% by weight
NiO+CoO: 0.1-4.4% by weight
As 2 O 3 +Sb 2 O 3 : 0.05-0.5% by weight
ΣMgO+CaO+SrO+BaO: 0-8.6% by weight
B 2 O 3 : 0-8.5% by weight
A1 2 O 3 : 0-0.55% by weight
ZnO: 0-10.5% by weight
It has surprisingly been discovered that in the present invention, the UV components that bring about the solarization are already absorbed in the surface layers of the filters and not further solarization can be brought about in the filter itself. A comparable effect can be attained by filtering the UV light source with 1-mm-edge filters for 280, 295, 305 and 320 nm. By this means, the highest-energy UV components are absorbed and are, accordingly, no longer available as excitation energy for forming pigment centers, which are also the cause for solarization in the glasses. This relationship is described in FIG. 5. By doping the glasses with PbO, SnO 2 and/or CeO 2 , TiO 2 , Fe 2 O 3 and V 2 O 5 absorption edge of the basic alkali silicate glasses can be shifted up to 60 nm toward the longer-wave spectral region.
Glasses capable of being used for the present invention, which have a layer thickness of 1 mm, can be divided among the following groups in terms of the width of their transmission bands (see, FIG. 6):
TABLE 1______________________________________τ.sub.max (%)exposure λ'1/2 λ"1/2 λm HWbefore after.sup.+ (nm)* (nm) (nm) (nm) Colorant______________________________________I. 88 87 290 460 375 170 Co.sup.2+II. 89 87 300 490 395 190 Co.sup.2+III. 82 81 310 390 350 80 Co.sup.2+ +Ni.sup.2+______________________________________ .sup.+ Exposure conditions as in aforesaid test procedure. *values ± 5 nm
In contrast to the filters of the present invention, Table 2 presents comparative test results with equivalent commercially available band pass filters and conversion filters:
TABLE 2______________________________________τ.sub.max (%)exposurebe- λ'1/2 λ"1/2 λm HWfore after.sup.+ (nm)* (nm) (nm) (nm) Colorant______________________________________BG3.sup.1 88 13 275 450 362 175 Co.sup.2+FG3.sup.2 89 42 270 550 410 280 Co.sup.2+UG1.sup.3 78 71 310 390 350 80 Co.sup.2+ +Ni.sup.2+______________________________________ .sup.+ Exposure conditions as in aforesaid test procedure. *values ± 5nm .sup.1 BG = blue, bluegreen and band filters; band pass filters .sup.2 FG = blue and brown color filters; conversion filters .sup.3 UG = black and blue glass band pass filters
The shift of the UV absorption edge in groups I and II toward longer wavelengths is apparent. To some extent, this narrows the transmission band in the farther UV band (260 to 310 nm).
According to the invention, because of the PbO and SnO 2 content in the various quantity ranges claimed for synthesizing the alkali silicate glasses, not only is a shift of the absorption edge to the longer-wave spectral region achieved, but also a marked reduction is brought about in the tendency toward solarization of the glasses.
The steepness of the absorption edge is favorably affected, depending on the type of glass, by SnO 2 in the range of from 0.1 to 1.7% by weight, i.e., by means of SnO 2 , a greater steepness of the absorption edge is attained (see, FIG. 7). As a result, the midpoint of the transmission band of the filters, which is measurable by the variable λ m (nm), is changed only negligibly as compared with the conventional filters having a greater tendency toward solarization (compare, Table 1 and 2).
The modification of the alkali silicate synthesis by PbO and SnO 2 necessitates particular provisions in the production of bubble-free, homogeneous optical filter glasses. To this end, according to the present invention, in addition to the classical refining agents As 2 O 3 and/or Sb 2 O 3 , depending on the basic glass synthesis, F, C1, NH 4 C1 and SO 3 are used, above all, for reinforcing the refining action. In addition to from 0-0.5% by weight of F - , the glasses used may also contain from 0-3% by weight of Li 2 O to lower the temperature for the viscosity range between 10 2 and 10 6 dPa·s.
The shift of the absorption edge is not only attainable by means of PbO and SnO 2 , but also by means of the ions having absorption bands between 250 and 400 nm, especially by means of the ions Ce 4+ , Ti 4+ , Fe 3+ , V 5+ , and Pd 2+ . Together with the refining agents, As 2 O 3 and/or Sb 2 O 3 , and the Coloring "filter ions," Co 2+ and Ni 2+ , the concentration of these ions should be no more than at a minimal level. This is because the interaction of two ambivalent ions in irradiation with ultraviolet light leads to quite pronounced solarization effects in alkali silicate glasses. This relationship is known and has been described in various publications, including:
Hideo Hosono et. al., J. of NCS 63 (1984), pages 357-63; and
Klaus Bermuth et. al., Glastechn. Ber. [Reports in Glass Technology] 58 (1985) 3, pages 52-58.
From Tables 1 and 2, it becomes clear from the example of group III of the glasses having the composition according to the invention, that the location of the absorption edge at 310 nm is not affected by the PbO and SnO 2 ingredients, but, instead, that a considerable reduction in solarization occurs as compared with glasses in which PbO and and SnO 2 are absent. It is conceivable that by the incorporation of Pb 2+ and Sn 2+ or Sn 4+ , a structural change in the silicate glasses takes place, such that the formation of pigment centers, due to UV irradiation, is rendered more difficult, or is even suppressed entirely.
The transmission of the basic glasses is characterized by the specific absorption of at least one of the following components:
1-1.5% by weight of CoO (optionally in the form of CoO and Co 2 O 3 ); and
0-4.4% by weight of NiO (optionally in the form of NiO and Ni 2 O 3 ).
In Table 3, which follows below, some examples from the useful composition range are provided:
TABLE 3______________________________________Examples of Compositions (% by weight)Group I Group II Group III1 2 3 4 5 6______________________________________SiO.sub.2 64.00 57.30 65.20 70.50 54.60 52.15B.sub.2 O.sub.3 8.65 8.45 17.30 -- 4.00 5.00Al.sub.2 O.sub.3 -- -- 3.00 -- 0.30 0.55Li.sub.2 O -- -- -- 3.00 -- --Na.sub.2 O 8.60 6.70 8.10 16.70 8.40 11.40K.sub.2 O 8.30 6.60 1.50 0.50 9.90 5.65MgO -- 1.60 -- -- -- 1.30CaO -- 1.50 -- 1.85 -- 4.80SrO -- 1.55 -- 1.90 -- --BaO 1.90 -- -- 0.45 -- 2.50ZnO 1.10 10.50 -- -- 1.80 5.70PbO 4.95 4.00 3.40 2.90 16.75 2.90TiO.sub.2 -- -- -- 0.80 -- --SnO.sub.2 1.20 1.25 0.60 0.30 0.10 1.65As.sub.2 O.sub.3 0.25 0.10 0.50 0.10 0.05 0.05Sb.sub.2 O.sub.3 -- 0.10 -- -- 0.25 --NH.sub.4 Cl 0.15 -- -- 0.30 -- --Cl -- -- 0.05 -- -- --F -- -- 0.10 0.50 0.10 --SO.sub.3 0.10 -- 0.10 -- 0.20 0.10CeO.sub.2 -- -- -- -- 0.15 0.25Fe.sub.2 O.sub.3 -- -- 0.05 -- -- 0.15V.sub.2 O.sub.5 -- 0.05 -- -- 0.10 --Co 0.20 0.30 -- -- 0.75 --CoO 0.60 -- 0.10 0.20 -- 1.50Ni -- -- -- -- 2.55 --NiO -- -- -- -- -- 4.35Totals 100.0 100.0 100.0 100.0 100.0 100.0______________________________________
Finally, FIG. 8 shows a comparison of the transmission curves of a conventional glass (BG 3) with the glass of Example 1, in each case, before and after exposure. In the glass of Example 1, the transmission curves of the glass before and after the exposure are identical, i.e., the exposure does not cause any loss in transmission.
With respect to the test conditions for the exposure, once again those of the aforesaid test procedure were selected.
EXEMPLARY EMBODIMENT
The invention will now be further described with reference being made to an examplary embodiment thereof. It should, however, be recognized that the following example is not intended as a definition of the scope or limitations of the present invention.
As illustrative of the present invention, for producing 100 kg of Co 2+ colored alkali silicate glass having the composition of Example 1, the following ingredients are mixed into a uniform mass of raw material in a mixing drum:
64.064 kg of Sipur (SiO 2 ) "Sipur" is a trademark for silicon dioxide of the Bremthaler Quarzitwerke, Usingen, Federal Republic of Germany.
15.367 kg of boric acid (H 3 BO 3 )
23.181 kg of sodium hydrogen carbonate (NaHCO 3 )
12.205 kg of potassium carbonate (K 2 CO 3 )
2.480 kg of barium carbonate (BaCO 3 )
1.101 kg of zinc oxide (ZnO)
5.067 kg of lead oxide red (Pb 3 O 4 )
1.200 kg of stannic oxide (SnO 2 )
0.253 kg of arsenic oxide (As 2 O 3 )
0.150 kg of ammonium chloride (NH 4 C1)
0.230 kg of sodium sulfate (Na 2 SO 4 )
0.200 kg of cobalt metal powder (Co)
0.844 kg of cobalt oxide (Co 2 O 3 )
This mixture is melted down in batches over a period of 6 to 7 hours at 1280 to 1320 degrees C, in ceramic or platinum fusing equipment. The degassing of the fused mass takes place in the temperature range of from 1470 to 1500 degrees C. over a period of from 2 to 4 hours.
The homogenization of the fused mass is performed at 1250 to 1480 degrees C. The time required for this is approximately 2 to 3 hours. The resulting fused glass is then poured into a pre-heated mold.
While only several embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that many modification may be made thereunto without departing from the spirit and scope of the invention.
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Alkali silicate glasses, pigmented with Co 2+ or with Co 2+ and Ni 2+ , and having the composition:
SiO 2 : 52-71% by weight
PbO: 2.9-16.8% by weight
SnO 2 : 0.1-1.65% by weight
Na 2 O: 6.7-16.7% by weight
K 2 O: 0.5-9.9% by weight
Na 2 O+K 2 O: 13.3-18.3% by weight
NiO+CoO: 0.1-4.4% by weight
As 2 O 3 +Sb 2 O 3 : 0.05-0.5% by weight
ΣRO: 0-8.6% by weight
B 2 O 3 : 0-8.5% by weight
Al 2 O 3 : 0-0.55% by weight
ZnO: 0-10.5% by weight,
in which R is Mg, Ca, Sr, Ba or a combination thereof, are disclosed. The alkali silicate glasses of the invention are useful as optical filter glasses.
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TECHNICAL FIELD OF INVENTION
The present invention relates to a porous composition for bone scaffold, and more particularly, to a porous composition for bone scaffold having excellent biocompatibility, bioaffinity and bioactivity with good mechanical properties.
BACKGROUND OF INVENTION
Tissue or organ repair has been the ultimate goal of surgery from ancient times to the present day. Biomaterials, as the structural components of medical devices, are used extensively in the treatment of disease, trauma and disability. The most significant advances have been made through the development of so-called bioactive materials. These bioactive materials interact with the host tissues to assist and improve the healing process.
CaCO 3 has been used for bone repair in the form of ceramic blocks, granules or CaCO 3 cement, it is a weak bioceramic alone without dextrin, gelatin, dextran and thus cannot be used on its own as major load-bearing implants in the human body. Dextrin was used because it is very firm, rigid and it is more tacky and faster setting. The process to produce the scaffolds is simple without using any sophisticated equipment and the scaffolds can be ready within 4-5 days. Easily sterilized either by exposure to high temperatures or gamma radiation and remain unaffected by one of these techniques. This scaffolds fall into the III category of medical devices, which are medical devices meant for permanent use which are not directly in contact with the blood stream nor the central nervous system, but do exert a biological effect or are absorbed totally or partially.
One of the most widely studied hard tissue engineering approaches seeks to regenerate the lost or damaged tissue by making use of the interactions between cells and biodegradable scaffolds. This strategy usually involves the seeding and in vitro culturing of cells within a 3-D polymeric matrix—a scaffold—prior to implantation. The bioresorbable scaffold must be biocompatible and porous interconnected network to facilitate rapid vascularization and growth of newly formed tissue.
Various source of Calcium Carbonate were used previously, some of the sources are limestone, coral which are found in a balance ecosystem. Natural coral exoskeleton derived from marine reefs is composed of calcium carbonate. It was introduced as a substitute for bone-graft in the mid-1970s, and has been used clinically to treat a variety of orthopaedic and craniofacial defects of bone. This type of coral besides their endangered species is very nature expensive, and sometimes very expensive to collect. Limestone is a rock collects from the deep-seabed different from the coral as a biominerals. These materials are well known for their excellent bone-bonding capabilities but they are brittle and have poor resistance to compressive stress. In order to minimise the dependency of the above sources, the cockle shell which is easily available is used. The present invention of porous bioceramic composition has excellent bone bonding capabilities, tough and good resistance to compressive stress.
Calcium carbonate-based ceramic in combination with dextrin were used as a novel technology in this study. Gelatin and dextran are another two materials in this component to support the scaffolds.
The porous 3-D scaffolds prepared contain mainly cockle shells (CaCO 3 ) and dextrin, and process through the heating and freeze-drying methods.
SUMMARY OF INVENTION
It is an object of the present invention to provide a porous composition for bone scaffold having high mechanical properties.
It is another object of the present invention to provide a porous composition for bone scaffold having proper size of pores and porosity as well as applicable mechanical properties in human body to promote fast tissue reaction and osteointegration due to its large specific surface area.
It is still another object of the present invention to provide a porous composition for bone scaffold without any problems due to the thermal difference.
It is still another object of the present invention to provide a porous composition for bone scaffold which can control its dissolution rate and biological properties in human body.
It is still another object of the present invention to provide a method for manufacturing the same. According to the method of the present invention, the porosity of the porous composition substrate can be adjusted appropriately.
In order to achieve these and other objects, the present invention provides a porous composition for bone scaffold. The porous composition according to the present invention comprising a mixture of cockle shell powder, dextrin, gelatin and dextran.
Wherein it is preferable that the average size of pores in the porous composition substrate is also between 20-400 nm
The present invention also provides to a method for preparing a porous composition for bone scaffold. The method of the present invention comprises the steps of: (a) dissolving gelatin, dextran and dextrin in hot deionized water, (b) stirring the mixture, (c) adding cockle shell powder to the mixture, (d) pouring the mixture into a shaped wax block, (e) drying the mixture in room temperature, f) removing the shaped wax block and obtaining a scaffold.
The present invention also provides another method for preparing a porous composition for bone scaffold. The method of the present invention comprises the steps of: a) dissolving gelatin, dextran and dextrin in hot deionized water, and adding cockle shell powder to the mixture (b) stirring the mixture, (c) pouring the mixture into a shaped wax block, (d) drying the mixture in a freeze drying machine.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-C illustrate the scaffold contained of macro-micropores with different sizes and a uniform interior of sample 334 .
FIGS. 2A-D illustrates the scaffold contained of macro-micropores with different sizes and a uniform interior of sample 334 .
FIGS. 3A-D illustrates the scaffold contained of macro-micropores with different sizes and a uniform interior of sample 352 (the pore sizes are estimated between 20 to 400 nm).
FIGS. 4A-B illustrates small diameter pores of sample 262 preferable to yield high surface area per volume.
FIGS. 5A-D illustrates the porosity and interconnectivity of the pores (of scaffold prepared by the freeze-drying method) using the Phenom SEM.
FIGS. 6A-B illustrate DSC—temp. vs. heat flow for two sample, sample 262 and 334 .
FIGS. 7A-B illustrate DSC—temp. vs. heat flow for one sample, sample 352 .
FIG. 8 illustrates a typical XRD pattern of the products (sample 352 ).
FIG. 9 illustrates a typical XRD pattern of the products (sample 262 ).
FIG. 10 illustrates a graph showing the amount of water absorbed in all samples.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A more complete appreciation of the invention and many of the attendant advantages thereof can be better appreciated by reference to the following detailed description and the accompanying drawings. The following examples are cited by way of illustration and therefore, should not be constructed to limit the scope of the present invention.
The present invention relates to a porous composition for bone scaffold. The porous composition comprises of a mixture of cockle shell powder, dextrin, gelatin and dextran. The cockle shell powder, the dextrin, the gelatin and the dextran are added at a certain amount respectively to form the mixture. Amount of the cockle shell powder is 33.33% by weight. Amount of the dextrin is ranging from 13.33% to 40% by weight. Amount of the gelatin is ranging from 13.33% to 20% by weight. Amount of the dextran is ranging from 13.33% to 40% by weight. A total mass of 150 g of the mixture is used as example where mass of the cockle shell is fixed at 50 g.
The present invention also relates to method for preparation of a porous composition for bone scaffold. In one embodiment, the method comprises of first, dissolving gelatin, dextran and dextrin in hot deionized water. Second, stirring the mixture. Third, adding cockle shell powder to the mixture. Fourth, pouring the mixture into a shaped wax block. Fifth, drying the mixture. Sixth, removing the shaped wax block and obtaining a scaffold and seventh, drying the scaffold.
In another embodiment, the method comprises of first, dissolving cockle shell powder, gelatin, dextran and dextrin in hot deionized water. Second, stirring the mixture. Third, pouring the mixture into a shaped wax block and fourth, drying the mixture in a freeze drying machine.
A more complete appreciation of the invention and many of the attendant advantages thereof can be better appreciated by reference to the following detailed description and the accompanying drawings. The following examples are cited by way of illustration and therefore, should not be constructed to limit the scope of the present invention.
EXAMPLES
Materials for Scaffolds Preparation
Gelatin
Gelatin which is a natural protein derived from the organic phase of bone is much cheaper and more easily obtainable in solutions than collagen. It is needed to be dissolved in water and crosslinked to form a polymer network. The gelatin used was derived from bovine skin. Gelatin is used to enhance the paste, the firmness and rigidity of scaffold. The gelatin provides the mechanical strength by changes of chain of amino acids which occurred during heating or freeze-drying process.
Dextran
Dextran is a physiologically harmless biopolymer because of its biocompatible, biodegradable, non-immunogenic and non-antigenic properties. Dextran is used to increase the porosity of the scaffolds.
Dextrin
Dextrin is a simple carbohydrate with a low molecular weight. Dextrin is used widely in industry, due to their non-toxicity and their low price. Dextrin is tacky and has fast setting ability than common starch pastes formed by unmodified starch. After dissolving, it tend to setback and form gels which eventually become very firm and rigid.
Cockle Shell ( Anadara Granosa ) Powder
Cockles were collected from the wet markets and the powder was prepared after removal of all the waste material from the shells.
Scaffolds Preparation
Preparation of Cockle Shell Powder
This study introduces a novel three-dimensional biomatrix obtained from the Cockle ( Anadara granosa ) as a scaffold for tissue engineering. The powder from the shell was prepared according to the method described by Zuki et al. (2004), which involved the removal of all the waste material after boiling the shells for 30 minutes. The shells were thoroughly cleaned until the shells become completely white. The black line in shell junction border was also removed. The shells were subject to boiling again for a few minute to remove all the residual material and were dried in the oven at 40° C. over night. The cockle shells were ground by using warring blender (Blendor®, HCB 550, USA) until they turned into powder form. The powder was sieved at 90 μm by using stainless steel siever (Retsch, Germany)) and sterilized by heat at 100° C. for few hours before ready to be used.
Preparation of the Scaffolds
Four-powder blend was formulated for the experiments. It consisted of Cockle Shell powder (50 g), Gelatin (20 and 30 wt. %), Dextran (20, 30, 40, 50 and 60 wt %), Dextrin (20, 40 and 60 wt %).
Five different types of the scaffolds numbered 334 , 352 , 262 , 226 , 244 with various composition of Gelatin, Dextran, Dextrin were prepared. The five scaffolds were prepared based on the following concentrations:
Scaffold 334 : 50 g cs, 30 g gel, 30 g dextran, 40 g dextrin
Scaffold 352 : 50 g cs, 30 g gel, 50 g dextran, 20 g dextrin
Scaffold 262 : 50 g cs, 20 g gel, 60 g dextran, 20 g dextrin
Scaffold 226 : 50 g cs, 20 g gel, 20 g dextran, 60 g dextrin
Scaffold 244 : 50 g cs, 20 g gel, 40 g dextran, 40 g dextrin
Keys
cs=cockle shell
gel=gelatin
Scaffolds Prepared by Heat Method
The powders of three materials (gelatin, dextran, dextrin) were dissolved in hot deionized water at 70-80° C. for 2 hours by using the heating homogenize stirrer machines (Wiggen Hauser® Heating Stirring), the cockle shell powder was added to the mixtures in the end. The paste of the mixtures was poured in wax block design that depends on the shape of the bone defect, and left over night for drying at room temperature (27° C.). After 24 hours, the wax was removed and leaving the scaffolds to continue to dry at the same temperature for 1-2 days. Then, the scaffolds were dried in oven at 60° C. for 2 days. The scaffolds become hard and ready for sterilization to be used at a later date.
Scaffolds Prepared by Freeze-Drying Method
Four powders (cockle shell powder, gelatin, dextran, dextrin) were blended together with deionized water at 50° C. for 60 minutes by using stirrer machine to homogenize the materials. The paste was poured into the mould and transferred immediately into the deep freezer −80° C. for 24 hrs. The block was removed and the scaffolds were dry by using freeze-dryer machines for 48 hrs at −50° C. The dry scaffolds were kept in clean place for sterilization.
Characterization of the Scaffolds
Environmenta Scanning Electron Microscopy (ESEM)
Environmental Scanning Electron Microscopy (Philips XL30 ESEM) analysis revealed that the scaffold contained of macro-microspores with different sizes, and showed a uniform interior. The size of the pores and their distribution and also the interconnectivity between the pores were analysed using the ESEM. Small diameter pores are preferable to yield high surface area per volume, as long as the pore size is greater than the diameter of a cell in suspension (typicaly 10 μm) ( FIGS. 1-5 ).
Degradation Manner
The degradation manner of the scaffolds was assessed in water by soaking for 10 days. This was to evaluate the integrity of the scaffolds for few days in the liquid system. The scaffolds lasted for more than 10 days without much visible of the surface degradation. Qualitatively, the scaffolds were observed to be uniformly tough and strong throughout the test. The degradation rates should be adjustable to the suitable rate of tissue regeneration. After 10 days evaluation, the integrity of the scaffolds still strong throughout the test.
Mechanical Tests
Compression test was conducted under the dry and wet condition of the scaffold with an Instron 4302 machine. Universal mechanical testing machine using 1-kN load cell (Canton). One sample of each type was tested. In each set, many samples of different size and shape was prepare but mostly like the bone except the compression used was rectangular produced of different geometries and dimensions as shown below in the Table 1. Stiffness of the different geometries and dimensions scaffolds were evaluated in the point stress region. The yield strength was taken at the yield point on stress-strain in MPa.
TABLE 1
The strength of the dry and wet scaffolds.
Yeild
Width
Thickness
strength
Modulus
NO
Sample
mm
mm
MPa
MPa
224
Dry
14.30
7.97
11.43
144.5
uninfiltrated
224
Dry
13.74
7.04
13.95
182.3
infiltrated
224
Wet
13.96
8.50
1.946
0.696
infiltrated
262
Dry
15.63
7.64
3.628
74.57
uninfiltrated
262
Dry
16.32
8.37
3.429
20.74
infiltrated
262
Wet
13.56
8.87
0.132
0.428
infiltrated
352
Dry
12.60
7.49
13.19
187.5
uninfiltrated
352
Dry
15.91
9.93
9.676
71.41
infiltrated
352
Wet
16.78
11.15
0.394
0.751
infiltrated
334
Dry
29.4
2.66
7.271
1231
uninfiltrated
334
Dry
29.13
2.92
5.801
33.24
infiltrated
334
Wet
29.10
4.49
0.007
4.077
infiltrated
226
Dry
15.38
9.78
4.894
48.05
uninfiltrated
226
Dry
13.89
7.80
5.250
148.8
infiltrated
226
Wet
15.75
9.57
2.779
0.639
infiltrated
Differential Scanning Calorimetry (DSC)
Different ratio of scaffolds samples were analyzed on differential scanning calorimetry (DSC). The thermal transition of powder was analysed by using METTLER TOLEDO (DSC822 e Swizzerland). Typically, 5 mg of three samples were weighed. They were scanned from room temperature (25° C.) up to 250° C. at the rate of 10° C./min.
DSC was used to analyse the thermal transition of the powders that used to fabricate scaffolds. The second peak observed could be ascribed to the melting of crystallites of the cockle shell powder, the first peaks of the sample observed refer to the three powders. The thermal signature was that of the scaffolds with a first peak 100° C. and second peak of sample. It also showed good mix ability between the materials in forming new bonds ( FIGS. 6-7 ).
X-Ray Diffraction Analysis
Examination of wide-angle X-ray diffraction was performed at room temperature to characterize the crystalline amorphous nature and identifies any crystalline phases present. Utilize the diffractometer system X'PERT.PRO Philips PW3040/60 (XRD) with the diffraction angles from 0-70°. The scaffolds were ground before the analysis. 40 kV acceleration voltage and 30 mA were used for analysis.
XRD was used to characterized the crystalline/amorphous nature of the CaCO 3 and to identify any crystalline phases present. Only the major CaCO 3 reflection peak, such as more than 1000 and between the 500 and 1000 were present in the X-ray diffraction pattern of these nanoCaCO 3 particles, no common secondary phase, such as gelatin, dextrin, dextran were found, which confirmed the phase composition of CaCO 3 ( FIGS. 8-9 ).
Water Absorption Test
The samples were infiltrated with different amounts of copolymer solution, which was made by poly (L-lactide) PLA and polycaprolactone PCL dissolving in dichloromethane (CH 2 Cl 2 ) non toxic solution and highly vaporized. Different types of scaffolds were soaked in water for 10 minutes and evaluated the amount of water absorbed. The second 10 minutes of soaking was conducted after the scaffolds were soaked in water for 10 min and dried.
The scaffolds were soaked in water for 10 min and evaluated for the amount of water absorbed by the freezing method.
The results in FIG. 10 reveals that, as the volume of the copolymer used gets larger, the resistance to water absorption becomes better. After the first 10 min, the sequence infiltrated scaffolds in group 244 (11.428), 352 (7.547) were more resistant than those infiltrated by group 334 (5.172), 226 (7.692), 262 (6.25).
The invention being thus described, it will be apparent that the same may be varied in many ways. Such variations are to be regarded as within the scope of the invention, and all such modifications as would be apparent to one skilled in the art are intended to be within the scope of the following claims.
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The present invention relates to a porous bioceramic composition for bone repair and method of fabrication of the same. 3D-scaffolds were fabricated with a novel micro- and macro-architecture. Porous scaffolds based on dextrin, dextran, gelatin and biomineral (CaCO 3 ) powder were fabricated by heating and freeze-drying methods. Fabrication of different compositions of porous scaffolds (20, 30 wt % of gelatin, 20, 40 wt % dextrin, 30, 40, 50, 60 wt % dextran bounder with the constant quantity of CaCO 3 50 g). The scaffolds properties were characterized by x-ray diffraction (XRD), differential scanning calorimetry (DSC), scanning electron microscopy (SEM) and compression tests.
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BACKGROUND OF THE INVENTION
This invention relates to the completion of lateral well bores, and in the preferred embodiment provides a relatively simple and inexpensive arrangement which facilitates passage of relatively large diameter objects into a completed lateral well bore whilst permitting passage of relatively large diameter objects past the lateral well bore into the portions of the original well bore located below the lateral.
In recent years, the technique of producing lateral well bores (also known as “laterals” and “branch well bores”) has been significantly developed. Laterals are well bores which are drilled to branch off an existing main well bore in order to gain access to the strata surrounding the main well bore. Typically, one or more laterals will be drilled from a main well bore starting from a point somewhat above hydrocarbon bearing strata surrounding the main well bore. The laterals are generally bored away from the main well bore in a generally downward direction (although horizontal or even upwardly extending laterals are known) to arrive in the hydrocarbon bearing strata at a point displaced from the main well bore. By this means, hydrocarbon material can be extracted from the formation surrounding the main well bore without drilling a fresh well bore from the surface.
In order to maximise the benefit of the lateral technique it is common to bore several laterals spaced apart angularly around the main well bore. Such arrangements are known as “multilaterals”. A number of arrangements for drilling laterals and multilaterals are disclosed, for example, in published International patent application WO 94/03699.
Especially in the case of multilaterals (although to an extent also in the case of single laterals) it is often desirable to have communication from a point in the main well bore above a lateral to a point in the main well bore below the lateral. Such communication may be used, for example, to permit hydrocarbon material to flow from a lower lateral past an upper lateral to the surface. In more sophisticated arrangements, access may be required past a lateral to allow service or development tools to be run past the lateral to work at a location below the lateral.
A number of arrangements have been proposed to facilitate this desirable communication between portions of the main well bore above a lateral and portions of the main well bore below the lateral.
In one early example of these techniques disclosed in U.S. Pat. No. 245,920 (Shell) a continuous casing is inserted to extend from a point in the main well bore above a lateral to a point below the lateral. After cementing, the main casing is perforated to provide fluid communication between those portions of the original main well bore located below the lateral and those portions of the original main well bore located above the lateral.
In WO 94/03699 a number of techniques are disclosed. In particular, in one technique it is proposed to install a lateral liner so that a portion of the liner resides in the main well bore, to cement the lateral liner in position, and then to wash over the portions of the lateral liner which reside in the main well bore with a view to producing a clean inverted Y junction. Also disclosed in WO 94/03699 is a technique whereby the lateral liner is installed with a portion of the lateral liner located in the main well bore above the lateral junction, the lateral liner is cemented in position, and a milling tool is run through the lateral liner along the central axis of the original main bore to form a milled opening in the lateral liner to facilitate communication between the portions of the main bore located below the lateral and portions of the main well bore located above the lateral.
More recently, U.S. Pat. No. 5,477,925 proposes use of a pre-formed window element which forms part of a completion string for the lateral. As proposed, the window element includes means for hooking onto the window formed in the casing of the main well bore. Such an arrangement ensures that the window element is located at precisely the correct depth relative to the window in the main well bore casing so as provide through communication between the portions of the main well bore located respectively above and below the lateral. Whilst this device represents a substantial improvement over the techniques of earlier proposals, the system does suffer from the advantage that the entire completion string must be correctly angularly oriented throughout the process of running the completion string into the lateral. This is because it is only by maintaining the correct angular orientation of the completion string that the window element will be presented to the main well bore casing window at the correct orientation to ensure seating.
All the above arrangements are characterised by one or more disadvantages. The technique of U.S. Pat. No. 2,452,920 provides fluid communication but does not permit the passage of tools between the portions of the main well bore above and below the lateral. Also, the technique of U.S. Pat. No. 2,452,920 requires precise positioning of a perforating tool which may not, in practice, be possible in many cases. The washover technique of WO 94/03699 can produce a clean inverted Y junction. However, the technique requires an additional somewhat uncertain operation (the washover operation) and can result in a unstable junction if applied to laterals drilled into unstable formations. The mill through technique of WO 94/03699 obviates the problem of an unstable junction but may be difficult to achieve in practice because the mill tool will tend to follow the lateral liner into the lateral rather than bore straight through the lateral liner as suggested by the illustrations of the patent specification. The technique of U.S. Pat. No. 5,477,925 requires the maintenance of the correct angular position of the lateral lining as it is run into the lateral to ensure that the window element is at the correct angular position relative to the main well bore casing window.
We have now devised a relatively simple technique which provides communication between the portions of a main well bore located above and below a lateral and which overcomes the disadvantages of the prior art outlined above.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention a method of completing a lateral well bore comprises installing a datum device in a main well bore at a point above the lateral, the datum device providing a datum height above the lateral; making up a completion string comprising a lining to be inserted in the lateral bore, a window element at the upper end of the liner, a swivel joint between the lining and the window element, and a datum device engaging member located above the window element; running the completion through the main well bore and into the lateral until at least a portion of the lining is located in the lateral; rotating the window element to place the window at a desired angular position relative to the main well bore; and running the completion string home to engage the datum device engaging member with the datum device.
By use of the method according to the present invention the bulk of the lateral completion (which may be several hundred meters in length) may be run into the lateral before the window element is rotated to achieve the correct angular orientation. The swivel between the window element and the casing facilitates rotation of the window element without requiring rotation of the casing. The engagement of the datum device ensures that the completion is run precisely the correct depth so that the window in the window element facilitates communication between the portions of the main well bore located above and below the lateral.
Preferably, the datum device provides an angular datum reference as well as a height datum reference. Accordingly, rotation of the window element to the correct angular orientation may be achieved by reference to the datum device. In a particularly preferred embodiment of the invention the datum device has a muleshoe engaging profile and the datum device engaging member secured to the window element comprises a muleshoe. By this means, as the completion is run home the engagement of the muleshoe with the datum device will automatically rotate the muleshoe and the window element to place the window element in the correct angular orientation. It will be noted that it may be desirable to provide for adjustment of the angular orientation of the muleshoe relative to the completion so that any errors in setting the datum device can be compensated for by a corresponding adjustment to the position of the muleshoe.
The datum element may be of any convenient form. In general, it will be desirable for the datum element to occupy the minimum possible annular zone within the main well bore so as to maximise the available diameter for the passage of the lateral completion. To this end, the datum device can be of the known big bore packer type set in the casing at the required position before the completion is run. However, in a particularly preferred embodiment of the inventions the datum device is a thin walled device, for examples, a tubular which has been expanded into locking engagement with the casing of the main well bore. In a particularly preferred embodiment of the invention, the datum device is in the form of the attachment device described in U.S. Pat. No. 6,899,183, the disclosure of which is incorporated herein by reference. This device provides a simple and secure angular and height datum and yet occupies only a small annular zone within the main well bore.
The invention will be better understood from the following description of a preferred embodiment thereof, given by way of example only, reference being had to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a main well bore having a lateral drilled therefrom, a thin walled device being positioned in the main well bore above the lateral;
FIG. 2 illustrates the upper portion of a completion string in accordance with the preferred embodiment to the present invention; and
FIG. 3 illustrates the completion string of FIG. 2 positioned within the main well bore and lateral illustrated in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring firstly to FIG. 1 , there is shown a main well bore 1 having a lateral well bore 2 drilled therefrom. The techniques necessary to drill the lateral are well established within the well drilling art. As illustrated, the main well bore 1 is fitted with a steel casing 3 which is cemented in position. The process of forming the lateral produces a window 4 in the casing 3 . As illustrated, the lateral 2 is not lined.
A datum device 5 , in the form of an attachment device in accordance with the description of the aforementioned U.S. provisional patent application, is shown mounted within the main well bore casing 3 at a point above the window 4 . The device 5 has been installed after the window has been formed, at a known spatial and angular position relative to the window 4 . Any appropriate technique may be used for correctly positioning the device 5 prior to setting. Because the device 5 has a fixed spatial and angular relationship to the window 4 the point 6 at the top of the device 5 is at a known spacing X from the top of the window 4 . Similarly, the point 6 has a known angular relationship to the top of the window 4 . As illustrated, the point 6 is offset by 90° in the anti-clockwise direction (when viewed from above) relative to the top of the window 4 .
Whilst the datum device 5 is preferably as disclosed in the aforesaid U.S. provisional patent application, it is to be appreciated that other datum device may be used. For example, a big bore packer or similar device may function as the datum device. Alternatively, a tubular may be expanded into locking engagement with the casing 3 . The essential characteristics of the datum device is that it provides a datum height X above the window 4 . Preferably, the datum device also provides a known angular relationship relative to the window 4 . As illustrated, the upper surface 7 of the device 5 has a muleshoe engaging profile the uppermost extremity of which provides the point 6 for datum angular reference.
It will be appreciated that whilst in the above description the datum distance has been described as between the point 6 and the upper edge of the window 4 , the datum distance may equally be defined as the distance between the point 6 and the lower edge of the window 4 or the centre line of the lateral 2 . The only important factor is that the datum distance provides a datum reference point having a known spatial relationship to the window 4 and the lateral 2 .
Referring now to FIG. 2 , there is shown schematically a completion string 10 in accordance with the preferred embodiment of the present invention.
The lower part of the completion string includes a liner 11 which, in use, will be positioned within the lateral 2 . The lining 11 may be several hundred meters in length and may include known tools for performing specific operations within the lateral.
Located above the casing 11 is a transition joint 12 which has formed therein a window 13 . The joint 12 forms a window element 14 the function of which will be clear from the following description with reference to FIG. 3 . Immediately below the window element 14 is a swivel 15 which allows rotation of the window element and the components above it relative to the components below it. According to the exact requirements for the completion a range of joints 16 and tools 17 , 18 may be positioned between the swivel 15 and the casing 11 . The tools 17 , 18 may, for example, be a CPC (cementing port collar) 17 and an ECP (external casing packer) 18 .
The upper end of the window element 14 is secured by means of a threaded connection 19 to a joint 20 having thereon a muleshoe 21 the profile of which is complementary to the muleshoe engaging profile 7 of the datum device 5 . A packer 22 is located above the joint 20 . Other components as required may be located above the packer 22 .
In use, the completion 10 is run into the main well bore 1 . The casing 11 is deflected into the lateral 2 . Deflection may be achieved by means of a deflector device positioned within the main well bore 1 or may be achieved automatically by suitably shaping the lower extremity of the casing to kick into the lateral. Once the casing has entered the lateral 2 the completion is run almost home without any attempt to control the rotational position of the components of the completion. Accordingly, the completion can be run into the lateral relatively easily. This situation continues until the muleshoe 21 of the completion engages the muleshoe engaging profile 7 of the datum device 5 . Once this happens, further downward movement of the completion will cause rotation of the completion components located above the swivel 15 . The swivel 15 allows the components located above it to rotate as required by the muleshoe profiles, without having to rotate the casing which has already entered the lateral. Eventually, the muleshoe 21 bottoms on the muleshoe engaging profile 7 of the device 5 . This configuration is shown in FIG. 3 . It will be noted that the effect of this arrangement is to position the window 13 of the window element 14 at a precisely known location relative to the window 4 of the main well bore casing. The positioning of the window 13 is both translational and rotational. In other words, the window 13 will be positioned at a precisely known depth relative to the window 4 and at a precisely known angular position relative thereto. If desired a packer anchor may be provided at the top of the completion to lock the completion in position and provide a seal between the completion and the primary casing 3 .
As illustrated in FIG. 3 , the window 13 facilitates the passage of tooling through the upper portion of the completion 10 and outwardly through the window 13 into the portions of the main well bore 1 located beneath the lateral. Equally, tooling can pass through the upper portions of the completion 10 and through the window element 14 into the lateral.
It will be appreciated that the invention provides a simple and reliable technique for completing a lateral and, at the same time, providing access to the regions of the main well bore located beneath the lateral. Once the datum device 5 has been set the entire completion operation can be completed in a single trip. The perforation, wash over or milling techniques of the prior art are not required.
It will be noted that because of the relatively small annular zone occupied by the datum device 5 the joint 20 and window element 14 may have a relatively large diameter and accordingly facilitate relatively large diameter access to both the lateral and the main well bore. It is envisaged that in a typical main well bore having a casing with a diameter of 9⅝ inch the datum device 5 of the preferred embodiment will facilitate passage of a completion having an outside diameter of between 7 inch and 7⅝ inch thereby permitting access through the window 13 of tools having a diameter of between 6 inch and 6¼ inch.
It will be noted that if desired a datum device may be positioned within the zone 23 below the lateral. Such a datum device may be of any suitable type, for example a big bore packer, an expanded tubular, or an attachment device as described in the aforementioned U.S. provisional patent application. Such a datum device may, for example, be used to support a deflector for the purpose of deflecting the completion into the lateral, or for supporting a deflector for deflecting tools into the lateral. Such deflectors may be recoverable. Additonally or alternatively a datum device in the zone 23 may be used to support a completion similar to that described above which is associated with a further lateral location below that illustrated in the drawing.
It will be appreciated that whilst the invention has been described in the context of an unlined (bare foot) lateral the invention may be applied to laterals which have previously been lined by, for example, the washover technique described in WO 94/03699.
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The present invention relates to the completion of lateral well bores and provides a method comprising the steps of installing a datum device in a main well bore so as to provide a datum height above the lateral: making a completion string ( 10 ) comprising a lateral lining ( 11 ), a window element ( 14 ) at an upper end of the lining ( 11 ), a swivel joint ( 15 ) located between the lining ( 11 ) and the window element ( 14 ), and a datum device engaging member ( 21 ) located above the window element ( 14 ); running the completion through the main well bore and into the lateral; rotating the window element ( 14 ) to place the window at a desired angular position; and running the completion string home to engage the datum device engaging member ( 21 ) with the datum device.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to tools of the type used by toolmakers, diemakers and others to determine the deviation from a predetermined angle of a manufactured part.
2. Description of Related Art
The precision required for many machine parts is extremely critical. The precision may be required for either an inside angle or an outside angle. Although there are known devices for measuring either an inside or an outside angle, such as that disclosed in U.S. Pat. No. 3,380,165, most are intended for one use or the other. Even devices such as that disclosed in U.S. Pat. No. 3,380,165 generally are most effective in measuring either an inside angle or an outside angle.
A related class of gauges are those intended to measure deviation from proper alignment of cylinders such as U.S. Pat. No. 1,852,760. In application, these devices combine the features of measuring both inside and outside angles although they measure what is substantially an inside angle. Also related to the class of angle gauges and capable of providing an indication of deviation from specified angles are devices such as the mechanic's square of U.S. Pat. No. 2,448,440, draftsman's squares, and carpenter's squares. The reliability of these devices however is a function of the precision with which they are manufactured, the care that has been taken with them over their period of use, and integral angles to which they are manufactured such as right angles and 45° angles. However, devices of this type by themselves, only indicate deviation. They are unable to provide a measure of that deviation from the desired angle.
Cylinder or cylinder type gauges have provided one solution to the need for deviation measurement devices. These gauges are used to measure an inside angle, that is the angle between a horizontal surface and an essentially vertical surface. However, they can be used for measuring what is a workpiece outside angle by placing one surface face of the workpiece angle on a horizontal surface and using the cylinder type square to measure the deviation of the substantially vertical surface defined by the second face of the angle. Cylinder type gauges include a base leg that is placed on the horizontal surface and a vertical leg, normally cylindrical, that is placed against the vertical surface to be measured. The gauge may be mounted in or on either the base or vertical leg but is most normally found on the vertical leg. U.S. Pat. Nos. 3,273,252; 3,570,132; 3,688,412; and 4,096,634 disclose squareness gauges of this general type.
Related to this method of measurement is the indicating square of Leszak, U.S. Pat. No. 2,397,280, which is a cross between a carpenter's square with one edge adjustable and the operation principles of a cylinder square. In Leszak, the adjustable edge is in contact with a dial or gauge for measuring deviation.
An inherent disadvantage of these known cylinder gauges is that they require a smooth horizontal surface on which the workpiece must be placed for their use. Further, that surface must be of sufficient size to provide a stable footing for the horizontal leg or arm of the square in addition to the workpiece.
SUMMARY OF THE INVENTION
It is an object of the instant invention to provide an easy to understand and useful apparatus for checking the squareness of workpieces to a great degree of accuracy.
It is another object of the invention to provide an apparatus that is adjustable so that it may be used with workpieces of variable sizes.
It is a further object of the invention to provide an apparatus that may be used quickly without the necessity of moving the workpiece to a satisfactory surface or requiring a extended period of time for setting up and adjusting the apparatus.
A further object of the invention is to provide an apparatus capable of measuring the squareness of outside corners wherein the corner is chamfered or otherwise shaped and/or one or both surfaces have surface perturbations such as holes, slots and/or grooves.
To achieve the above and other objects clear to one skilled in the art, the apparatus adapted to measure an angular deviation from a specified angle between first and second surface of a workpiece comprises a handle having a face on one surface for contacting the first surface of the workpiece and having a slot passing therethrough, an arm slidably received in the slot, means for locking the arm in a fixed position relative to the handle, a gauge mounted adjacent the end of the arm opposite the face of the handle, the gauge having a feeler point for contacting the second surface of the workpiece, and a contact member positioned along the arm so as to be offset from the face of the handle, the contact member contacting the second surface of the workpiece. To aid in the determination of angular deviation, a scale is provided on the face of the arm. The zero point of the scale is aligned with the longitudinal axis of the feeler point thereby providing a measure of distance from the feeler point to the face of the handle. In the preferred embodiment, the contact point is a member slidable along the arm, the contact point member having means for being locked into position. In a second embodiment, the contact point is an extension to the handle, extending from the side of the handle containing the face for contacting a first surface of the workpiece.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the accompanying drawings in which:
FIG. 1 is a side elevation of a first embodiment of the angle gauge of this invention;
FIG. 2a is a front view of a slidable contact member;
FIG. 2b is a side view of the slidable contact member;
FIG. 3 is a top view of the end of the arm of the angle gauge;
FIG. 4 is a top view of a second embodiment of the end of the arm of the angle gauge;
FIG. 5 is a side elevation of a second embodiment of the angle gauge; and
FIG. 6 is an end view of the invention shown in FIGS. 1 and 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiment of the angle gauge 10 shown in FIG. 1 includes a handle 12, an arm 30 slidably received in opening 13 of handle 12, a contact member 50 slidably mounted on arm 30 and a gauge 40 fixedly mounted to an end of arm 30.
Handle 12, made of a metal or other hard and damage resistance substance, is of a boxlike configuration having a length, width and depth ratio of preferably approximately 5:1.5:1. The edges 16 between back surface 15 and the side surfaces, as well as between bottom surface 19 and the side surfaces can be shaped by rounding or chamferring for comfort in handling. Front face 18 is smooth and provides the contact surface for contact with a first surface 64 of workpiece 61. An opening 14 is provided in the lower segment of handle 12 to reduce the weight of the apparatus and to facilitate handling. Opening 14 is parallel to front surface 18 and back surface 15. At an upper end of handle 12 is an arm opening 13. Arm opening 13 passes from face surface 18 to back surface 15 and preferably has a square or rectangular cross-section. The longitudinal axis of arm opening 13 is perpendicular to face 18.
Arm 30, having a cross-section of the same shape as but slightly smaller than arm opening 13, is slidably received in arm opening 13. Mounted in an opening (not shown) in surface 21 of handle 12 is retention means 20. Retention means 20 is preferably a thumb screw received in a threaded opening and of such a length as to be capable of engaging arm 30 passing through arm opening 13 to fix arm 30 in position. Arm 30 preferably has a distance scale 32, either English or metric, on at least one surface.
Slidably mounted on arm 30 by means of opening 56 is contact member 50. The lower surface of contact member 50, extending below arm 30, defines contact point 52. Contact member 50 is fixed in position on arm 30 by means of thumb screw 54 or other retention means known to one skilled in the art. Although contact member 50, as shown in FIG. 2, completely surrounds arm 30, other configurations are possible so long as they allow contact member 50 to be securely fixed in position on arm 30 and ensure contact point 52 lies in a plane passing through the longitudinal axis of arm 30 and the longitudinal axis of thumb screw 54.
Adjacent an end of arm 30, opposite that passing through handle 12, is gauge stem opening 34. Gauge stem opening 34 extends parallel to handle 12 to receive stem 46 of deviation gauge 40. Upper surface 33 of arm 30 is configured to have an arc like surface 39 corresponding to the outer circumference of deviation gauge 40.
Extending from stem 46, below arm 30 is feeler point 48 which also defines a 0 point on scale 32. Feeler point 48 is movable along a line defining the longitudinal axis of stem 46 and is mechanically or electrically connected to a readout on the face of gauge 40. Feeler point 48 contacts second surface 62 of workpiece 61 at a point further removed from face 18 of handle 12 than does contact point 52 of contact member 50. Gauge 40, which may be electronic or mechanical, has means for being calibrated. The calibration means can be an adjustment mechanism 42 for bringing needle 45 into alignment with a zero point or other predetermined point of a scale on the gauge face or for placing a zero or other indication on an electric readout when the gauge is positioned on a calibration workpiece having a precise 90° corner. Alternatively, the calibration means can be a rotatable bezel ring 44 having a scale thereon which may be rotated to align the zero point and needle during calibration.
Gauge stem 46 is retained in gauge stem opening 34 by means of set screw 35 (FIGS. 3-4). Set screw 35 may extend laterally across the width of arm 30 such that with slot 37, between gauge stem opening 34 and the end of arm 30, it is capable of reducing the circumference of gauge stem opening 34 thereby tightly clamping gauge stem 46 in arm 30. Alternatively, set screw 35 may be introduced from the end of arm 30 and upon tightening fixedly engage gauge stem 46. The distance between the longitudinal axis of feeler point 48 and front surface 18 of handle 12 may be determined from scale 32.
FIG. 5 shows a second embodiment of the invention. The embodiment in FIG. 5 differs from the preferred embodiment by the inclusion of the contact member in handle 12. Contact member 29 is an extension of handle 12 in the direction toward deviation gauge 40. Extension 29 has a front face 27 which parallels face 18 of handle 12. The lower surface of extension 29 appears, in profile, like a sign wave curve consisting of recess 26 and a contact portion 28. Contact portion 28 contains contact point 52.
Measurement opening 22 is provided in handle 12 to permit determination of the distance between feeler point 48 and face 18. Immediately below measurement opening 22, and aligned with face 18, is alignment mark 24 for designating the scale 32 graduation on arm 30 for reading as a distance measurement. Alternatively, the distance between feeler point 48 and face 27 could be read from scale 32 and a known distance between face 27 and face 18 added thereto for the total distance deviation gauge 40 is displaced from workpiece surface 64.
In use, the apparatus is calibrated as discussed above in the discussion of adjustment mechanism 42 and bezel ring 44. Following calibration, front surface 18 of handle 12 is placed against first surface 64 of the workpiece. Thumb screw 20 is loosened and arm 30 positioned so as to place feeler point 48 of gauge 40 at the point to be checked. Thumb screw 20 is tightened locking arm 30 securely in position with respect to handle 12. Thumb screw 54 of contact member 50, in the preferred embodiment, is loosened and contact member 50 moved along arm 30 to a position close to but away from face 18 of handle 12 to avoid chamfers, holes or other surface discontinuities in workpiece 61 such as corner 66 shown in FIG. 1. Contact point 52 is positioned on a point lying in the plane defining the upper, or second, surface 62 of workpiece 61. So placed, the deviation registered, from the zero point, by deviation gauge 40 provides a measurement of an opposite side of a right angle triangle. The distance from feeler point 48 to surface 18, which is parallel to and is virtually collocated with first surface 64 of workpiece 61, can be read from scale 30 to provide a measurement of an adjacent side of a right angle triangle. The angular deviation from square can be determined by the expression: ##EQU1## where α is the angle of deviation.
The second embodiment is used in exactly the same manner as the first embodiment. However, fixed contact member 29 limits the use of embodiment 2 with workpieces having chamfered corners, holes, slots or other perturbations on the second surface 62 closely adjacent first surface 64.
Although certain preferred embodiments have been shown and described, it should be understood that many changes and modifications may be made therein without departing from the spirit and scope of the invention.
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This invention relates to a gauge device which may be used by a toolmaker or machinist to determine the squareness of surfaces on a workpiece. The device has a handle having a gauge mounted adjacent an end of the arm opposite the handle and an intermediate contact point such that the inner surface of the handle and the intermediate contact point define the planes of the surfaces of the workpiece to be measured. The device is easily used, easily transported, and capable of use with work-pieces having chamfered or otherwise altered corners, holes, slots or other imperfections that make determination of squareness difficult.
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FIELD OF THE INVENTION
The present invention relates to an apparatus and method for detecting space-time multi-user signal of a base station having an array antenna; and, more particularly, to an apparatus and method for detecting a space-time multi-user signal of a base station having an array antenna by estimating a vector channel impulse response based on accurately estimated space-time information, generating a system matrix based on the estimated vector channel impulse response and a user's code, and eliminating interference of the received signal by applying the system matrix to a zero forcing block linear equalizer.
DESCRIPTION OF THE PRIOR ART
Primary factors degrading a performance of a code division multiple access (CDMA) base station system are multiple access interference (MAI) and a multipath fading.
In order to cancel the primary factors degrading the performance of the CDMA base station system, a multipath fading is eliminated by using a rake receiver to properly mix a desired signal and a separable multi-path signal of the desired signal. However, the rake receiver may be the optimal receiver in single user environment and furthermore a performance of the rake receiver is seriously degraded by MAI in a multi-user environment.
As a conventional technology to eliminate MAI, a multi-user detector is used to simultaneously detect multi-user signals while cancelling interference between them.
As another conventional technology to eliminate MAI, an array antenna is used in a base station to enhance the desired signal and mitigate the interference effects from other users. The base station having the array antenna provides better performance and increase capacity than a base station using single antenna. However, the receiver of the base station having the array antenna requires a module for multiplying and combining a beamforming weight according to a rake fingers since the receiver becomes equivalent to a space-time rake receiver. Therefore, it is very difficult to implement the space-time rake receiver to support many users.
Recently, there is growing interest in a space-time multi-user detector including an array antenna and a multi-user detector for providing better performance.
An optimized receiver and a linear receiver for a CDMA system was introduced by Xiadong Wang and H. Vicent Poor in an article entitled “Space-Time Multi-user Detection in Multipath CDMA channels”, IEEE transactions on Signal Processing, vol. 47, no. 9, pp. 2356-2374, 1997. The introduced receivers include a multi-user detector and are operated based on a space-time processing method. The introduced receivers are proper to a consecutive transmission method. However, the introduced receivers require a module for multiplying an array antenna response vector to a back-diffused signal for each rake finger and combining the multiplying results because the introduced receivers cancel interference signal by allocating a rake finger to separable multipath for users using identical channel, performing a back-spreading on corresponding path of each user per each rake finger and estimating an array antenna response vector.
Another conventional technology is introduced by K. Lun and Z. Zhang in an article entitled “Combined Spatial Filter and Joint Detector” in Proceedings of International Conference on Communication, vol. 3, May, 2003. In the article, K. Lun and Z. Zhang introduces a technology for a space-time multi-user detector satisfying a zero forcing analysis algorithm in a block transmission type time division synchronized CDMA (TD-SCDMA). That is, the introduced technology obtaining a space diversity estimates a channel by using a channel estimating unit for each user per each antenna and estimates data sequence of each user through a block linear equalizer. However, a vector channel cannot be accurately estimated because of low usability of channel space information. That is, the usability of channel space information is lowered since the conventional technology estimates a channel according to each antenna.
Furthermore, anther conventional space-time multi-user detector in a block transmission type time division synchronize code division multiple access (TD-SCDMA) is introduced by J. J. Blanz, A. Papathanassiou, M, Haadrt, I. Furio, P. W. Baier in an article entitled “Smart Antenna for Combined DOA and Joint Channel Estimation in Time-Slotted CDMA Mobile Radio System with Joint Detection”, in IEEE Transaction on Vehicular Technology, vol. 49, no. 2, pp. 293-306. Another conventional space-time multi-user detector is a combination of a beam former and a multi-user detector. That is, another conventional space-time multi-user detector eliminates ISI and MAI through combined signals per each user after estimating directivities of all users based on signal received from each antenna and forming a beam for multipath of each user. Since the conventional space-time multi-user detector is additionally included in a space-time rake receiver, a module multiplying and combining beamforming weight vector per a rake finger is additionally required. Therefore, it is also difficult to implement a base station to support many users.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide an apparatus and method for detecting a space-time multi-user signal of a base station having an array antenna by estimating a vector channel impulse response based on accurately estimated space-time information, generating a system matrix based on the estimated vector channel impulse response and a user's code, and eliminating interference of the received signal by applying the system matrix to a zero forcing block linear equalizer.
In accordance with one aspect of the present invention, there is provided an apparatus for detecting a space-time multi-user signal in a base station having an array antenna, including: a radio frequency (RF)/intermediate frequency (IF) processing unit for converting received signals through an array antenna into digital baseband signals by over-sampling each received signal corresponding to each antenna; a data/reference splitting unit for receiving the digital baseband signals and dividing the digital baseband signals into data signals and reference signals; a channel estimating unit for receiving the reference signals and estimating a delay time information of paths for each user and a channel impulse response corresponding to each path per antenna; a beamforming weight vector generating unit for receiving the reference signals and the delay time information of to thereby generate a beamforming weight vector of each path; a system matrix generating unit for receiving the channel impulse response and the beamforming weight vector to there by generate a system matrix and calculating a correlation matrix of the system matrix for each antenna and a sum of the correlation matrix; a code matched filter BANK unit for receiving the data signals and the system matrix to multiply the system matrix to the data signals per each antenna; a antenna combining unit for combining signals outputted from the code matched filter BANK unit; and an interference cancelling unit for cancelling an interference signal of output of the antenna combining unit by using the sum of the correlation matrix.
In accordance with another aspect of the present invention, there is provided a method for detecting a space-time multi-user signal, including the steps of: a) converting received signals through an array antenna to digital baseband signals; b) dividing the digital baseband signals to data signals and reference signal signals; c) estimating a delay time information of paths for each user and a channel impulse response corresponding to each path per antenna by using the reference signals; d) generating a beamforming weight vector of each path by using the reference signals and the delay time information; e) generating a system matrix of each antenna by using the channel impulse response and the beamforming weight vector and calculating a correlation matrix of the system matrix for each antenna and a sum of the correlation matrix; f) multiplying a transpose matrix of a system matrix for each antenna and a received sequence by using the data signals and a the system matrix, and combining the multiplying results; and g) obtaining a transmitted sequence value by cancelling an interference by multiplying the combined value and an inverse matrix of the sum of the correlation matrix.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present invention will become apparent from the following description of the preferred embodiments given in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram illustrating an apparatus for detecting a space-time multi-user signal in an array antenna base station in accordance with a preferred embodiment of the present invention;
FIG. 2 is a detailed diagram illustrating an apparatus for detecting a space-time multi-user signal in an array antenna base station in accordance with a preferred embodiment of the present invention;
FIG. 3 is a diagram for explaining a structure of a system matrix of an antenna in an apparatus for detecting a space-time multi-user signal in accordance with a preferred embodiment of the present invention;
FIG. 4 is a graph for explaining a channel impulse response vector of each user in an apparatus for detecting a space-time multi-user signal in accordance with a preferred embodiment of the present invention;
FIG. 5 is a flowchart of generation of a system matrix in a method for detecting a space-time multi-user signal in an array antenna base station in accordance with a preferred embodiment of the present invention; and
FIG. 6 is a flowchart of a method for detecting a space-time multi-user signal in an array antenna base station in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
At first, a space-time multi-user detector in a base station using an array antenna will be explained by using below equations.
It assumes that a base station having a linear array with K a antenna elements provides services to K users simultaneously. If a data block transmitted by k th user is d (k) =[d 1 (k) , d 2 (k) , . . . , d Nk (k) ] T when each user transmits N k data symbols, a sum of data symbols of all users is expressed as N t . The data block sequence d of K users can be expressed by following Eq. 1.
d =[ d (1)T , . . . , d (2)T , . . . , d (K)T ] T =[ d 1 (1) ,d 2 (1) , . . . ,d N 1 (1) ,d 2 (2) ,d N 2 (2) , . . . ,d 1 (K) ,d 2 (K) , . . . ,d N K (K) ] T Eq. 1
Also, each data symbol is spread by a user's unique spreading code c q (k) ,q=1,2, . . . ,Q k ,k=1,2, . . . ,K which has a length of Q k . Therefore, a chip sequence transmitted data block of each user can be expressed as following Eq. 2.
s
_
i
(
k
)
=
∑
n
=
1
N
k
d
_
n
(
k
)
c
_
i
-
(
n
-
1
)
Q
k
(
k
)
,
i
=
1
,
2
,
…
,
N
c
Q
c
;
Eq
.
2
k
=
1
,
2
,
…
,
K
In Eq. 2, N c Q c is the number of chips during a data block, and it becomes identical for all users within a base station.
It assumes that the W is the maximum delay spread assumed integer multiple of chip period, the W-paths fading channel impulse response vector of each user can be written by W×1 vector g (k) ,k=1,2, . . . ,K, where the element of g (k) ,k=1,2, . . . ,K is the complex Rayleigh fading gain of the multipaths of k th user.
Also, if an array response of k a th antenna of k th user for all path is W×1 vector a (k,k a ) ,k=1,2, . . . ,K,k a =1,2, . . . ,K a , a vector channel impulse response h (k,k a ) of k a th antenna is W×1 vector expressed as following Eq. 3.
h (k,k a ) = g (k) ∘ a (k,k a ) ,k=1,2, . . . ,K a Eq. 3
where ∘ denotes element-wise product.
Considering the received signal model of a data block except a reference signal, the received sequence of k a th antenna is the sum of the convolution of the transmitted chip sequence of length N c Q c with the vector channel impulse response h (k,k a ) , and perturbed by noise sequence n (k a ) of length N c Q c +W−1,
e
_
i
(
k
a
)
=
∑
k
=
1
K
h
_
(
k
,
k
a
)
*
s
_
i
(
k
)
+
n
_
i
(
k
a
)
=
∑
k
=
1
K
∑
w
=
1
W
∑
n
=
1
N
k
a
_
w
(
k
,
k
a
)
g
_
w
(
k
)
d
_
n
(
k
)
c
_
i
-
(
n
-
1
)
Q
k
-
w
+
1
(
k
)
+
n
_
i
(
k
a
)
,
i
=
1
,
2
,
…
,
N
c
Q
c
+
W
-
1
Eq
.
4
The total received sequence e of length K a (N c Q c +W−1) at all K a antennas is expressed as e = A · d + n .
where, A is called a system matrix of K a (N c Q c +W−1)×N t , which elements consist of the convolution of a vector channel impulse response h (k,k a ) with a unique spreading code of a user. And a vector n is the combined noise vector at all K a antennas with noise covariance matrix R nn =E{ nn H }
In order to estimate a transmitted sequence d based on a total received sequence, a zero forcing block linear equalizer (ZF-BLE) is generally used. The zero forcing block linear equalizer obtains d that maximizes a likelihood ratio function. The estimation value {circumflex over (d)} can be calculated by following Eq. 5.
{circumflex over (d)} =( A H R nn −1 A ) −1 A H R nn −1 e Eq. 5
A space-time multi-user detector according to the present invention is constructed by simplifying Eq. 5 to a below Eq. 6 through assuming a noise covariance matrix as R nn =σ n 2 I.
d
_
^
=
(
A
_
H
A
_
)
-
1
A
_
H
e
_
︸
–
z
Eq
.
6
In the present invention, a base station can detects a transmitted sequence of space-time multi-user by using a mathematical method and a space-time multi-user detection apparatus according to the present invention will be explained with reference to the above mentioned equations and accompanying drawings.
FIG. 1 is a diagram illustrating an apparatus for detecting a space-time multi-user signal in a base station using an array antenna in accordance with a preferred embodiment of the present invention.
As shown in FIG. 1 , the apparatus for detecting a space-time multi-user signal includes a RF/IF processing unit 10 , a data/reference splitting unit 20 , a channel estimating unit 30 , a beamforming weight vector generating unit 40 , a system matrix generating unit 50 , a code matched filter BANK unit 60 , a antenna combining unit 60 and an interference cancelling unit 80 .
The RF/IF processing unit 10 converts a signal received through an array antenna to a digital baseband signal by over-sampling the received signal according to each antenna.
The array antenna includes K a antenna array elements.
The data/reference splitting unit 20 generates a signal vector of a chip rate through decimation by receiving the digital baseband signal from the RF/IF processing unit 10 , and divides to data and a reference signal.
The channel estimating unit 30 receives the reference signal from the data/reference splitting unit 20 and estimates a delay time information of each path of each user, and estimates a channel impulse response of each path of each user per each antenna.
Details of the channel estimating unit 30 are shown in FIG. 2 . The channel estimating unit 30 includes a delay time estimator 31 and a channel estimator 32 . The delay time estimator 31 estimates the delay time information of each path of each user from the reference signal vector from the data/reference splitting unit 20 and the channel estimator 32 estimates a channel impulse response for each path of each user per each antenna.
The beamforming weight vector generating unit 40 receives the reference signal from the data/reference splitting unit 20 and the delay time information from the channel estimating unit 30 , and calculates a beamforming weight vector for each path of each user's.
As shown in FIG. 2 , the beamforming weight vector generating unit 40 includes a reference signal generator 41 and a vector generator 42 . The reference signal generator 41 generates a reference signal of each user and the vector generator 42 generates a beamforming weight vector for each path of each user by using reference signal vectors received through each antenna and the generated reference signal from the vector generator 42 based on the delay time information from the channel estimating unit 30 .
The system matrix generating unit 50 receives the channel impulse response of each path of each user from the channel estimating unit 30 and the beamforming weight vector from the beamforming weight vector generating unit 40 , and makes a system matrix for each antenna and calculates a correlation matrix of the system matrix for each antenna, and adds the correlation matrix of each antenna.
As shown in FIG. 2 , the system matrix generating unit 50 includes a vector channel response estimator 51 , a code generating unit 52 , a convolution unit 53 , a multipath mixer 54 , a system matrix generator 55 and a system correlation matrix generator 56 .
The vector channel response estimator 51 estimates a vector channel impulse response for each path of each user and code generating unit 52 generates a spreading code of each user.
The convolution unit 53 generates a column vector by convoluting each user's code from the code generating unit 52 and the vector channel impulse response from the vector channel response estimator 51 for each path of each user per each antenna.
After generating the column vector, the multipath combiner 54 combines the column vector to the multipath according to each path and the system matrix generator 55 obtains a matrix per each antenna by consisting of the combined column vector.
The system correlation matrix generating unit 56 obtains a correlation matrix of the system matrix per each antenna by using a system matrix generated at the system matrix generator 55 and calculates a sum of the correlation matrices.
The system matrix generated from the system matrix generator 55 is transferred to the code matched filter BANK unit 60 and the sum of correlation matrices of the system matrix is transferred to the interference cancelling unit 80 .
The code matched filter BANK unit 60 receives the data from the data/reference splitting unit 20 and the system matrix A from the system matrix generating unit 50 and multiplies a Hermitian transpose matrix of the system matrix for each antenna with a received sequence e .
The antenna combining unit 70 combines outputs from K a code matched filters of the code matched filter BANK unit 60 .
That is, the code matched filter BANK unit 60 and the antenna combining unit 70 are operated as z = A H e in Eq. 6
The interference cancelling unit 80 cancels interference signal by using the sum of the correlation matrices from the system matrix generating unit 50 and a combined vector from the antenna combining unit 70 . That is, the interference signal cancelling unit 80 performs operations expressed as ( A H A ) −1 z in Eq. 1 and obtains a transmitted sequence estimating value d by receiving the sum of the correlation matrixes of a system matrix of each antenna from the system matrix generating unit 50 , calculating a inverse matrix of the sum of the correlation matrices and multiplying the inverse matrix to outputs of the antenna combining unit 70 .
The channel estimating unit 30 , the beam weight vector generating unit 40 and the system matrix generating unit 50 will be explained in detail with reference to FIGS. 3 to 5 .
The system matrix A is a matrix of K a (N c Q c +W−1)×N t constructed with column vectors each of which is a user's vector channel impulse response convoluted with a user's unique spreading code. The convolution of a user's unique spreading code c (k) of a k th user of a k a th antenna in one data symbol period and a user's vector channel impulse response h (k,k a ) is shown in Eq. 7.
b
_
(
k
,
k
a
)
=
c
_
(
k
)
*
h
_
(
k
.
k
a
)
=
(
b
1
(
k
,
k
a
)
b
2
(
k
,
k
a
)
⋯b
Q
k
+
W
-
1
(
k
,
k
a
)
)
T
,
Eq
.
7
k
a
=
1
,
2
,
⋯
,
K
a
,
k
=
1
,
2
,
⋯
,
K
All of users K for k a th antenna and a matrix A (k a ) for N k ,k=1,2, . . . ,K can be constructed as below Eq. 8.
A
(
k
a
)
=
(
A
ij
(
k
a
)
)
,
i
=
1
,
2
,
…
,
N
c
Q
c
+
W
-
1
;
j
=
1
,
2
,
…
,
K
t
A
Q
k
·
(
n
-
1
)
+
l
,
N
k
·
(
k
-
1
)
+
n
(
k
a
)
=
{
b
_
l
(
k
,
k
a
)
for
n
=
1
,
2
,
…
,
N
k
;
l
=
1
,
2
,
…
,
Q
k
+
W
-
1
;
k
=
1
,
2
,
…
,
K
0
else
Eq
.
8
FIG. 3 shows a structure of a system matrix A (k a ) of k a th antenna based on Eq. 8. If the number of users is 2 (K=2), a size of data block of 1 st user is 3 (N 1 =3), a spreading factor is 2 (Q 1 =2), a size of data block of 2 nd user is 2 (N 2 =2) and a spreading factor is 3 (Q 2 =3), and a maximum delay spread is 6 chips (W=6), a channel impulse response of the user is shown in FIG. 4 and a structure of a system matrix A (k a ) for k a th antenna is shown below.
A
_
(
k
a
)
=
[
b
1
(
1
,
k
a
)
b
2
(
1
,
k
a
)
b
3
(
1
,
k
a
)
b
1
(
1
,
k
a
)
b
4
(
1
,
k
a
)
b
2
(
1
,
k
a
)
b
5
(
1
,
k
a
)
b
3
(
1
,
k
a
)
b
1
(
1
,
k
a
)
b
6
(
1
,
k
a
)
b
4
(
1
,
k
a
)
b
2
(
1
,
k
a
)
0
b
5
(
1
,
k
a
)
b
3
(
1
,
k
a
)
b
6
(
1
,
k
a
)
b
4
(
1
,
k
a
)
0
b
5
(
1
,
k
a
)
b
6
(
1
,
k
a
)
0
0
b
2
(
2
,
k
a
)
b
3
(
2
,
k
a
)
b
4
(
2
,
k
a
)
0
b
5
(
2
,
k
a
)
b
2
(
2
,
k
a
)
b
6
(
2
,
k
a
)
b
3
(
2
,
k
a
)
b
7
(
2
,
k
a
)
b
4
(
2
,
k
a
)
b
8
(
2
,
k
a
)
b
5
(
2
,
k
a
)
b
6
(
2
,
k
a
)
b
7
(
2
,
k
a
)
b
8
(
2
,
k
a
)
]
A
_
1
(
k
a
)
A
_
2
(
k
a
)
As shown, a system matrix A (K a ) of k a th antenna can be obtained as a user's code and a vector channel impulse response and it can be used as the system matrix in regardless of synchronization of each user's signal.
Since the user's code is already known, the vector channel impulse response can be obtained in the system matrix generating unit 50 through output of the channel estimating unit 30 and the beamforming weight vector generating unit 40 .
Hereinafter, generation of a system matrix will be explained with reference to FIG. 5 .
FIG. 5 is a flowchart showing generation of a system matrix in a method for detecting a space-time multi user in an array antenna base station in accordance with a preferred embodiment of the present invention.
The channel estimating unit 30 extracts a delay time information for each path of each user from a reference signal vector received according to each antenna, which is divided from the data/reference splitting unit 20 at step S 511 .
The channel estimating unit 30 estimates a channel impulse response h a (k,k a ) ,k=1,2, . . . ,K,k a 1,2, . . . ,K a for each path of each user per each antenna at step S 512 .
The beamforming weight generating unit 40 generates a reference signal of each user by receiving the delay time information for the each path of each user from the channel estimating unit 30 at step S 513 .
The beamforming weight vector generating unit 40 generates a beamforming weight vector of each path of each user by using a reference signal vector extracted according to the delay time information and a reference signal of each user at step S 514 .
That is, the beamforming weight vector generating unit 40 generates the beamforming weight reference vector w (k,k a ) ,k=1,2, . . . ,K,k a =1,2, . . . ,K a by using various algorithms requiring the reference signal such as a sample matrix inversion (SMI) algorithm, a normalized-least mean square (N-LMS) algorithm, a recursive least square (RLS) algorithm or a maximal ratio combining algorithm.
The system matrix generating unit 50 estimates W×1 of each user's vector channel impulse response from the channel impulse response vector and the beamforming weight vector from the channel estimating unit 30 and the beamforming weight vector generating unit 50 at step S 515 .
The channel impulse response vector ĝ (k) can be expressed as below Eq. 9 and each user's vector channel impulse response ĥ (k,k a ) can be expressed as below Eq. 10.
g
_
^
(
k
)
=
∑
k
a
=
1
K
a
w
_
a
(
k
,
k
a
)
*
·
h
_
a
(
k
,
k
a
)
,
k
=
1
,
2
,
…
,
K
Eq
.
9
h
_
^
(
k
,
k
a
)
=
w
_
(
k
,
k
a
)
·
g
_
^
(
k
)
,
k
=
1
,
2
,
…
,
K
,
k
a
=
1
,
2
,
…
,
K
a
Eq
.
10
The system matrix generating unit 50 generates a spreading code of each user at step S 516 .
The system matrix generating unit 50 generates a column vector by convoluting the vector channel impulse response of each user and a code of each user at step S 517 .
The column vectors are combined according to a path at step S 518 . That is, the system matrix generating unit 50 b (k,k a ) ,k=1,2, . . . ,K,k a =1,2, . . . ,K a by combining W column vectors for each path.
The system matrix generating unit 50 obtains a system matrix of each antenna by combining the column vectors at step S 519 . That is, the system matrix generating unit 50 obtains system matrix A (k a ) ,k a =1,2, . . . ,K a of each antenna to be suitable to the b (k,k a ) , the known number of the users and the number of data symbols of each user.
FIG. 6 is a flowchart showing a method for detecting a space-time multi-user in a base station having an array antenna in accordance with a preferred embodiment of the present invention.
At first, the RF/IF processing unit 10 converts a received signal through the array antenna to a digital baseband signal by over-sampling the received signal according to each antenna at step S 610 .
The data/reference splitting unit 200 generates a chip rate of signal vector by decimating the received signal and divides data and a reference signal at step S 620 .
The channel estimating unit 30 estimates a channel impulse response for each path of each user and a delay time information of each path of each user by using the reference signal, and the beamforming weight vector generating unit 40 calculates the beamforming weight vector for the each path of each user by using the reference signal and the delay time information at step S 630 .
The system matrix generating unit 50 receives the channel estimating value and the beamforming weight vector, generates a system matrix per each antenna and obtains a sum of correlation matrixes of system matrix at step S 640 .
Since obtaining of the system correlation matrix is already described with reference to FIG. 5 , detailed explanation of the steps 630 and 640 is omitted.
The code matched filter BANK unit 60 receives system matrixes ( A (k a ) ,k a =1,2, . . . ,K a ) of each antenna and data of the received signal, and multiplies Hermitian transpose matrix and the receiving sequence ( e ) at step S 650 .
The antenna combining unit 70 receives signals outputted from the code matched filter BANK unit 60 and combines the outputted signals at step S 660 .
The interference cancelling unit 80 receives the sum of the correlation matrix of each antenna from the system matrix generating unit 50 , calculates a inverse matrix of the sum of the correlation matrix and obtains the transmitted sequence estimating value by multiplying the inverse matrix to outputs of the antenna combining unit 70 to cancel the interference at step S 670 .
As described above, a space-time multi-user detector according to the present invention estimates a vector channel based on a received signal through an array antenna, forms a system matrix by using the estimated vector channel and a user's code and applies the system matrix to a zero forcing algorithm. Accordingly, the space-time multi-user detector according to the present invention is easy to implement compared to a conventional rake receiver based space-time multi-user detector with a module multiplying and combining beamforming weight vectors according to a rake finger.
Also, the space-time multi-user detector according to the present invention accurately estimates space information of a channel by estimating a vector channel based on a received signal through an antenna. Therefore, a performance of the space-time multi-user detector is dramatically increased.
Furthermore, the space-time multi-user detector according to the present invention can be used as a space-time multi-user detector in synchronous or asynchronous CDMA systems.
The present application contains subject matter related to Korean patent application No. 2004-0103776, filed with the Korean Patent Office on Dec. 9, 2004, the entire contents of which being incorporated herein by reference.
While the present invention has been described with respect to the particular embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the scope of the invention as defined in the following claims.
|
An apparatus and method for detecting a space-time multi-user signal are disclosed. The apparatus includes: an RF/IF processing unit for converting received signals through an array antenna into digital baseband signals; a splitting unit for dividing the digital baseband signals into data signals and reference signals; a estimating unit for estimating a delay time information and a channel impulse response; a vector generating unit for receiving the reference signals and the delay time information of to thereby generate a beamforming weight vector; a matrix generating unit for receiving the channel impulse response and the beamforming weight vector to there by generate a system matrix; a filtering unit for receiving the data signals and the system matrix to multiply the system matrix to data per each antenna; a antenna combining unit for combining signals outputted from the filtering unit; and an interference cancelling unit for cancelling an interference signal.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present Application is based on International Application No. PCT/EP2006/061944, filed on Apr. 28, 2006, which in turn corresponds to France Application No. 05 04378 filed on Apr. 29, 2005, and priority is hereby claimed under 35 USC §119 based on these application. Each of these applications are hereby incorporated by reference in their entirety into the present application.
FIELD OF THE INVENTION
[0002] The present invention relates to a roaming electronic transaction terminal. It also relates to a secure system for electronic transactions comprising one or more roaming terminals. The invention applies notably for the securing of terminals carrying out checks and contractual transactions on supports equipped with memories, it being possible for these supports to be through contactless read and write cards comprising for example transport entitlements, payment means or any other entitlements to be turned to account.
BACKGROUND OF THE INVENTION
[0003] An example of electronic transactions using contactless cards relates to transport entitlements. These cards allow users to access means of transport by passing the former across readers placed at the entry points of stations or on entry to vehicles. The entitlements are realized and stored in the memory of the cards. Just as for conventional means, of the type for example of the orange cards in the Paris region, the entitlements stored in the cards correspond to various types of subscription or contracts as a function notably of the geographical area covered, the capacity of the user and the duration. Checking the validity of a subscription requires particular means contrary to a conventional paper entitlement where the characteristics of the subscription are visible. Notably, electronic reading means making it possible to read the content of the contract stored in a card are required. The agents in charge of checking transport entitlements must therefore be permanently equipped with apparatus for reading electronic supports such as memory cards for example.
[0004] These agents, the inspectors, must also have the capability of issuing transport entitlements or of modifying the contracts, for example the subscriptions. Their apparatuses must therefore also be capable of reading and writing the data registered in the memory of the cards.
[0005] These reading and writing apparatuses can also be used in fixed points of sale for example at newsagents that are authorized to issue transport entitlements. In particular the users must be able to reload their cards in these fixed points of sale.
[0006] The problem of security arises in regard to agents or points of sale, at newsagents for example. It is necessary in particular to prevent the utilization of electronic transactions in the event of theft of these reading and writing terminals which are generally of roaming type, be they carried by agents or installed in points of sale.
SUMMARY OF THE INVENTION
[0007] An aim of the invention is notably to prevent any malicious or fraudulent use of an electronic transaction terminal. For this purpose, the subject of the invention is a roaming electronic transaction terminal comprising an application package support and a coupler for carrying out the read and write operations on a medium that are required for the electronic transactions in conjunction with the application package. The coupler comprises means for creating a write time window and a read time window on the basis of a secure input signal, all writing and all reading being disabled outside of the corresponding windows.
[0008] In a particular embodiment, the coupler comprises a clock, a first register for counting the time of the read time window and a second register for counting the time of the write time window, the registers being initialized as a function of the secure signal. The value of the first register is compared with a first value REG_R defining the read time window and the value of the second register is compared with a second value REG_W defining the write time value, reading being disabled when the value of the first register reaches the first value REG_R and writing being disabled when the value of the second register reaches the second value REG_W.
[0009] Advantageously, the read time window and the write time window have different values. The write time window is for example less than the read time window.
[0010] The exchanges with the coupler are done for example according to two channels:
the coupler and the application package support communicate with one another through a confidential link; the coupler communicates with an exterior checking facility ( 5 ) through a secure link; the key Kv that makes it possible to open the confidential session being generated by the coupler, the opening of a confidential session being carried out by mutual identification by means of the key Kv. Advantageously, this key Kv is provided to the application package support by way of the exterior checking facility.
[0013] The link between the coupler and the checking facility passes for example through the application package support which comprises a routing program for routing the data from the coupler to the checking facility.
[0014] The secure signal giving rise to the initialization of the write and read time windows is for example generated by the opening of a communication session between the coupler and the checking facility. A time window can for example be initialized by a coded signal input on the application package support. Advantageously, only the write time window can be initialized by a signal input on the application package support.
[0015] Advantageously, the application package support and the coupler each comprise for example a log of the electronic transactions performed in a given period, the logs being dispatched to a checking facility which performs a reconciliation of the logs, a reconciliation defect revealing a missing or falsified transaction.
[0016] The invention also relates to a secure system for electronic transactions composed of a checking facility and of one or more terminals such as that previously described. Advantageously, the checking facility and the coupler communicates in the form of a secure session by mutual authentication based on a key contained in the checking facility and in the coupler.
[0017] The main advantages of the invention are that it secures the use of a roaming electronic transaction terminal, that it makes it possible to detect the loading of fraudulent data or software onto this type of terminal and to prevent the use thereof, and that it is suited to all types of electronic transaction applications.
[0018] Still other objects and advantages of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein the preferred embodiments of the invention are shown and described, simply by way of illustration of the best mode contemplated of carrying out the invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious aspects, all with out departing from the invention. Accordingly, the drawings and description thereof are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The present invention is illustrated by way of example, and not by limitation, in the figures of the accompanying drawings, wherein elements having the same reference numeral designations represent like elements throughout and wherein:
[0020] FIG. 1 , through a schematic an electronic transaction terminal according to the invention;
[0021] FIG. 2 , an illustration of a possible embodiment of a system and of a terminal according to the invention;
[0022] FIG. 3 , an example of relative durations of a write time window and of a read time window.
DETAILED DESCRIPTION OF THE INVENTION
[0023] FIG. 1 presents through a schematic a roaming electronic transaction terminal according to the invention. The terminal 1 comprises an application package support 2 and a coupler 3 . The support 2 and the coupler 3 exchange data through a link 4 . The terminal can dialog with a server 5 through a link 6 . The application package carried by the support 2 processes for example an entire ticketing application, going for example from the checking of entitlements to the issuing of entitlements and to the generation or modification of subscription contracts. The support 2 is for example of the pocket computer type more commonly called a PDA. The coupler 3 comprises notably the function of reading the content of an electronic support and/or the function of writing to this same support. This electronic support is for example a contactless intelligent card with read and write capability. The coupler is not dedicated as such to a particular application, it is a simple read and write peripheral for a contactless card for example.
[0024] Subsequently in the description and by way of example reference will be made to a ticketing application. The coupler 3 will be called the ticketing coupler and will be intended to perform reading and writing operations on contactless cards, the latter comprising the entitlements checked or issued by the application. Still within the framework of an exemplary application, the entitlements in question will be transport entitlements and the application support will be of the PDA type carried by an agent. When he is on an assignment, this agent will therefore be equipped with the PDA 2 and the ticketing coupler 3 .
[0025] FIG. 2 presents by a more detailed schematic an exemplary embodiment of a terminal 1 according to the invention. The terminal 1 is an apparatus for checking and selling realized transport entitlements, stored on cards with contactless reading. It comprises a PDA 2 and a ticketing coupler 3 . The PDA 2 comprises the ticketing application program 21 . This application handles for example the checking of the transport entitlements stored in the contactless cards as well as the issuing of entitlements. It also handles subscription contract modifications or renewals. An entitlement check is done through a card reading operation. An entitlement or contract modification/renewal is issued through an operation of reading and writing on the card. The nature and the duration of a subscription are stored on a card through a write operation. To determine the price to be payed by the user a read operation may be necessary to verify the user's characteristics, his rights to a reduction for example. To handle all the ticketing operations the application package 21 contained in the PDA stores for example all the types of contracts by types of user, by durations, by geographical areas, by transport means etc.
[0026] The PDA exchange data with the coupler 3 through a link 4 . This link can be wireless, of the “bluetooth” type for example. On initialization, the application or a part of the ticketing application is loaded into the coupler through this link 4 into a memory space 22 envisaged for this purpose. The terminal 1 additionally comprises a link 6 with a server 5 .
[0027] The link 4 between the PDA 2 and the coupler 3 therefore allows exchange of data between these two elements. The confidentiality of the exchanges between the coupler and the PDA is ensured by a key Kv which serves for mutual identification. The key Kv serves for mutual identification for example through exchange of randomly drawn keys. It is for example changed regularly on the initiative of the coupler or PDA. In one mode of operation, this key Kv is for example renewed randomly by the coupler and provided to the PDA. Thus, a key Kv i+1 is for example dispatched to the PDA enciphered with the previous session key Kv i . For this purpose, the coupler 3 comprises a program 23 for managing this key Kv, notably for random generation of the various keys Kv i , of which it is composed. The PDA not being supposed reliable, this key is simply confidential.
[0028] The coupler 3 is the secure element of the roaming terminal 1 . It comprises for example a ticketing application for reading and writing entitlements, the ticketing processing being implemented additionally by PDA. Only the coupler 3 can execute the operations for reading and writing contactless cards that are necessary for the electronic ticketing transactions.
[0029] The link 6 between the terminal 1 and the server 5 allows notably the exchanging of data between the coupler 3 and the server 5 . The connection between the coupler and the server is for example secured by mutual authentication based on keys Kab 24 , 25 contained in the server 5 and in the coupler 3 . The authentication complies for example with the ISO 9798-2 protocol. The coupler and the server being supposed reliable, these keys are secret. The PDA 2 can serve as communication relay between the coupler and the server. It comprises for example for this purpose a routing program 26 . The exchanges that it routes by way of this program 26 are therefore encrypted by the key Kab and are therefore known only to the ends of the chain, namely the coupler 3 and the server 5 .
[0030] The coupler 3 is considered to be a peripheral from the ticketing point of view. However it is not as such dedicated to a ticketing application. The application depends notably on the software loaded into the memory 22 of the coupler dedicated to the application. It is possible to load all types of application, in particular other than ticketing.
[0031] The electronic transactions are done with the coupler. It acts as read and write peripheral. Specifically it reads the cards and writes to the cards that are necessary for the ticketing application, while the PDA processes these ticketing applications in particular it performs the processing of the transport entitlements such as sales or issuing of entitlements or sales or modifications of subscriptions for example.
[0032] The coupler communicates with the PDA and with the server. Its links with the exterior are therefore made through two channels:
in the form of a secure session through the key Kab with the server 5 via the coupler-server link 6 ; in the form of a confidential session through the key Kv with the PDA 2 via the coupler-PDA link.
[0035] The confidential session prevents a coupler that is not paired with a PDA from being operated. The confidential session is established across the link 4 between the coupler and the PDA. If the PDA does not know the key Kv generated by the coupler 3 , the opening of sessions between the PDA and the coupler is not possible. The two elements 2 , 3 cannot be paired and the terminal 1 does not operate.
[0036] The secure session 6 is notably the only one which makes it possible to reload the internal data necessary for the operation of the coupler, that is to say notably the application package. It makes it possible therefore to load the application software 22 specific to the coupler, in the case of the example of FIG. 2 , and the other necessary internal data. Through this secure session, the server 5 also makes it possible to pair the coupler and the PDA by providing the confidential key Kv to the PDA, when the coupler gives it the key under session secured by key Kab. In particular in the case where the PDA has lost its key Kv, the means of retrieving it is to connect to the server in a manner that is made secure through the coupler-server link 6 . This holds notably in the case of the first initialization where the server reloads the key Kv into the PDA after having taken cognizance thereof on the part of the coupler under secure session obtained with the key Kab.
[0037] This secure session also makes it possible to open an operating time window for the coupler.
[0038] In particular, the coupler 3 comprises a real time clock 27 and registers for storing values of read time windows 10 and write time windows 11 . The coupler 3 also comprises temporal registers 28 , 29 associated with the clock 27 for measuring time intervals. More particularly a first temporal register 28 is allotted to the counting of the time of the read time window and a second temporal register 29 is allotted to the counting of the time of the write time window. The clock and its associated registers 28 , 29 work even when no voltage is applied. When the link is established between the server 5 and the coupler 3 by mutual authentication, the registers 28 , 29 are initialized to the value of the clock 27 , equal to REG H. For this purpose the clock 27 is for example a counter incremented by edges of a quartz oscillator. When operational, the coupler compares the value REG_R and REG_W of these registers 28 , 29 with the data the value REG_H of the clock 27 plus respectively T_R and T_W recorded in the registers 10 , 11 . These data T_R and T_W respectively define the value of the read time opening and of the write time opening. When the value REG_W of the register 29 dedicated to writing exceeds for example the value REG_H+T_W the coupler is write disabled. It can then no longer execute subscription or ticket sale operations, or else contract modification operations for example. When the value REG_R of the register 28 dedicated to reading exceeds for example the value REG_H+T_R the coupler is read disabled. It can then no longer execute checking operations. T_W can for example be fixed at a day and T_R can for example be fixed at a week.
[0039] FIG. 3 illustrates through two timecharts an exemplary time window 31 for writing and an exemplary time window 32 for reading. By virtue of the clock 27 the coupler stores the instant of the last initialization of the temporal registers 28 , 29 . This initialization is performed at an instant t 0 during a communication established with the server 5 . On the occasion of this initialization, the server can also modify the values of the registers 10 , 11 defining the time windows. In fact, during a communication session with the server 5 , the following data can be reloaded:
application software, for example ticketing software; the values T_R and T_W of the durations of the read and write time windows.
[0042] Thus upon the establishment of a communication by mutual authentication between the server 5 and the coupler 3 , a write time window is initialized and a read window is initialized. Beyond the first window any write operation is impossible and beyond the second window any read operation is impossible. An agent can thus connect the coupler 3 to the server 5 at the start of an assignment for example. Then he disconnects and goes off to his assignment. If his terminal 1 is stolen or lost, the ticket or subscription contract sales operations will not be able to exceed 24 hours counting from the initialization connection to the server. Likewise beyond a week any read operation will be impossible. These durations of read and write time windows can of course be parametrized as a function of the type of assignment.
[0043] In the example of FIG. 3 the durations of the time windows do not have the same duration for writing and reading. For certain applications these windows could be of the same durations. An advantage afforded by different window durations 31 , 32 is flexibility of use. The case of an agent checking and issuing transport entitlements illustrates notably this advantage. At the instant to the agent connects his terminal 1 to the server. More particularly the coupler 3 enters into communication with the server 5 . The time window for writing is then open for example for a duration of 24 hours and the time window for reading is then open for a duration of a week. In this case it is possible to envisage the capability of resetting the temporal register 29 envisaged for the write time window a certain number of times without direct connection to the server. The agent can then telephone a service which obtains a code for him for resetting this temporal register 29 , the time window being reinitialized for 24 hours. The operation can be repeated over a week, the duration for which the read time window 32 is open. This window 32 requires a connection to the server 5 so as to be reinitialized. Advantageously, an agent who lives far away from the place where the server 5 is stored does not need to travel every day to reinitialize the time window for writing at the server or in proximity. Beyond a week any use of the terminal is nevertheless impossible since the time window for reading is closed and it can only be reactivated by a connection by mutual authentication to the server. In case of malfunction of the clock or the temporal registers, a system is for example designed to disable the operation of the coupler. In the exemplary embodiment of FIG. 2 the initialization of the write 31 and read 32 time windows is done through a secure connection to the server 5 . Thus in this case, the initializations of the time windows are done through a secure signal originating from a server or from any other exterior facility. However it is possible to envisage another initialization mode, operating for example in parallel. This secure signal can also be entered in the form of a code input by an agent or a user to the coupler, notably and in an advantageous manner for opening the write window 31 .
[0044] The coupler 3 comprises for example additionally a register 12 which comprises the log of the transactions performed by the coupler 3 during a given period limited or otherwise. Said register stores in this log 12 all the cards that it has processed. In particular for each transaction it can store a sequence number 121 , an operation code 122 and a physical number of the card 123 or any other code for identifying the card. This log is dispatched by secure session to the server 5 , for example each time the coupler is placed in communication by mutual authentication with the server. As indicated previously the secure session can be effected through the link 6 between the coupler and the server through the use of the key Kab.
[0045] The PDA 2 likewise comprises a log of the transactions 13 during a given period, limited or otherwise. It involves the transactions performed by PDA itself. The transactions held in this log are stored at each transaction performed by the PDA 2 . The log 13 of the PDA comprises for each stored transaction the sequence number 131 seen from the PDA, the number 132 of the PDA or any other identifier of the latter and the physical number 133 of the card which is the subject of the transaction or any other code making it possible to identify this card. The identifier of the card is dispatched by the coupler via the link 4 . The transactions stored by the PDA correspond to the transactions stored by the coupler.
[0046] The logs 12 , 13 comprise for example the instant of each transaction, the instant being for example provided by the clock 27 of the coupler 3 . The log 13 can be dispatched regularly to the server 5 , for example by way of the link 6 between the coupler 3 and the server 5 which passes through the PDA. The log 13 of the PDA can also be dispatched by any other means to the server, for example by telephone link or by network.
[0047] The server thus has the two logs of the transactions, the log 12 stored by the coupler and the log 13 stored by the PDA. Theoretically these logs relate to the same transactions. The server can thus comprise a function for comparing these two logs 12 , 13 . Advantageously these two logs afford a degree of additional security to the terminal 1 . In particular, this security makes it possible to detect fraudulent transactions. A difference between the two logs, for example a transaction missing from the log 13 of the PDA indicates a fraud. This fraud can be due for example to a fraudulent sale stored in the log 12 of the coupler but not stored in the PDA log 13 , or vice versa. It is thus possible to detect and identify transactions deleted or modified by a malicious agent or user.
[0048] Thus, the server 5 can correlate the data of the transactions that it receives from the PDA 2 , which are unreliable, with the data of the transactions, safe, that it receives from the coupler 3 in the form of a log. Its monitoring role extends to other terminals. It verifies notably that what has been validated has indeed been sold and what has been sold has indeed been payed for. It makes it possible to pair a coupler with a PDA by providing the confidential key Kv to the PDA when the coupler gives it the key in a session made secure by the key Kab. A system composed of the server 5 and of one or more roaming electronic transaction terminals such as that previously presented then forms a secure system for electronic transactions.
[0000] The server 5 is the only element of the system which makes it possible to reload the coupler since it is the only one to know the key Kab. The logs 12 , 13 could be dispatched to checking facilities other than the server 5 to perform their reconciliation, with the appropriate links. This checking facility 5 performs a reconciliation of the transactions stored in the log 12 of the coupler 3 and those stored in the log 13 of the PDA 2 . A reconciliation defect, that is to say a transaction present in one register and not in the other, indicates an erroneous transaction, fraudulent or not. An exemplary reconciliation is the comparison performed on the aforesaid data 121 , 122 , 123 , 131 , 132 , 133 of the logs 12 , 13 . Other types of reconciliations of the transactions stored in these logs 12 , 13 are possible.
[0049] The invention has been presented with regard to a ticketing application, more particularly to the processing of transport entitlements by a roaming terminal. It can of course be applied to other sectors and more generally to other types of electronic transactions calling upon a roaming terminal requiring a certain security level. Additionally the medium used in the exemplary application is a contactless read and write card. It is obviously possible to use other types of medium. Likewise the application package support 2 has been described as being a PDA. It is possible to use other types of application package supports, for example a portable computer, a portable telephone or any other type of man-machine interface capable of connecting to a server 5 and to a coupler 3 . The link 6 between the coupler 3 and the server 5 and the link 4 between the coupler and the PDA have been described as being wireless links, for example of bluetooth type. These links have the advantage of rendering the use of the PDA more practical. Other types of links can be used.
[0050] Finally the application package support 2 and the coupler 3 have been presented as two components having different physical supports. In another embodiment, the application package support 2 and the coupler 3 could be placed on one and the same physical support. Nevertheless the separation of the application package support 1 and of the coupler 3 , that is to say the fact of communicating through a confidential link 4 , affords an additional security element. In particular the server 5 or any other exterior checking facility makes it possible only to pair a coupler 3 and an application package support 2 . Specifically the key Kv for example which makes it possible to open the communication sessions between the application package support 2 and the coupler 3 is provided by the server 5 to the coupler through a secure link, by means of the key Kab for example. The coupler thereafter transmits this key Kv to the application package support 2 . As was indicated previously this key can be renewed, for example in a random manner.
[0051] It will be readily seen by one of ordinary skill in the art that the present invention fulfils all of the objects set forth above. After reading the foregoing specification, one of ordinary skill in the art will be able to affect various changes, substitutions of equivalents and various aspects of the invention as broadly disclosed herein. It is therefore intended that the protection granted hereon be limited only by definition contained in the appended claims and equivalents thereof.
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The present invention relates to a roaming electronic transaction terminal. It also relates to a secure system for electronic transactions comprising one or more roaming terminals. The terminal ( 1 ) has an application package support ( 2 ) and a coupler ( 3 ) for carrying out the read and write operations on a medium that are required for the electronic transactions in conjunction with the application package. The coupler ( 3 ) comprises means for creating a write time window and a read time window on the basis of a secure input signal, all writing and all reading being disabled outside of the corresponding windows. The invention applies notably for the securing of terminals carrying out checks and contractual transactions on supports equipped with processors and memories, it being possible for these supports to be through contactless read and write cards comprising for example transport entitlements, payment means or any other entitlements to be turned to account.
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TECHNICAL BACKGROUND
[0001] The present invention is generally directed to three-dimensional imaged nonwoven fabrics and the methods for employing such three-dimensional imaged nonwoven fabrics as a means for cleaning surfaces. A particularly preferred embodiment of a three-dimensional imaged nonwoven fabric of the present invention is in facial cleansing applications.
BACKGROUND OF THE INVENTION
[0002] Over the years, the use of disposable substrates in cleaning applications has been well practiced. Suitable substrates have included sponges, woven and nonwoven fabrics, and various combinations thereof. Further, such substrates have been impregnated with cleaning agents such as astringents, solvents, detergents and other chaotropes. The resulting cleaning products fabricated from such impregnated substrates have found acceptance with the general public as a convenient and practical means for the cleaning of surfaces. In particular, such constructs have been reasonably successful in the facial cleansing market.
[0003] Substrates of particular importance in the facial cleansing market include those fabrics that are imparted with apertures, or otherwise exhibit regions devoid of substrate matrix. It is has been conjectured by the fabricators of facial cleansing products practicing the use of such apertured fabric that the presence of the apertures improve the ability of the substrate to quickly build a beneficial lather during the cleansing process.
[0004] The presence of apertures in a facial cleansing product has been found to be a difficult and complex material to fabricate due to a need to have an absolute minimum in the occurrences of occluded apertures. Occlusion of the aperture, for example by the fibrous matrix of a nonwoven substrate, has multiple deleterious affects. First, the occlusion results in an expected reduction of efficacy during a lather generation procedure due to the further constriction of the occlusion by the buildup of applied detergent agents. Second, an apertured substrate is difficult to fabricate so as to be functional and at the same time aesthetically pleasing. The very real problem of aesthetic appeal to the end-user is based on the fact that the human eye is attracted to variation in repeating patterns. An intermittent occlusion, even if only subtle in degree, will result in the user perception of a low quality product. The need for uniformity of aperture must be anticipated during the fabrication process and substrate material rejected should the aperture clarity at any time fall outside of predetermined specifications, thus leading to an exceedingly high level of potential material being rejected.
[0005] There remains a need for a disposable substrate for cleaning applications, and particularly facial cleansing products, which is capable of forming lather, and does not suffer from the deleterious affects inherent to apertured substrates.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to enhancing the cleaning of surfaces by the contact application of a non-apertured nonwoven fabric having a three-dimensional image imparted therein. The three-dimensional image of the non-apertured nonwoven fabric induces the formation of lather due to pronounced surface projections that come in contact with the cleaning surface and provide air passageways that are parallel to the plane of the substrate. The imaged nonwoven fabric disclosed herein exhibits low Tinting qualities thereby reducing the potential of fiber contamination of the cleaned surface and is sufficiently durable that the sample can be used in a brisk manner.
[0007] A method of making the present durable nonwoven fabric comprises the steps of providing a precursor web that is subjected to hydroentangling. The precursor web is formed into an imaged nonwoven fabric by hydroentanglement on a three-dimensional image transfer device. The image transfer device defines three-dimensional elements against which the precursor web is forced during hydroentangling, whereby the fibrous constituents of the web are imaged by movement into regions between the three-dimensional elements of the transfer device.
[0008] In the preferred form, the precursor web is hydroentangled on a foraminous surface prior to hydroentangling on the image transfer device. This pre-entangling of the precursor web acts to integrate the fibrous components of the web, but does not impart imaging as can be achieved through the use of the three-dimensional image transfer device in subsequent steps.
[0009] It is further contemplated by the present invention that the use of a semi-durable three-dimensional imaged nonwoven fabric can be employed in facial cleansing applications, whereby three-dimensional image of the nonwoven fabric induces the formation of lather due to pronounced surface projections which come in contact with the facial skin and provide air passage ways necessary for lather propagation that are parallel to the plane of the non-apertured substrate. The imaged nonwoven fabric is further designed to facilitate optimal performance when used in the wetted state and when treated with or subject to surfactant compounds.
[0010] Other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention will be more easily understood by a detailed explanation of the invention including drawings. Accordingly, drawings which are particularly suited for explaining the invention are attached herewith; however, is should be understood that such drawings are for explanation purposes only and are not necessarily to scale. The drawings are briefly described as follows:
[0012] [0012]FIG. 1 is a diagrammatic view of an apparatus for manufacturing a durable three-dimensional imaged nonwoven fabric, embodying the principles of the present invention;
[0013] [0013]FIG. 2 is a plan view of a three-dimensional image transfer device of the type used for practicing the present invention, referred to herein as “hexagon nub”;
[0014] [0014]FIG. 3 is a plan view of a three-dimensional image transfer device of the type used for practicing the present invention, referred to herein as “bar nub”;
[0015] [0015]FIG. 4 is a plan view of a three-dimensional image transfer device of the type used for practicing the present invention, referred to herein as “criss-cross nub”;
[0016] [0016]FIG. 5 is a plan view of a three-dimensional image transfer device of the type used for practicing the present invention, referred to herein as “round nub”;
[0017] [0017]FIG. 6 is a plan view of a three-dimensional image transfer device of the type used for practicing the present invention, referred to herein as “large segmented diamond”;
[0018] [0018]FIG. 7 is a plan view of a three-dimensional image transfer device of the type used for practicing the present invention, referred to herein as “zig-zag”;
[0019] [0019]FIG. 8 is a plan view of a three-dimensional image transfer device of the type used for practicing the present invention, referred to herein as “large honeycomb”;
DETAILED DESCRIPTION
[0020] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.
[0021] Nonwoven fabrics are used in a wide variety of applications where the engineered qualities of the fabric can be advantageously employed. These types of fabrics differ from traditional woven or knitted fabrics in that the fabrics are produced directly from a fibrous mat, eliminating the traditional textile manufacturing processes of multi-step yarn preparation, and weaving or knitting. Entanglement of the fibers or filaments of the fabric acts to provide the fabric with a useful level of integrity. Subsequent to entanglement, fabric integrity can be further enhanced by the application of binder compositions and/or by thermal stabilization of the entangled fibrous matrix.
[0022] U.S. Pat. No. 3,485,706, to Evans, hereby incorporated by reference, discloses processes for effecting hydroentanglement of nonwoven fabrics. More recently, hydroentanglement techniques have been developed which impart images or patterns to the entangled fabric by effecting hydroentanglement on three-dimensional image transfer devices. Such three-dimensional image transfer devices are disclosed in U.S. Pat. No. 5,098,764, hereby incorporated by reference, with the use of such image transfer devices being desirable for providing a fabric with enhanced physical properties as well as having a pleasing appearance.
[0023] For application in cleaning products, a nonwoven fabric must exhibit a combination of specific physical characteristics. For example, the nonwoven fabrics used in cleansing of the face should be soft and drapeable so as to conform to the contours of the face and yet withstand brisk agitation inherent to facial cleansing procedures. Further, nonwoven fabrics used in cleaning applications must be resistant to abrasion and Tinting yet also exhibit sufficient strength and tear resistance.
[0024] With reference to FIG. 1, therein is illustrated an apparatus for practicing the present method for forming a nonwoven fabric. The fabric is formed from a fibrous matrix preferably comprising staple length fibers, but it is within the purview of the present invention that different types of fibers, or fiber blends, and with inclusive of an optional scrim layer, can be employed. The fibrous matrix is preferably carded and air-laid or cross-lapped to form a precursor web, designated P.
[0025] Manufacture of a nonwoven fabric embodying the principles of the present invention is initiated by providing the precursor nonwoven web preferably in the form of a blend of staple length fibers. Such fibers may be selected from natural or synthetic composition, of homogeneous or mixed fiber length. Suitable natural fibers include, but are not limited to, cotton, wood pulp and viscose rayon. Synthetic fibers, which may be blended in whole or part, include thermoplastic and thermoset polymers. Thermoplastic polymers suitable for this application include polyolefins, polyamides and polyesters. The thermoplastics may be further selected from homopolymers, copolymers, conjugates and other derivatives including those thermoplastic polymers having incorporated melt additives or surface-active agents. Staple lengths are selected in the range of 0.25 inch to 6 inches, the range of 1 to 2 inches being preferred and the fiber denier selected in the range of 1 to 15, the range of 2 to 6 denier being preferred for general applications. The profile of the fiber is not a limitation to the applicability of the present invention.
[0026] The composition of the three-dimensional imaged nonwoven fabric can be specifically chosen in light of the cleaning agent to be impregnated therein or applied thereon. For example, if a water based surfactant compound is to be applied, a hydrophilic naturally derived fiber such as rayon or a hydrophilic melt additive in a polyester staple fiber would facilitate in the imaged nonwoven fabric absorbing a controlled amount of a cleaning compound. Should it be known that an abrasive cleaning surface facing material is desirable, a polypropylene staple fiber selected from the upper denier range of staple fibers would be advised.
[0027] It is within the purview of the present invention that a scrim can be interposed in the formation of the precursor nonwoven web. The purpose of the scrim is to reduce the extensibility of the resultant three-dimensional imaged nonwoven fabric, thus reducing the possibility of three-dimensional image distortion and further enhancing fabric durability. Suitable scrims include unidirectional monofilament, bi-directional monofilament, expanded films, and thermoplastic spunbond.
[0028] It is also within the purview of the present invention that a binder material can be either incorporated as a fusible fiber in the formation of the precursor nonwoven web or as a liquid fiber adhesive applied after imaged fabric formation. The binder material will further improve the durability or otherwise provide enhanced cleaning performance of the resultant imaged nonwoven fabric during use.
[0029] [0029]FIG. 1 depicts the means for imparting the three-dimensional quality during the manufacture of the nonwoven fabric. The image transfer device shown as imaging drum 18 can be selected from a broad variety of three-dimensional image types. Exemplary FIGS. 2, 3, 4 , and 5 , are three-dimensional images of the “nub” type. Fibrous nubs are formed during the process of entangling on the imaging drum 18 , these nubs extending out of the planar background of the resulting fabric. These fibrous nubs act as the high points and resulting surface contact. FIGS. 6, 7, and 8 , are examples of the “geodesic” type of images. In this image type, regular blocks of entangled constituent fibers extended out of the planar background, the fibrous blocks creating high points that are particular effective at providing air passageways parallel to the substrate surface. Due to the flexibility inherent to the fabrication of the image on the image transfer device, variations in three-dimensional image including multi-planar images, variations in image juxtaposition, and the ability to create complex images having no discontinuities allow for the creation of profiles in nonwoven fabrics heretofore impossible.
[0030] It is contemplated that the air passageways defined by the surface projections, with reference to the machine direction (MD) and cross-direction (CD), comprise between about 29% and 83%, per linear inch of fabric, with the passageways each having a dimension between about 0.063 inch and 0.625 inch.
EXAMPLES
Example 1
[0031] Using a forming apparatus as illustrated in FIG. 1, a nonwoven fabric was made in accordance with the present invention by providing a precursor web comprising 100 percent by weight polyester fibers as supplied by Wellman as Type T-472 PET, 1.2 dpf by 1.5 inch staple length. The precursor fibrous batt was entangled by a series of entangling manifolds such as diagrammatically illustrated in FIG. 1. FIG. 1 illustrates a hydroentangling apparatus for forming nonwoven fabrics in accordance with the present invention. The apparatus includes a foraminous-forming surface in the form of belt 12 upon which the precursor fibrous batt P is positioned for pre-entangling by entangling manifold 14 . In the present examples, each of the entangling manifolds 14 included 120-micron orifices spaced at 42.3 per inch, with the manifolds successively operated at 100, 300, and 600 pounds per square inch, with a line speed of 45 feet per minute. The precursor web was then dried using two stacks of steam drying cans at 300° F. The precursor web had a basis weight of 1.5 ounce per square yard (plus or minus 7%).
[0032] The precursor web the received a further 2.0 ounce per square yard air-laid layer of Type-472 PET fibrous batt. The precursor web with fibrous batt was further entangled by a series of entangling manifolds 14 , with the manifolds successively operated at 100, 300, and 600 pounds per square inch, with a line speed of 45 feet per minute. The entangling apparatus of FIG. 1 further includes an imaging drum 18 comprising a three-dimensional image transfer device for effecting imaging of the now-entangled layered precursor web. The image transfer device includes a moveable imaging surface which moves relative to a plurality of entangling manifolds 22 which act in cooperation with three-dimensional elements defined by the imaging surface of the image transfer device to effect imaging and patterning of the fabric being formed. The entangling manifolds 22 included 120 micron orifices spaced at 42.3 per inch, with the manifolds operated at 2800 pounds per square inch each. The imaged nonwoven fabric was dried using two stacks of steam drying cans at 300° F.
[0033] The three-dimensional image transfer device of drum 24 was configured with a multiple image forming surface consisting of five different patterns, as illustrated in FIGS. 2, 3, 4 , and 5 .
Example 2
[0034] An imaged nonwoven fabric was fabricated by the method specified in Example 1, where in the alternative, the precursor fibrous batt was comprised of viscose rayon as supplied by Lenzing at T-8191, 1.5 dpf by 1.5 inch staple length. Final weight of the dried prebond layer before layering of PET fiber was 1.5 ounces per square yard.
Example 3
[0035] An imaged nonwoven fabric was fabricated by the method specified in Example 1, where in the alternative, the precursor fibrous batt was comprised of 2.0 ounces per square yard PET fiber.
Example 4
[0036] An imaged nonwoven fabric was fabricated by the method specified in Example 2, where in the alternative, the precursor fibrous batt was comprised of 2.0 ounces per square yard viscose rayon.
Fabric Strength/Elongation ASTM D5034 Elmendorf Tear ASTM D5734 Handle-o-meter ASTM D2923 Stiffness-Cantilever Bend ASTM D5732 Fabric Weight ASTM D3776
[0037] The test data in Table 1 shows that nonwoven fabrics approaching, meeting, or exceeding the various above-described benchmarks for fabric performance in general, and to commercially available products in specific, can be achieved with fabrics formed in accordance with the present invention. Fabrics having basis weights between about 1.0 ounce per square yard and 6.0 ounces per square yard are preferred, with fabrics having basis weights of between about 3.0 ounces per square yard and 4.0 ounces per square yard being most preferred. Fabrics formed in accordance with the present invention are durable and drapeable, which is suitable for cleaning applications.
[0038] From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims.
Combined El- El- Combined Elong- Thre- Grab Grab Grab Grab Canti- Canti- men- men- Tensile ation Fiber Dimen- Ten- Ten- Elong- Elong- Soft- Soft- lever lever dorf dorf per per Com- sional Basis sile sile ation ation ness ness Bend Bend Tear Tear Basis Basis position Image Weight Bulk (MD) (CD) (MD) (CD) (MD) (CD) (MD) (CD) (MD) (CD) Weight Weight Example 1 3.8 0.092 68.0 46.7 42.7 109.7 85 35 8.2 5.3 1458.7 3751.1 30.0 39.9 Example 2 4.1 0.074 44.4 40.3 32.0 108.2 98 23 8.4 5.6 1129.8 3085.6 20.4 33.8 Example 3 4.3 0.093 75.6 53.0 45.7 111.8 114 48 9.0 5.7 1547.8 4157.8 29.9 36.6 Example 4 4.5 0.083 46.1 41.9 34.4 98.0 127 34 8.8 5.6 1441.0 2966.4 19.6 29.4
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The present invention is directed to enhancing the cleaning of surfaces by the contact application of a non-apertured nonwoven fabric having a three-dimensional image imparted therein. The three-dimensional image of the non-apertured nonwoven fabric induces the formation of lather due to pronounced surface projections that come in contact with the cleaning surface and provide air passageways that are parallel to the plane of the substrate. The imaged nonwoven fabric disclosed herein exhibits low linting qualities thereby reducing the potential of fiber contamination of the cleaned surface and is sufficiently durable that the sample can be used in a brisk manner.
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BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates to digital circuitry designs of state machines, and more specifically, to systems, methods and computer products for efficiency improvements in the digital circuitry designs.
[0003] 2. Description of Related Art
[0004] An electrical circuit with memory elements may be modeled using state equations and state variables to describe the behavior and state of the system. A complete set of state variables for a system, coupled with logic that defines the transitions between states, typically contains enough information about the system's history to enable computation of the system's future behavior. Simplifying the model to reduce the number of state variables, or simplifying the logic that defines state transitions, lessens the computational cost of analyzing the model, for example, to verify that it conforms to a given specification.
[0005] The synthesis and verification of state variable models can require tremendous amounts of computational resources. A process for reducing design size would be useful in reducing computational requirements, thus enhancing logic synthesis and verification. What is needed is an automated method of reducing design size while preserving the behavior of the design with respect to verification results.
SUMMARY
[0006] Embodiments disclosed herein address the above stated needs by providing a framework by which to assess the impact of specific gate upon the behavior of a sequential design. This framework includes methods of sequential cofactoring, that is, the injection of circuitry which toggles the valuation of a gate at a particular time-step. This framework generalizes combinational toggle analysis which is used for applications such as assessing observability don't care conditions, i.e., conditions under which a gate may be eliminated to enhance synthesis or verification. This generalization enables an efficient framework to perform sequential-analysis based reductions which are more powerful than combinational analysis. In addition, several distinct applications are disclosed which benefit from this particular modeling vs. methods of sequential generalization which cofactor across all time-frames. Said method is implemented through the addition and manipulation of circuitry to a design, hence is applicable for analysis using logic evaluation frameworks such as logic simulators or formal verification algorithms, as well as hardware-based frameworks such as logic emulators/accelerators and even fabricated chips.
[0007] Various embodiments disclosed herein provide systems, computer products and methods for sequential cofactor-based circuit design for a sequential circuitry netlist. An arbitrary gate of the sequential circuitry is selected for analysis, and then the sequential circuitry netlist is configured to connect the arbitrary gate to a multiplexer. The sequential circuitry netlist is also configured to connect selector control circuitry to a selector input of the arbitrary gate. In response to detecting a ctime signal applied to the selector input, the multiplexer output is set to alter the arbitrary gate output, and a determination is made as to whether the sequential circuitry behavior remains equivalent during time that the multiplexer output is set to alter the arbitrary gate output.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawings, which are incorporated in and constitute part of the specification, illustrate various embodiments of the invention. Together with the general description, the drawings serve to explain the principles of the invention. In the drawings:
[0009] FIG. 1A depicts inputs and outputs for positive and negative cofactoring;
[0010] FIG. 1B depicts inputs and outputs for ODC-based netlist analysis;
[0011] FIGS. 2A-B depicts circuitry for sequential positive and negative cofactoring;
[0012] FIG. 3 is a flowchart depicting a method of sequential positive and negative cofactoring according to various embodiments of the invention;
[0013] FIGS. 4A-B depicts circuitry for sequential ODC netlist analysis;
[0014] FIG. 5 is a flowchart depicting a method of sequential inversion based ODC netlist analysis according to various embodiments of the invention; and
[0015] FIG. 6 depicts a computer system 600 suitable for implementing and practicing various exemplary embodiments.
DETAILED DESCRIPTION
[0016] One technique for performing reduction on a circuitry design is the observability don't care based analysis. This type of analysis identifies conditions under which the value of a gate does not impact the overall behavior of the circuit, thus yielding flexibilities under which the design may be simplified. Such techniques operate by inverting the value of a specific gate and enumerating conditions under which the original gate and the modified gate evaluate the same. Alternate verification paradigms rely upon cofactoring, that is, replacing a gate of the design by constant 0 vs. I to reduce verification complexity or to enumerate the impact of that gate upon the remainder of the circuit. Both of these styles of analysis have traditionally been limited to operating on combinational circuits. This disclosure adapts combinational cofactoring for verification and synthesis through sequential cofactoring for use in digital circuitry designs of state machines and additionally enumerates several applications to exploit the benefit of these novel techniques. Furthermore, this sequential cofactoring solution may be achieved purely in terms of logic circuitry, allowing it to be used in a variety of circuit-based analysis frameworks such as logic simulators, FPGAs and hardware accelerators, formal reasoning algorithms, and even semiconductor devices.
[0017] FIG. 1A depicts inputs and outputs for positive and negative cofactoring. This example illustrates an arbitrary design with four inputs i 1 . . . i 4 and four outputs o 1 . . . o 4 . Generally, the design being analyzed may have an arbitrary number of inputs and outputs (the same may be said of the designs of FIG. 1B , FIG. 2A-2B , and FIG. 4A-4B ). Cofactor-based analysis has a variety of traditional applications in verification. For example, given a combinational netlist, cofactor-based analysis may be used as a case splitting procedure by first analyzing the behavior of the netlist if an arbitrary gate is positively cofactored, then negatively cofactored. An example of the type of analysis which may be performed upon the cofactored circuit is satisfiability checking where one may wish to assess whether a particular gate in the netlist may evaluate to a given value, e.g., 1. The cofactoring simplifies the netlist representation, such that the analysis performed on the cofactored netlist may be substantially lesser in computational resources since satisfiability checking generally requires exponential runtime with respect to netlist size. FIG. 1A depicts inputs and outputs involved in netlist cofactoring. The figure shows an original netlist N with four inputs i 1 . . . i 4 , then with input i 1 being positively and negatively cofactored.
[0018] FIG. 1B depicts inputs and outputs for observability don't care (ODC) based netlist analysis, another traditional application similar to cofactor-style analysis. ODCs refer to conditions under which the value of a particular gate does not affect the behavior of the overall netlist, due to being masked by other values of other gates. For example, given a small netlist consisting of an AND gate with inputs gate 1 and gate 2 , an ODC condition for gate 1 is that gate 2 evaluates to 0. Under this situation, the AND gate will evaluate to 0 regardless of the value of gate 1 . ODCs may be used to optimize circuits for enhanced synthesis or verification, e.g., if the circuit has a gates which is equal to gate 1 except in states where gate 2 =0, gate 1 and gate 3 may be merged to reduce netlist size without altering the overall netlist behavior. Performing ODC analysis often entails analyzing two copies of a netlist, one being the original netlist and the other being a netlist where the gate whose ODC conditions are being assessed has an inverter injected at its output as depicted in FIG. 1B . The arbitrary gate conditions under which the outputs of the netlist are equal represent the ODC space with respect to the gate under analysis. FIG. 1B shows the ODC formulation for netlist N with respect to gate g 1 .
[0019] FIGS. 2A-B depicts circuitry for sequential positive and negative cofactoring for arbitrary gate i 1 , one facet of the current disclosure. Sequential cofactoring generalizes upon the combinational cofactor. However, instead of merely replacing an arbitrary gate i 1 by a constant, the sequential cofactor replaces that arbitrary gate by a multiplexor 201 and circuitry 205 designed to control the multiplexor for one time frame. The dotted lines in FIGS. 2A-B merely indicate one implementation for circuitry 205 designed to evaluate to 1 for only one time-frame upon detecting a first incidence of ctime=1. It should be noted that the circuitry depicted in FIGS. 2A-B (and FIGS. 4A-B ) may be located within the circuitry design located entirely on a single chip, or equivalently located along with whatever representation of the circuitry being analyzed happens to be applicable to the desired application—e.g., within a field programmable gate array (FPGA) or other reconfigurable hardware module used for hardware acceleration. In some implementations some of the inputs i 1 -i 4 and outputs o 1 -o 4 may not necessarily be chip inputs or outputs. These inputs and outputs may simply connect to other Circuitry in the netlist. In other implementations one or more of the inputs and outputs may, in some instances, be chip inputs/outputs. Further, in some implementations the number of netlist inputs or outputs may be considerably greater.
[0020] In the embodiments depicted in FIGS. 2A-B the selector s of the multiplexor is selected by a gate (the circuitry 205 ) which may evaluate to 1 for only one arbitrary time-frame. When the selector s evaluates to 1, a constant is driven at the output of the multiplexor. The constant equals 1 in FIG. 3A and 0 in FIG. 3B . At other timeframes aside from the first assertion of ctime=1, the arbitrary gate is driven at the output of the multiplexor 201 . The input variable “ctime” in at least one embodiment is a new arbitrary gate introduced to control the time-frame when the cofactor value will be driven onto i 1 during its first assertion to value 1. In alternative embodiments, “ctime” may be connected to arbitrary circuitry—e.g., to allow the application embedding the circuitry of 205 to control this first assertion time, possibly in response to other activity in the circuit or under control of a human interacting with said application. Examples of circuit activity which may trigger the ctime assertion include the detection of a specific type of instruction at a specific interface within a circuit, the detection of a data buffer filling or emptying, the detection of a specific request or grant condition at an arbitration unit of the circuit or an indication that a specific number of circuit “clocks” or time have elapsed during the analysis. The cofactoring is accomplished through multiplexor 201 which drives the cofactor constant when its selector s evaluates to 1, otherwise it drives i 1 . The selector is driven by logic which evaluates to 1 exactly upon the first assertion of “ctime.” Past assertions are accounted for by register r 1 which initializes to 0, then remains 1 after the first assertion of the “ctime.”
[0021] FIG. 3 is a flowchart 300 depicting a method of sequential positive and negative cofactoring according to various embodiments of the invention. The method begins at 301 and proceeds to 303 to define the circuit netlist specifying the initial circuit design. This includes defining the conventions and terms, setting the initial conditions of the system model, and may entail importing data to prepare the netlist for the design to be manipulated through sequential cofactoring. An exemplary netlist contains a directed graph with vertices representing gates, and edges representing interconnections between those gates. The gates have associated functions, such as constants, primary inputs (which may be referred to as arbitrary gates or sometimes as RANDOM gates), combinational logic such as AND gates, and sequential state holding elements. A sequential state holding element has one or more inputs and at least one output, each of which may be characterized by discrete states (e.g., logical 1 or logical 0). The various embodiments can be practiced with any sort of state machine including state holding elements (e.g., registers, latches, RAM circuitry, or the like), sometimes called memory elements. The state of the output (or the state of each output, if more than one) is determined by the previous states of the input channels. The initialization time or reset time of a register is referred to herein as time zero (t=0). Registers typically have two associated components, their next-state functions and their initial-value functions. Both of these associated components may be represented as other gates in the graph. Semantically, for a given register the value appearing at its initial-value gate at time logical 0 will be applied as the value of the register itself (time “0”=“Initialization” or “reset” time). The value appearing at its next-state function gate at time “i” will be applied to the register itself at time “i+1”. Certain gates of the model may be labeled as targets. Targets correlate to the properties sought to be verified. One goal of the verification process is to find a way to drive a “1” to a target node, and generate a “trace” illustrating (or reporting) this scenario if one is found. Another goal of verification is to prove that no such assertion of the target is possible, that is, there is no way to drive a “1” to the target node.
[0022] Upon completing 303 to define the circuit netlist the method proceeds to 305 to select an arbitrary gate to replace with a multiplexer. By arbitrary gate it is simply meant that a gate (or set of gates) is chosen for analysis. For example, in FIGS. 2A-B the input i 1 is chosen as the gate to be analyzed by replacing i 1 with multiplexer 201 under control of circuitry 205 . In 307 the multiplexer inputs and output are configured. One multiplexer input is tied to an input i associated with the selected arbitrary gate. The other multiplexer input is tied to a constant, either 1 as in FIG. 2A or else 1 as in FIG. 2B . As depicted in FIGS. 2A-B the output of multiplexer 201 is tied to the point in the circuitry formerly connected to input i 1 . The method then proceeds to 309 to set the circuitry to initial conditions.
[0023] In block 311 the evaluation for equivalence begins for the arbitrary gate being analyzed. This may simply entail recording the inputs and outputs for later analysis, or may be done after each clock period, depending upon the complexity of the circuitry being analyzed and the particularities of the implementation. Alternatively, this may entail creating a secondary copy of the netlist, manipulating it as per the flowchart of FIG. 3 yet driving an alternate constant value at said multiplexor circuitry so that the behavior of the two copies may be directly compared for equivalence or inequivalence (refer to the two netlists of FIGS. 2A and 2B , respectively). As yet another alternative, it is possible that no direct equivalence comparison is needed Instead, this sequential cofactor circuitry may be used to manipulate a design under analysis to see if it may trigger some behavioral modification (e.g., the failure of “self-check” circuitry or any other form of behavioral correctness checking specification), and the evaluation of equivalence refer solely to the modified design exhibiting expected behavior. The method proceeds to 313 to begin operation of the synchronous circuit. Values for the inputs (e.g., i 1 through i 4 of FIGS. 2A-B ; Note again that the particular number of inputs of the design will generally vary, and FIGS. 2A-B merely represent one particular design) are applied to the circuitry in their proper sequence. Upon completing 313 the method proceeds to 315 to determine whether 1 has been applied to the ctime input for the first time.
[0024] Applying ctime=1 the first time causes circuitry 205 to control the multiplexer 201 selector to select the constant output—either a constant 1 as per FIG. 2A or a constant 0 as per FIG. 2B . After the first time a 1 input has been applied to ctime the circuitry 205 no longer will apply the constant voltage (1 or 0). Instead the multiplexer 201 selector is controlled to provide arbitrary gate input i 1 at the output of the multiplexer 201 at all times after the initial application of ctime=1 has been processed. In other words the multiplexer control circuitry 205 “remembers” that ctime=1 has already taken place, and therefore controls multiplexer 201 to apply input i 1 at the multiplexer 201 output. Upon detecting the initial application of ctime=1 the method proceeds from 315 along the YES path to 317 to set the multiplexer 201 output to a constant value for one time frame. The method then proceeds to 319 to evaluate the equivalence of the circuit and then on to 321 to determine whether the analysis is complete. Back in 315 , if it is determined that the ctime input is not 1 for the first time the method proceeds from 315 along the NO path to 319 to evaluate the equivalence of the circuit. Upon completing 319 the method proceeds to 321 .
[0025] In block 321 if it is determined that the evaluation is not yet complete the method proceeds from 321 along the NO path back to 313 to iterate the synchronous circuit, thus causing another set of inputs (e.g., i 1 -i 4 from FIGS. 2A-2B ) to be applied to the circuitry. However, if it is determined in 321 that the analysis is complete the method proceeds from 321 along the YES path to 323 to determine whether the sequential cofactor is equivalent to the i 1 input at the particular time undergoing analysis—that is, the results flowing from the application of ctime=1 applied to the input in place of i 1 . Upon completing block 323 the method proceeds to 325 and ends.
[0026] FIGS. 4A-B depicts circuitry for sequential observability don't care (ODC) netlist analysis. Note that this circuitry is with respect to a single arbitrary design with four inputs i 1 -i 4 and four outputs o 1 -o 4 . Generally, the design being analyzed may have an arbitrary number of inputs and outputs. ODC analysis, as disclosed herein, is a sequential generalization of the inversion-based ODC-analysis procedure. Similarly to the sequential cofactor, logic is introduced to create a signal that evaluates to 1 for one specific time-frame, particularly, the first time-frame when the newly introduced input ctime evaluates to 1. This signal is also used to select a multiplexor m 1 . If the selector is 0, the original behavior of gate g 1 is driven through the multiplexor. In response to 1 being applied to the selector the inverted behavior of gate g 1 is driven through the multiplexor.
[0027] FIG. 5 is a flowchart 500 depicting a method of sequential inversion based ODC netlist analysis according to various embodiments of the invention. The method begins at 501 and proceeds to 503 to define the circuit netlist specifying the initial circuit design. As discussed above in conjunction with FIG. 3 defining the netlist includes defining the conventions and terms, setting the initial conditions of the system model, and may entail importing data to prepare the netlist for the design to be manipulated through sequential ODC introduction. Once the circuit netlist is defined in 503 the method proceeds to 505 to select an arbitrary gate to replace with a multiplexer. In this embodiment the selected gate may not necessarily be a gate directly connected to an input or an output of the circuitry being analyzed. But rather, the selected gate may be any gate within the circuitry. Once the gate is selected in 505 the method proceeds to 507 . In 507 an output of the selected gate is tied to the multiplexer, as can be seen in FIGS. 4A-B . The output 407 of gate g 1 is fed to an input of multiplexer 401 . An inverted output 407 of gate g 1 is also fed to a multiplexer 401 input. As discussed above for the similar circuitry of FIGS. 2A-B , the circuitry 405 is designed to evaluate to 1 for only one time-frame upon detecting a first incidence of ctime=1 being applied. Returning to block 507 , once the gate is tied to the multiplexer the method proceeds to 509 to set the multiplexer select circuitry to initial conditions. The method then proceeds to 511 .
[0028] In block 511 the evaluation for equivalence begins for the gate being analyzed. Similar to the discussion of block 311 from FIG. 3 , in some implementations the equivalence analysis may take place after data is gathered, or through directly comparing an original netlist to the behavior of the modified netlist as per blocks 505 - 509 , or be performed more implicitly through merely assessing behavior with respect to an available design specification. For certain arrangements block 511 may entail beginning to record the synchronous circuit inputs and outputs for later analysis. In other implementations the equivalence analysis may take place on the fly as the data is being shifted through the synchronous circuit. The method proceeds to 513 to iterate the synchronous circuitry, beginning its operation for evaluation. Values for the inputs (e.g., i 1 through i 4 of FIGS. 4A-B ) are applied to the circuitry in their proper sequence, and the values of the outputs o 1 through o 3 , and the output ( 409 in FIG. 4B ) of the multiplexer, are observed for evaluation. The method then proceeds to 515 to determine whether or not 1 has been applied to the ctime input for the first time. At all circuitry iterations before ctime=1 for the first time the multiplexer ( 401 in FIG. 4B ) is controlled so that the d 0 input is selected for the multiplexer output. Applying ctime=1 the first time causes circuitry 405 to control the multiplexer ( 401 of FIG. 4B ) selector to select the inverted gate output d 1 . After the first time a 1 input has been applied to ctime the circuitry ( 405 of FIG. 4B ) no longer will apply the inverted gate output, that is, the d 1 input of multiplexer ( 401 in FIG. 4B ). Instead the multiplexer 401 selector is controlled to pass the gate output (multiplexer d 0 input) at the output of the multiplexer ( 401 in FIG. 4B ) at all times after the initial application of ctime=1 has been processed.
[0029] Returning to FIG. 5 , in block 515 if the initial application of ctime=1 is detected the method proceeds from 515 along the YES path to 517 to set the multiplexer 401 output to the inverted arbitrary gate output provided to multiplexer input d 1 . The method then proceeds to 519 to evaluate the equivalence of the circuit, and then on to 521 to determine whether the analysis is complete. Returning to block 515 , if it is determined that the ctime input is not 1 for the first time the method proceeds from 515 along the NO path to 519 to evaluate the equivalence of the circuit, and then on to 521 .
[0030] In block 521 if it is determined that the evaluation is not yet complete the method proceeds from 521 along the NO path back to 513 to iterate the synchronous circuit again, thus causing another set of inputs i 1 -i 4 to be applied to the circuitry of FIG. 4B . However, if it is determined in 521 that the analysis is complete the method proceeds from 521 along the YES path to 523 to determine the result of the sequential ODC analysis, namely, to determine whether the circuitry is equivalent with an inverted output of arbitrary gate g 1 being provided via the multiplexer 401 . Upon completing block 523 the method proceeds to 525 and ends.
[0031] There are a number of benefits and applications for the sequential cofactoring constructs, namely the sequential positive and negative cofactoring described in conjunction with FIG. 3 and the method of sequential inversion based ODC netlist analysis described in conjunction with FIG. 5 . We first note that when analyzing sequential netlists, combinational-style cofactoring of replacing an arbitrary gate by a constant may not preserve the verification task of checking whether a target gate can ever evaluate to 1. For example, a particular target may assert only if a given arbitrary gate toggles from 0 to 1. If we tie that arbitrary gate to 0 and check whether the target can be asserted, it cannot. If we tie that arbitrary gate to 1 and check whether the target can be asserted, it cannot. However, without the cofactoring, the target can indeed assert. Thus, while cofactoring as a case splitting strategy works properly for combinational netlists, it does not work properly for sequential netlists. Various embodiments of the current invention overcome this drawback. A similar drawback is observed for ODC type analysis, and is overcome by the sequential inversion-based ODC aspect of this invention.
[0032] It should be noted that there are several applications to demonstrate the utility of sequential cofactoring, since unlike combinational cofactoring it is no longer necessarily the case that the cofactors result in simpler sub-problems. For ODC-style analysis, the benefits of the sequential cofactoring analysis are clear. They enable the identification of don't care conditions over time for the overall circuit, whereas use of the combinational ODC construct on combinational portions of the overall sequential netlist (e.g., between registers and their next-state functions) is suboptimal since it does not take into consideration don't cares which propagate through the registers.
[0033] Another application where the sequential cofactor is useful is for identifying the subset of the netlist which is sensitized by the behavior of a specific gate, possibly under specific time-frames. For example, to develop a case-splitting strategy for enhanced verification it is useful to identify a subset of logic that may be used to process a specific opcode. Alternatively, one may wish to analyze a small “cut” (subset) of logic which is impacted by a specific gate. The “cut” refers to the number of nets which fan out from logic which may be impacted, to logic which has not yet been identified as being impacted. This cut may be used to direct algorithms which simplify the netlist representation in the fanin of the cut for enhanced synthesis or verification. The assessment of logic which may be sensitized by the behavior of the gate may be performed by analyzing the behavior of both cofactors with respect to a sequence of input stimuli, and enumerating those gates which differ in behavior across the cofactors.
[0034] The benefit of our sequential cofactor for such enumeration is twofold: first, one may use an inductive style analysis where each register within both copies of the netlist (for both cofactors) are randomized, but to the same value, then ctime is tied to 1 forcing the cofactor value to be sensitized at time 0 of the inductive instance. This simplifies the logic in the cofactoring further. Second, one may wish to specifically manipulate the analysis of the sequentially cofactored netlist during the time-frame of the cofactoring. For example, one may wish to use the ctime variable to case-split upon when performing symbolic simulation. This may reduce the complexity of analyzing the sequential cofactoring substantially, particularly when using bounded formal analysis such as symbolic simulation or bounded model checking
[0035] FIG. 6 depicts an exemplary computer system 600 suitable for implementing and practicing various exemplary embodiments. The computer system 600 may be configured in the form of a desktop computer, a laptop computer, a mainframe computer, or any other arrangements capable of being programmed or configured to carry out instructions. The computer system 600 may be located and interconnected in one location, or may be distributed in various locations and interconnected via a local or wide area network (LAN or WAN), via the Internet, via the public switched telephone network (PSTN), or other such communication links. Other devices may also be suitable for implementing or practicing the embodiments, or a portion of the embodiments. Such devices include personal digital assistants (PDA), wireless handsets (e.g., a cellular telephone or pager), and other such consumer electronic devices preferably capable of being programmed to carry out instructions or routines.
[0036] Typically, a computer system 600 includes a processor 601 which may be embodied as a microprocessor or central processing unit (CPU). The processor 601 is typically configured to access an internal memory 603 via a bus such as the system bus 621 . The internal memory 603 may include one or more of random access memory (RAM), read-only memory (ROM), cache memory, or a combination of these or other like types of circuitry configured to store information in a retrievable format. In some implementations the internal memory 603 may be configured as part of the processor 601 , or alternatively, may be configured separate from it but within the same packaging. The processor 611 may be able to access internal memory 603 via a different bus or control lines (e.g., local bus 605 ) than is used to access the other components of computer system 600 .
[0037] The computer system 600 also typically includes, or has access to, one or more storage drives 607 (or other types of storage memory) and floppy disk drives 609 . Storage drives 607 and the floppy disks for floppy disk drives 609 are examples of machine readable mediums suitable for storing the final or interim results of the various embodiments. The storage drive 607 is often a hard disk drive configured for the storage and retrieval of data, computer programs or other information. The storage drive 607 need not necessary be contained within the computer system 600 . For example, in some embodiments the storage drive 607 may be server storage space within a network or the Internet that is accessible to the computer system 600 for the storage and retrieval of data, computer programs or other information. For example, the computer system 600 may use storage space at a server storage farm accessible by the Internet 650 or other communications lines. The floppy disk drives 609 may include a combination of several disc drives of various formats that can read and/or write to removable storage media (e.g., CD-R, CD-RW, DVD, DVD-R, floppy disk, etc.). The computer system 600 may either include the storage drives 607 and floppy disk drives 609 as part of its architecture (e.g., within the same cabinet or enclosure and/or using the same power supply), as connected peripherals, or may access the storage drives 607 and floppy disk drives 6 . 09 over a network, or a combination of these. The storage drive 607 is often used to store the software, instructions and programs executed by the computer system 600 , including for example, all or parts of the computer application program for project management task prioritization.
[0038] The computer system 600 may include communication interfaces 611 configured to be communicatively connected to the Internet, a local area network (LAN), a wide area network (WAN), or connect with other devices using protocols such as the Universal Serial Bus (USB), the High Performance Serial Bus IEEE- 1394 and/or the high speed serial port (RS-232). The computers system 600 may be connected to the Internet via the wireless router 601 (or a wired router or other node—not show) rather than have a direct connected to the Internet. The components of computer system 600 may be interconnected by a bus 621 and/or may include expansion slots conforming to any of various industry standards such as PCI (Peripheral Component Interconnect), ISA (Industry Standard Architecture), or EISA (enhanced ISA).
[0039] Typically, the computer system 600 includes one or more user input/output devices such as a keyboard and/or mouse 613 , or other means of controlling the cursor (e.g., touchscreen, touchpad, joystick, trackball, etc.) represented by the user input devices 615 . The communication interfaces 611 , keyboard and mouse 613 and user input devices 615 may be used in various combinations, or separately, as means for receiving information and other inputs to be used in carrying out various programs and calculations. A display 617 is also generally included as part of the computer system 600 . The display may be any of several types of displays, including a liquid crystal display (LCD), a cathode ray tube (CRT) monitor, a thin film transistor (TFT) array, or other type of display suitable for displaying information for the user. The display 617 may include one or more light emitting diode (LED) indicator lights, or other such display devices. In addition, most computer systems 600 also include, or are connected to, one or more speakers and microphones 619 for audio output and input. Speech recognition software may be used in conjunction with the microphones 619 to receive and interpret user speech commands.
[0040] The invention may be implemented with any sort of processing units, processors and controllers capable of performing the stated functions and activities. For example, the processor 601 (or other processors used to implement the embodiments) may be a microprocessor, microcontroller, DSP, RISC processor, or any other type of processor that one of ordinary skill would recognize as being capable of performing the functions or activities described herein. A processing unit in accordance with at least one exemplary embodiment can operate computer software programs stored (embodied) on a computer-readable medium such as the internal memory 603 , the storage drive 607 , or other type of machine-readable medium, including for example, floppy disks, optical disks, a hard disk, CD, flash memory, ram, or other type of machine readable medium as recognized by those of ordinary skill in the art.
[0041] State holding elements, or state elements, are discussed above in terms of being implemented as registers or gates. However, in some embodiments any sort of state holding element or memory element may be used to implement various embodiments, including for example, registers, latches, state machines, or the like. For the purposes of illustrating and explaining the invention the terms variable, gate and register have been used interchangeably throughout this disclosure.
[0042] Various activities may be included or excluded as described above, or performed in a different order, while still remaining within the scope of at least one exemplary embodiment. For example, block 509 may be omitted so that the circuitry begins at some random state, or at a state other than an initial condition state. Other steps or activities of the methods disclosed herein may be omitted or performed in a different manner while remaining within the intended scope of the invention. The method may be implemented through the addition and manipulation of circuitry to a design, hence is applicable for analysis using logic evaluation frameworks such as logic simulators or formal verification algorithms, as well as hardware-based frameworks such as hardware emulators/accelerators and even fabricated chips. Detection that design behavior is unaffected by the introduction of said multiplexer and associated logic may be used to indicate the opportunity to simplify said design for enhanced synthesis or verification, or to denote other desirable characteristics of said design, e.g. fault tolerance.
[0043] The invention may be implemented with any sort of processing units, processors and controllers (e.g., processor 601 of FIG. 6 ) capable of performing the stated functions and activities. For example, the processor 601 may be embodied as a microprocessor, microcontroller, DSP, RISC processor, or any other type of processor that one of ordinary skill would recognize as being capable of performing the functions described herein. A processing unit in accordance with at least one exemplary embodiment can operate computer software programs stored (embodied) on computer-readable medium such as the disk drives 609 , the storage drive 607 or any other type of hard disk drive, CD, flash memory, ram, or other computer readable medium as recognized by those of ordinary skill in the art. The computer software programs can aid or perform the steps and activities described above. For example computer programs in accordance with at least one exemplary embodiment may include: source code for selecting an arbitrary gate of the sequential circuitry for analysis, source code for configuring the sequential circuitry netlist to connect the arbitrary gate to a multiplexer, source code for configuring the sequential circuitry netlist to connect selector control circuitry to a selector input of the arbitrary gate, source code for detecting an incoming call, source code for detecting a ctime signal applied to said selector input source code for in response to the ctime signal, setting, by the execution of said instructions, the multiplexer output to alter the arbitrary gate output, and source code for determining, by the execution of said instructions, whether the sequential circuitry behavior remains equivalent during time that the multiplexer output is set to alter the arbitrary gate output. There are many further source codes that may be written to perform the stated steps and procedures above, and these are intended to lie within the scope of exemplary embodiments.
[0044] The use of the word “exemplary” in this disclosure is intended to mean that the embodiment or element so described serves as an example, instance, or illustration, and is not necessarily to be construed as preferred or advantageous over other embodiments or elements. The description of the various exemplary embodiments provided above is illustrative in nature and is not intended to limit the invention, its application, or uses. Thus, variations that do not depart from the gist of the invention are intended to be within the scope of the embodiments of the present invention. Such variations are not to be regarded as a departure from the spirit and scope of the present invention.
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Methods, systems and computer products are provided for reducing the design size of an integrated circuit while preserving the behavior of the design with respect to verification results. A multiplexer is inserted at the gate being analyzed, and the multiplexer selector is controlled to provide a predetermined output for one frame at the point being analyzed. It is then determined whether the circuit remains equivalent during application of the predetermined output in order to decide whether the gate being analyzed is a candidate for replacement.
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FIELD OF THE INVENTION
The present invention relates to a process of producing transgenic plants transformed on a chromosome. Further the invention relates to a process of screening nucleotide sequences for a desired phenotype in plants. The invention also relates to transgenic plants and to libraries of plants or plant seeds obtained or obtainable according to the processes of the invention. Further, the invention relates to vectors for these processes and to plants or plant cells transformed therewith.
BACKGROUND OF THE INVENTION
Currently used methods of stable plant transformation usually employ direct (microprojectile bombardment, electroporation or PEG-mediated treatment of protoplasts, for review see: Gelvin, S. B., 1998, Curr. Opin. Biotechnol., 9, 227-232; Hansen & Wright, 1999, Trends Plant Sci., 4, 226-231) or Agrobacterium -mediated delivery of pre-engineered DNA fragment(s) of interest into plant cells. Manipulations with said DNA vectors in planta are restricted to simplifying the resolution of complex integration patterns (U.S. Pat. No. 6,114,600; Srivastava & Ow, 2001, Plant Mol Biol., 46, 561-566; Srivastava et al., 1999, Proc. Natl. Acad. Sci. USA, 96, 11117-11121) or removal of auxiliary DNA sequences from vectors stably integrated into chromosomal DNA. The methods of stable Agrobacterium -mediated integration of T-DNA regions within plant cells use whole desired DNA fragment flanked with left (LB) and right (RB) border sequences necessary for T-DNA transfer and integration into the host chromosomal DNA (U.S. Pat. No. 4,940,838; U.S. Pat. No. 5,464,763; EP0224287; U.S. Pat. No. 6,051,757; U.S. Pat. No. 5,731,179; WO9400977; EP0672752). In most cases, the approaches are directed to the integration of one specific T-DNA region into the chromosomal DNA. Also, co-integration of two or more different T-DNA regions was tried (U.S. Pat. No. 4,658,082). The latter approach is used for segregating different T-DNAs in progeny for various purposes. For example, Komari and colleagues (U.S. Pat. No. 5,731,179) describe a method of simultaneously transforming plant cells with two T-DNAs, one carrying a selectable marker functional in plants, while another T-DNA contains a desired DNA fragment to be introduced into plant cells.
In general, the DNA regions designed for stable integration into plant cells are pre-engineered in vitro by employing standard molecular biology techniques (Sambrook, Fritsch & Maniatis, 1989, Molecular cloning: A laboratory manual, 2nd ed. Cold Spring Harbor, N.Y.: CSH Laboratory Press). Also, in vivo engineering in bacterial cells is used, for example in order to assemble the binary vector with the help of homologous recombination (U.S. Pat. No. 5,731,179). Manipulations with T-DNA in planta are restricted to T-DNA regions pre-integrated into a chromosome like removing certain sequences from T-DNA, e.g. sequences encoding selectable markers including morphological abnormality induction genes. The removal of unwanted DNA fragments from T-DNA regions occurs either with the help of site-specific recombination (WO9742334; Endo et al., 2002, Plant J., 30, 115-122) or by means of transposition (U.S. Pat. No. 5,792,924).
Site-specific recombination has been used for removing auxiliary sequences from T-DNA regions. Although site-specific recombinase/integrase-mediated DNA excision is more efficient than integration, the selection for excision events is a necessity, which leads to an additional step of tissue culture or screening of progeny for desired recombination events. In summary, all processes of manipulation with T-DNAs stably integrated into plant chromosomes are time-consuming, unflexible, and in general restricted to simple excision (with less efficiency—to integration) of desired DNA fragments. In addition, these processes are usually very limited in combinatorial diversity, as they are restricted to simple manipulations with a limited number of known genes and regulatory elements.
Offringa et al. (EMBO J. (1990), 9, 3077-3084) have described an extrachromosomal homologous recombination event between two Agrobacterium -delivered T-DNAs in plant cells followed by integration of the recombination product into nuclear DNA. The extrachromosomal homologous recombination efficiency between the co-delivered T-DNAs in the plant cell was however too low to have practical applications for vector engineering in vivo and was therefore used as control experiment in scientific studies of the mechanism of homologous recombination in plants (Offringa et al., 1990, EMBO J., 9, 3077-3084; Tinland et al., 1994, Proc. Natl. Acad. Sci. USA, 91, 8000-8004; Puchta et al., 1996, Proc. Natl. Acad. Sci. USA, 93, 5055-5060). The frequency of homologous recombination followed by integration into chromosomal DNA was approximately 1% of the plant co-transformation frequency with two T-DNAs (Offringa et al., 1990, EMBO J., 9, 3077-3084; Tinland et al., 1994, Proc. Natl. Acad. Sci. USA, 91, 8000-8004; Puchta et al., 1996, Proc. Natl. Acad. Sci. USA, 93, 5055-5060). Due to the low overall efficiency of this process, practical applications of this method have not been developed.
The frequency of targeted integration of transiently delivered T-DNA into a pre-engineered loxP site in plants is also very low. For example, Vergunst and colleagues (1998, Nucl. Acids Res., 26, 2729-2734) demonstrated that the frequency of Cre-mediated site-specific integration of an Agrobacterium -delivered T-DNA fragment of interest into a genomic T-DNA region with a loxP site is within the range of 1.2-2.3% of the number of random integration events. Due to this low efficiency, such integration processes require an additional selection round and the use of tissue culture to recover the cells carrying recombination events. In contrast to that, the frequency of chromosomal double-stranded DNA rearrangements with the help of site-specific recombinases is significantly higher and occurs in 29-100% of all plant germ cells (Zuo et al., 2001, Nature Biotechnol., 19, 157-161; Luo et al., Plant J., 23, 423-430). This is not surprising, as site-specific integrases/recombinases require double stranded DNA substrate for recognition of recombination sites and performing the reaction of site-specific recombination (Panigrahi et al., 1992, Nucleic Acids Res., 20, 5927-5935; Martin et al., 2002, J. Mol. Biol., 19, 107-127; Thorpe et al., 2000, Mol. Microbiol., 38, 232-241).
All data mentioned above suggest that T-DNA transiently delivered into the plant cell is a poor substrate for site-specific recombinases.
In a previous invention, we have overcome the above-described low efficiency by site-specific recombination-mediated assembly of RNA-viral amplicons (WO02/088369). The assembled viral amplicons were capable of strong autonomous amplification, cell-to-cell and systemic movement and, therefore, could strongly amplify the rare recombination events. Said viral amplicons were assembled in planta from two or more vectors by recombinase-mediated site-specific recombination and contained a gene of interest to be expressed transiently with the aim of achieving the strongest possible expression of the gene of interest throughout a plant that was infected by said vectors. However, expression of gene of interest was transient; stable transformation of plant chromosomes for stable and inheritable expression of a gene of interest was not addressed.
For many applications, the methods described in WO02/088369 can, however, not be used due to the following problems: Amplification and spread of the viral amplicon leads to viral disease symptoms that compromise plant health. Therefore, these methods cannot be used for gene function determination (functional genomics) since disease symptoms frequently obscure the function of a gene to be determined or prevent expression of the function to be determined. Further, expression of a gene of interest from an amplicon gives rise to unnaturally high expression levels leading to phenotypes different from the natural phenotype of that gene, perhaps due to unnatural interactions with functions of native genes of that plant.
Therefore, it is an object of the invention to provide an efficient, rapid and highly versatile process for transforming a plant or plant cells on a chromosome, notably a nuclear chromosome, whereby genetically stable transgenic plants or plant cells may be produced. It is another object of the invention to provide a process of producing transgenic plants transformed on a chromosome, whereby (e.g. for reducing cloning work) the DNA sequences to be integrated in said chromosome can be engineered in planta. It is a further object to provide a process of stably transforming plants or plant cells on a chromosome with a DNA sequence of interest having toxic effects on bacteria normally used for cloning said DNA sequence of interest. It is another object of the invention to provide a process of genetic transformation of plant nuclear DNA, which allows for screening for an optimal expression unit of a gene of interest. It is a further object to provide a process of stably transforming plants or plant cells on a chromosome, whereby vectors can be used in a modular fashion, for reducing the cloning work and the overall size of the vector molecules. It is another object of the invention to provide a process of stably transforming plants or plant cells on a chromosome, whereby said process allows screening of DNA libraries for desired functions in plants. It is further object of the invention to provide an in planta process of shuffling genetic elements/gene fragments, whereby said process is linked with a process of stably transforming plants or plant cells with a DNA sequence of interest resulting from said shuffling.
GENERAL DESCRIPTION OF THE INVENTION
The above objects are achieved by a process of producing transgenic plants or plant cells transformed on a chromosome with a DNA sequence of interest and capable of expressing a function of interest from said DNA sequence of interest, said process comprising:
(a) providing plant cells or plants with at least two different vectors, whereby
(i) said at least two different vectors are adapted to recombine with each other by site-specific recombination in said plant cells for producing a non-replicating recombination product containing said DNA sequence of interest, (ii) said at least two different vectors are adapted for integrating said DNA sequence of interest into said chromosome, (iii) said DNA sequence of interest contains sequence portions from at least two of said at least two different vectors, said sequence portions being necessary for expressing said function of interest from said DNA sequence of interest; and
(b) selecting plants or plant cells expressing said function of interest.
The invention further provides transgenic plants or parts thereof (like seeds) produced or producible by the process of the invention. Further, libraries of plants or plant seeds obtained or obtainable by this process are provided. The process of the invention has many important applications, among which its use in DNA library screening, gene function analysis and functional genomics, and directed evolution including gene shuffling may be mentioned. Moreover, complex and/or large DNA sequences of interest to be introduced in a plant chromosome can be assembled in planta from smaller precursors (see FIG. 12 ). The process of the invention can, however, also be used for introducing a gene to be expressed in a chromosome of a plant cell or plant. In an important embodiment, all genes and/or coding sequences and/or expressible sequences of said DNA sequence of interest integrated into a chromosome are of plant origin, whereby no unnatural sequences can be outcrossed from the transgenic plants of the invention to other organisms.
The inventors of this invention have surprisingly found that transiently delivered T-DNA can be efficiently used for in planta engineering of a sequence of interest for integration into a chromosome. Preferably, the efficiency of achieving stable integration events is comparable to that for a standard Agrobacterium -mediated transformation. The reason for this unexpectedly high efficiency has not yet been elucidated. The overall process of the invention is of sufficient efficiency for enabling routine applications of the process of the invention. For example, screening of DNA libraries for a useful trait can for the first time be performed in planta with a low danger of missing library members that are not compatible with the prokaryotic systems used for cloning in traditional approaches. This allows to combine the processes of vector engineering (e.g. for functional genomics or directed evolution purposes) with the creation of stable transformants, thus significantly speeding up the process of screening for desired combinations of genetic elements under test.
The process of the invention allows to produce transgenic plants or plant cells that are stably transformed on a chromosome with a DNA sequence of interest, whereby said DNA sequence of interest derives from at least two different vectors. Stable transformation of a chromosome means integration of said DNA sequence of interest in said chromosome such that said DNA sequence of interest is replicated together with said chromosome. Preferably, said DNA sequence of interest can be inherited during cell division and organism reproduction for several generations.
In step (a) of the process of the invention, a plant or plant cells are provided with at least two different vectors, whereby said at least two different vectors are as defined below. Herein, “different vectors” means preferably “different types of vectors”. Plant cells may be provided with said at least two different vectors in issue culture, notably in tissue culture of plant cell protoplasts. Further, explants (e.g. root explants, leaf discs) of a plant may be provided with said at least two different vectors. Moreover, entire plants or parts of entire plants may be provided with said vectors.
Said providing of step (a) may be performed by a direct transformation method (e.g. particle bombardment, electroporation, PEG-mediated transformation of protoplasts) or by Agrobacterium -mediated T-DNA delivery, whereby Agrobacterium -mediated T-DNA delivery is preferred due to its superior efficiency in the process of the invention. Said at least two different vectors may be provided to said plant or said plant cells consecutively. However, said providing with said at least two different vectors is not separated by a cycle of reproduction of the transformed plant or a cycle of regeneration of a plant transformed with one vector followed by transformation with another vector of said at least two different vectors. Preferably, said plant or said plant cells are provided with said at least two vectors in a one-step procedure. In the case of direct vector delivery, this means that mixtures of said vectors are preferably used in step (a). In the case of Agrobacterium -mediated T-DNA delivery, mixtures of Agrobacterium strains (or cells) are preferably used, whereby each strain or cell contains a different Ti-plasmid, each Ti-plasmid containing a different vector of said at least two different vectors. Most preferably, a particular Agrobacterium strain contains one type of Ti-plasmid having a certain vector, but no Ti-plasmids containing a different vector, whereas another Agrobacterium strain contains another type of Ti-plasmid having another type of vector but not Ti-plasmids containing a different vector. I.e. no Agrobacterium cell provides more than one type of said at least two different vectors. Providing said plant cells or plants in a one step procedure with said vectors, notably simultaneously, is work-efficient and gives a good overall efficiency of the process of the invention.
After having provided said plants or said plant cells with said at least two different vectors, a recombination product containing said DNA sequence of interest is formed within plant cells by site-specific recombination between at least two of said at least two different vectors. For this purpose, each of said at least two different vectors is adapted to recombine with at least one other vector of said at least two different vectors. If three or more different types of vectors are used, each may be adapted to recombine with every other vector. For some applications, it may however be sufficient if each vector of said at least two different vectors is adapted to recombine with one other vectors of said at least two different vectors.
Said adaption to recombination may be achieved by including site-specific recombination site(s) on said vectors for enabling said site-specific recombinations. Preferably, said site-specific recombination is adapted such that the reversion (i.e. the back reaction) of said site-specific recombination occurs with low probability. This may e.g. be achieved by providing the enzyme for said recombination transiently (e.g. by rendering the recombinase gene non-expressible by said recombination). More preferably, a site-specific recombinase/recombination site system is chosen that performs irreversible recombinations, which may be achieved by using an integrase together with the appropriate recombination sites. Integrases use two different recombination sites (like AttP and AttB in the case of phi C31 integrase), which allows directed and irreversible recombination.
A gene of a site-specific recombinase or integrase compatible with the selected site-specific recombination sites should be provided (e.g. with one of said at least two different. vectors) such that said recombinase or integrase can be expressed. Preferably, said recombinase or integrase gene is provided on one of said at least two different vectors such that (i) it can be expressed prior to the site-specific recombination event and (ii) such that its expression is blocked after said recombination has occurred. Alternatively, the plant cells or plants provided with said at least two different vectors in step (a) may already contain and express a gene coding for a recombinase or integrase.
By said site-specific recombination between said at least two different vectors, one or more different recombination products may be formed, whereby at least one recombination product contains said DNA sequence of interest. A recombination product containing said DNA sequence of interest is non-replicating in order to avoid disease symptoms due to strong replication of said recombination product. Preferably, all recombination products are non-replicating. Non-replicating means that the recombination product is not a viral nucleic acid capable of autonomous replication, since this generally produces disease symptoms that are incompatible with many applications like gene function determinations. Most preferably, said recombination product does not encode a functional viral replicase supporting replication of the recombination product.
Said DNA sequence of interest contains sequence portions from at least two of said at least two different vectors, whereby said sequence portions are necessary for expressing said function of interest from said DNA sequence of interest. While the DNA sequence of interest may contain three or more sequence portions of three or more different vectors, the DNA sequence of interest preferably contains two sequence portions of two vectors of said at least two different vectors. Recombination between said at least two different vectors may result in the formation of more than one recombination product. At least one recombination product contains said DNA sequence of interest. Other recombination products may be formed that do not contain said DNA sequence of interest.
Said DNA sequence of interest contains sequence portions from at least two of said at least two different vectors. At least two of said sequence portions are necessary for expressing said function of interest from said DNA sequence of interest. Therefore, said function of interest cannot be expressed, if only one vector is provided to said plant cells or said plant. Said DNA sequence of interest may of course also contain sequences deriving from said at least two different vectors that are not necessary for expressing said function of interest.
In a basic embodiment, said plant or said plant cells are provided with two different vectors and a recombination product containing said DNA sequence of interest is assembled from these two different vectors. Said DNA sequence of interest will then contain the two sequence portions of these two different vectors. In a more complex embodiment, said plant or said plant cells are provided with three or more different vectors, which allows the assembly of two or more recombination products each containing a different DNA sequences of interest. Each of said two or more different DNA sequences of interest is preferably assembled from two different vectors. This allows the production of two or more different transgenic plants or plant cells, each transformed on a chromosome with a different DNA sequence of interest. As an example, said plant or plant cell may be provided with three different (types of) vectors referred to as vector A, vector B, and vector C, said vectors containing sequence portions a, b, and c, respectively. Site-specific recombination between vector A and vector B allows assembly of DNA sequence of interest ab. Site-specific recombination of vector A and vector C allows assembly of DNA sequence of interest as. Thus, after segregation and/or selection, two different transgenic plants may be obtained, one being transformed on a chromosome with DNA sequence of interest ab and the other one being transformed on a chromosome with DNA sequence of interest ac. Depending on the arrangement of recombination sites on these three vectors, further DNA sequences of interest may be assembled (e.g. DNA sequences of interest bc, ba, ca, or cb) and further transgenic plants or plant cells may be produced accordingly, each being transformed on a chromosome with one of these DNA sequences of interest.
By providing plant cells or plants with many different vectors, a large number of different DNA sequences of interest (e.g. dozens, hundreds or even more different DNA sequences of interest) may be assembled and introduced into a chromosome for producing many different transgenic plants or plant cells. DNA libraries may in this way be provided to plants or plant cells. The transgenic plants or plant cells produced thereby may then be screened for a useful trait or a desired phenotype. It is in such screening methods where the full potential of the present invention can be made use of.
If three or more different types of vectors are used in the process of the invention, each vector may be adapted to recombine with all other of said at least two different vectors. In the above example with vectors A, B, and C, up to six different DNA sequences of interest may then be formed (ab, ac, bc, ba, ca, and cb). In this general embodiment, the largest combinatorial variety of DNA sequences of interest (and thus transgenic plants) may be formed. In a more special embodiment, a primary vector may be used in a mixture with a set of secondary vectors. Different DNA sequences of interest may then be formed, each containing a sequence portion from said primary vector and a sequence portion from a vector of said set of secondary vectors. The primary vector may e.g. provide sequences that render sequence portions of the secondary vectors expressible after assembly of a DNA sequence of interest containing a sequence portion of said primary vector and a sequence portion of a vector of said set of secondary vectors.
For producing transgenic plants or plant cells that are transformed on a chromosome with a DNA sequence of interest, said at least two different vectors are adapted for integrating said DNA sequence of interest into said chromosome. Said chromosome may be a nuclear chromosome, a plastid chromosome, or a mitochondrial chromosome. Nuclear and plastid chromosomes are preferred and a nuclear chromosome is most preferred. Said adaption for integration depends on the type of chromosome. For integrating said DNA sequence of interest in the plastid chromosome, i.e. the plastome, homologous recombination may e.g. be used. In this case, said vectors and/or the respective sequence portions are adapted such that the recombination product that contains said DNA sequence of interest also contains sequences homologous to plastome sequences for allowing integration of said DNA sequence of interest in the plastome. The sequences homologous to plastome sequences are preferably chosen such that integration takes place at a desired site of the plastome. Methods of plastome transformation are well-established for several plant species, see e.g. Svab et al., 1990 Proc Natl Acad Sci USA. 87, 8526-8530; Koop et al., 1996, Planta, 199, 193-201; Ruf et al., Nat Biotechnol. 2001, 19 (9):870-875; for a review see Maliga, P. 2002, Curr Opin Plant Biol., 5, 164-172; WO 02/057466.
Integration of a DNA sequence of interest into a nuclear chromosome may be achieved e.g. by site-targeted transformation into a pre-engineered integration site using site-specific recombination. Alternatively, said at least two different vectors are adapted such that said DNA sequence of interest or said non-replicating recombination product contains homology sequences that facilitate integration of said DNA sequence of interest into said chromosome by homologous recombination. Preferably, however, nuclear integration is achieved using Agrobacterial T-DNA left and right border sequences in said DNA sequence of interest (see further below and examples). For this purpose, said at least two different vectors are adapted such that said DNA sequence of interest in said non-replicating recombination product has T-DNA border sequences. One or all of said at least two different vectors may contain a functional cytokinin autonomy gene, whereas said DNA sequence of interest is preferably devoid of a functional cytokinin autonomy gene.
A transgenic plant or plant cells transformed on a chromosome with a DNA sequence of interest is capable of expressing a function of interest from said DNA sequence of interest Produced transgenic plants or plant cells that are not capable of expressing a function or that express a function that is not of Interest, may be eliminated in step (b) of the process of the invention. Regarding said function of interest, the process of the invention is not limited. Typically, said function of interest is encoded in a coding sequence contained in said DNA sequence of interest. Said function of interest may be a function of DNA, RNA (notably messenger RNA) or of a protein encoded in said DNA sequence of interest. Preferably, said function of interest is a function of RNA or of a protein encoded in said DNA sequence of interest and expression of said function requires transcription of a coding sequence in said DNA sequence of interest. If said function is a function of a protein encoded in said DNA sequence of interest, expression of said function requires transcription and translation of a coding sequence of said DNA sequence of interest. For said transcription and optionally said translation, the DNA sequence of interest should contain the control elements needed therefore, like a pomoter, a 5′-non-translated region, a 3′-non-translated region, and/or a polyadenylation signal, etc. Said function of interest may e.g. be an antibiotic resistance that may be used for said selection of step (b). More than one function of interest may be expressed from said DNA sequence of interest. Said function of interest is normally related to the reason for performing the process of the invention. Typically, a selectable marker used in step (b) of the invention is among the functions of interest that can be expressed from said DNA sequence of interest.
At least two sequence portions of at least two different vectors are necessary for expressing said function of interest from said DNA sequence of interest. Said function of interest is rendered expressible by assembling said DNA sequence of interest by site-directed recombination between at least two of said at least two different vectors. There are several possibilities how said function of interest can be rendered expressible according to the invention:
Said assembling of said DNA sequence of interest may e.g. bring a coding sequence encoding said function of interest under the control of a regulatory element (e.g. a promoter) necessary for expressing said coding sequence. Thus, a functional expression unit may be formed in said DNA sequence of interest by said assembly. This possibility is particularly preferred if the process of the invention is used for screening a large number of DNA sequences like a collection of DNA sequences (e.g. a library) for a useful trait. Said collection of DNA sequences may e.g. be differently mutated forms of a chosen coding sequence of a protein, whereby said differently mutated forms may e.g. be produced by randomly introducing mutations (e.g. by error-prone PCR or gene shuffling), and a mutant protein encoded by said chosen coding sequence having desired properties may be identified with the process of the invention. In such a screening process, a primary vector may provide said regulatory sequence(s) required for expressing a test sequence from said library and a set of secondary vectors each contains a different test sequence. In this way, a set of transgenic plant cells or plants may be produced each containing a different DNA sequence of interest, whereby these different plants or plant cells may be screened for a useful function of interest (a useful trait of interest) encoded in one of said test sequences.
Alternatively, the process of shuffling can be performed in planta during the process of site-specific recombination-mediated assembly of said DNA sequence of interest. As is shown in FIG. 1B , the vector families A n and B n may be libraries of different variants of structural/functional domains of a protein of interest. Joining said domains through site-specific recombination can create combinatorial diversity of the protein of interest generated in planta. The coding sequences of the diversified protein of interest are stably integrated into plant chromosomal DNA. A schematic representation of a vector most suitable for such shuffling is shown in FIG. 11 .
Another important embodiment allows screening for optimal regulatory sequences (e.g. a promoter) for optimally (in whichever sense) expressing a chosen coding sequence. In this case, a primary vector may provide said coding sequence and a set of different regulatory sequences are provided with a set of secondary vectors. Various transgenic plants or plant cells containing various DNA sequences of interest may be screened and a suitable regulatory element for expressing said chosen coding sequence may be found.
In a further embodiment, said assembling of said DNA sequence of interest may bring together fragments of a coding sequence that codes for a function of interest to be expressed. Preferably, two fragments of a coding sequence are brought together by said assembling, whereby each fragment is provided with a different sequence portion of a different vector. Preferably, each fragment of said coding sequence is not capable of expressing said function of interest in the absence of the other fragment. This may be easily achieved by splitting a coding sequence into two fragments such that each fragment contains a portion necessary for expressing the function of interest. Said two fragment may then be introduced in a vector, whereby two different vectors according to this invention are formed. Each sequence portion may provide some of the regulatory sequences required for expressing said coding sequence from said assembled DNA sequence of interest.
For rendering said coding sequence expressible, expression of said function of interest from said DNA sequence of interest may comprise intron-mediated cis-splicing. Said assembling may assemble concomittantly an intron, notably a self-splicing intron, such that splicing of an RNA expression product of said coding sequence results in an mRNA having both fragments properly connected to each other such that a desired protein may be correctly translated (e.g. as depicted in FIGS. 10 and 11 ). In more detail,
a first vector of said at least two different vectors may contain a first sequence portion that contains: a first part of a sequence coding for the function to be expressed and, downstream thereof, a 5′ part of an intron, and a second vector of said at least two different vectors may contain a second sequence portion that contains: a second part of a sequence coding for a function to be expressed and, upstream thereof, a 3′ part of an intron.
This important embodiment is also illustrated in the examples.
In step (b) of the process of the invention, transgenic plants or plant cells expressing said function of interest are selected. Said selecting may comprise applying an antibiotic or inhibitor suitable for said selectable marker to plant cells or plants obtained in step (a). Said selecting may also comprise screening for transformed plants or plant cells in which recombination between at least two of said at least two different vectors has occurred. Further, said selecting preferably comprises selection for integration of said DNA sequence of interest into said chromosome. Step (b) may also comprise allowing segregation of differently transformed plant cells, notably of plant cells containing different (e.g. differently assembled) DNA sequences of interest. Said selecting, and optionally said segregating, may comprise the use of a selectable marker gene e.g. on said DNA sequence of interest. For this purpose, said at least two different vectors may be adapted such that said DNA sequence of interest contains a selectable marker gene or another sequence that allows screening for transformed plants or plant cells containing said DNA sequence of interest.
Step (b) may be implemented by many different embodiments. A sequence portion of one of said at least two different vectors may contain a selectable marker, whereby said selectable marker is included in said DNA. sequence of interest by said assembling. In a strongly preferred embodiment, said selectable marker is turned on by said assembling of said DNA sequence of interest such that it provides an antibiotic resistance to plant cells containing said assembled DNA sequence of interest but it does not provide antibiotic resistance to cells in which said assembling has not occurred. Most preferably, the selectable marker gene cannot be transcribed in said plant cells from one of said at least two different vectors. This embodiment may be implemented such that said selectable marker is placed under the control of a genetic element, allowing transcription of said selectable marker gene after said assembling of said DNA sequence of interest, e.g. by placing the coding sequence of said selectable marker under the control of a promoter. Advantageously, an IRES (internal ribosome entry site) element may control translation of said selectable marker (cf. FIG. 11 ). References describing the use of IRES elements are given below.
In a further important embodiment, said transgenic plants or plant cells are screened for the absence of one or all of said at least two different vectors and/or for the absence of recombination products thereof with the exception of recombination products containing said DNA sequence of interest. With this embodiment, the production of transgenic plants or plant cells can be avoided that contain unnecessary foreign DNA sequences deriving from said at least two different vectors. These unnecessary foreign DNA sequences may disturb expression of said DNA sequence of interest or may compromise the determination of said function of interest (e.g. in functional genomics studies). This embodiment may be implemented with the use of a counter-selectable marker. Optionally, said screening may be supported by PCR analysis and selection of suitable transformants. At least one of said at least two different vectors may contain a counter-selectable marker gene or another sequence that allows efficient screening against transformed cells containing one of said at least two different vectors. Preferably, said at least two different vectors are adapted such that, after said recombination, said counter-selectable marker gene is contained in recombination products other than nucleic acid molecules containing said DNA sequence of interest. Said counter-selectable marker gene or said another sequence that allows efficient screening against transformed cells containing one or more of said at least two different vectors may advantageously be under translational control of an internal ribosome entry site (IRES) element.
The invention also provides transgenic plants or parts thereof like seeds produced by the process the invention. Preferably, all coding sequences and/or expressible sequences of said sequence of interest in said transgenic plants or parts thereof are of plant origin. Moreover, library of plants, of plant cells, or of plant seeds obtained or obtainable according to process of the invention are provided.
PREFERRED EMBODIMENTS OF THE INVENTION
A process of producing transgenic multi-cellular plants or plant cells stably transformed on a nuclear chromosome with a DNA sequence of interest and capable of expressing a function of interest from said DNA sequence of interest, said process comprising:
(a) providing plant cells or plants with at least two different vectors by Agrobacterium -mediated delivery, whereby
(i) said at least two different vectors are adapted to recombine with each other by site-specific recombination in said plant cells for producing a non-replicating recombination product containing said DNA sequence of interest, (ii) said at least two different vectors are adapted for integrating said DNA sequence of interest into said chromosome such that said DNA sequence of interest contains T-DNA border sequences, (iii) said DNA sequence of interest contains sequence portions from at least two of said at least two different vectors, said sequence portions being necessary for expressing said function of interest from said DNA sequence of interest; and
(b) selecting plants or plant cells expressing said function of interest.
A process of producing different transgenic multi-cellular plants or plant cells transformed on a chromosome, preferably a nuclear chromosome, with a DNA sequence of interest and capable of expressing a function of interest from said DNA sequence of interest, said process comprising the following steps (A) and (B):
(A) providing plants or plant cells with a mixture of
(i) a primary vector having a primary sequence portion a 1 and (ii) a set of n secondary vectors each having a secondary sequence portion selected from the set (b 1 , b 2 , . . . , b n ), whereby n is an integer of >1, said primary sequence portion a 1 is necessary for expressing the function of a secondary sequence portion (b 1 , b 2 , . . . , b n ), said primary vector and said secondary vectors are adapted such that said primary vector can recombine with every member of said set of n secondary vectors by site-specific recombination for producing recombination products containing different DNA sequences of interest of the type (a 1 b 1 , a 1 b 2 , . . . , a 1 b n ) or the type (b 1 a 1 , b 2 a 1 , . . . , b n a 1 ), said primary vector and said secondary vectors are adapted to integrate said DNA sequences of type (a 1 b 1 , a 1 b 2 , . . . , a 1 b n ) or type (b 1 a 1 , b 2 a 1 , . . . , b n a 1 ) into a chromosome,
(B) selecting transformed plants or plant cells expressing a function of interest, preferably from a DNA sequence of interest of type (a 1 b 1 , a 1 b 2 , . . . , a 1 b n ) or type (b 1 a 1 , b 2 a 1 , . . . , b n a 1 ).
Said different transgenic multi-cellular plants differ inter alia in that they contain different DNA sequences of interest Said recombination products containing a DNA sequences of interest may be replicating or non-replicating. Preferably, they are non-replicating as defined in the general description of the invention. Said mixture of primary and secondary vectors is preferably provided to said plant cells by a mixture of Agrobacterium cells, each cell providing one type of vector.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows the general scheme of in planta assembly of a DNA sequence of interest designed for stable integration into plant chromosomal DNA. RS stands for recombination sites.
FIG. 1A shows schematically the assembly of a DNA sequence of interest from two (precursor) vectors.
I—assembly of a DNA sequence of interest (AB) from two different vectors (A and B) by site-specific recombination.
II—assembly of a DNA sequence of interest (AB) from two precursor vectors (AA′ and B′B) that include helper sequences (A′ and B′) absent in said DNA sequence of interest (AB).
FIG. 1 B—shows schematically the assembly of a DNA sequence of interest from more than two different vectors.
I—assembly of a DNA sequence of interest having two-components (A n B n ) from a library of the precursor vectors A and B, where n is the number of precursor vectors in the library.
II—assembly of the three component DNA sequence of interest (ABC) from a library of the precursor vectors A, B and C. RS 1 and RS 2 are recombination sites recognised by different recombinases/integrases.
FIG. 2 depicts schematically the T-DNA regions of binary vectors pICBV19 and pICH10605. GUS—beta-glucuronidase gene; P35S—CaMV35S promoter; BAR—phosphinothricin acetyltransferase gene (pICH10605 has intron disrupting BAR coding sequences); PNOS—promoter of agrobacterial nopaline synthase gene; TNOS—transcription termination region of agrobacterial nopaline synthase gene; TOCS—transcription termination region of octopine synthase gene.
FIG. 3 depicts schematically the T-DNA region of binary vector pICH7410.
GFP—gene encoding green fluorescent protein; NPT—neomycin phoshotransferase II gene conferring resistance to kanamycin; POCS—promoter region of the agrobacterial octopine synthase gene; NTR—3′ non-translated region of tobacco mosaic virus (TMV) RNA; AttB—recombination site.
FIG. 4 depicts schematically the T-DNA regions of plasmids pICH11140 and pICH11150.
PACT2-i—promoter of the Arabidopsis actin2 gene with first intron.
FIG. 5 depicts the T-DNA regions of the binary vectors pICBV16 and pICH8430.
PACT2—promoter of the arabidopsis actin2 gene; TVCV polymerase—RNA-dependent RNA polymerase of turnip vein-clearing virus (TVCV); MP—tobamoviral movement protein; IRESmp75—IRES of crTMV movement protein.
FIG. 6 depicts schematically the T-DNA regions of the binary vectors pICH11160 and pICH11170.
FIG. 7 depicts schematically the T-DNA region resulting from site-specific recombination between T-DNAs of pICH11150 and pICH11170. This region carries a BAR gene interrupted by an intron containing an AttR site. Intron splicing after transcription allows expression of a functional BAR protein.
FIG. 8 depicts schematically the T-DNA regions of the binary vectors pICH12022 and pICH12031 designed for transformation of monocotyledonous plants. PUBQ—promoter of the maize ubiquitin gene; PACT1—promoter of the rice actin1 gene; IPT—gene coding for isopentenyl transferase.
FIG. 9 depicts schematically the T-DNA region resulting from site-specific recombination between T-DNA regions of binary vectors pICH12022 and pICH12031. The region carries a functional BAR gene with an intron under control of the rice actin1 promoter PACT1.
FIG. 10 depicts a scheme of assembling a DNA sequence of interest (C) from two precursor vectors (A and B) including assembly of a functional selectable marker gene from fragments of said selectable marker gene designated “Selectable” and “marker”. Concomittantly, an intron (designated “INTRON”) is assembled from intron fragments designated “INT” and “RON”. P—promoter; T—transcription termination region; CSM—counter-selectable marker; IRES—internal ribosome entry site.
FIG. 11 depicts a scheme of assembling a DNA sequence of interest (C) from two precursor vectors (A and B) including assembly of a functional gene of Interest from fragments of said gene of interest designated “Gene of” and “Interest”. A selectable marker under translational control of an IRES element is rendered expressible by said assembly by placing it under the transcriptional control of a promoter. Both precursor vectors A and B contain a counter-selectable marker gene CSM. By said assembling, CSM ends up in recombination product D that does not contain said gene of interest Using said CSM, transgenic plants or plant cells can be selected that do not contain precursor vector A, nor precursor vector B, nor recombination product D. P—promoter; T—transcription termination region; CSM—counter-selectable marker; IRES—internal ribosome entry site.
FIG. 12 depicts schematically assembly of a complex DNA sequence of interest C by site-specific recombination in planta of vectors A and B. P—promoter; T—transcription termination region; CSM—counter-selectable marker; IRES—internal ribosome entry site; Ds (3′ or 5′)—non-autonomous transposable element (Ds) ends recognised by the Ac transposase; dSpm (3′ or 5′)—non-autonomous transposable element (dSpm) ends recognised by Spm transposase; GOI—gene of interest.
FIG. 13 depicts schematically a method of generating different allelic vectors from a DNA sequence of interest assembled in planta according to FIG. 12 . P—promoter; T—transcription termination region; CSM—counter-selectable marker; IRES—internal ribosome entry site; Ds (3′ or 5′)—non-autonomous transposable element (Ds) ends recognised by Ac transposase; dSpm (3′ or 5′)—non-autonomous transposable element (dSpm) ends recognised by Spm transposase; GOI—gene of interest.
FIG. 14 depicts schematically the T-DNA regions of the binary vectors pICH15820 and pICH15850 designed for transformation of dicotyledonous plants. These vectors may be cotransformed into plants and complement each other according to the invention. PACT2-I—promoter of the Arabidopsis actin2 gene with intron; IPT—gene encoding for isopentenyl transferase; PIPT—IPT promoter; TIPT—IPT gene transcription termination region; NLS—nuclear localisation signal; TNOS—transcription termination region of agrobacterial nopaline synthase gene; TOCS—transcription termination region of octopine synthase gene.
FIG. 15 depicts schematically the T-DNA regions of binary vectors pICH17320 and pICH17330 designed for transformation of dicotyledonous plants. These vectors may be cotransformed e.g. with pICH15850 for performing the process of the invention. PSpm—promoter of Z. mays Spm transposase; PHsp81.1—promoter of the Arabidopsis HSP81.1 gene; IPT—gene encoding isopentenyl transferase; PIPT—IPT promoter; TIPT—IPT gene transcription termination region; NLS—nuclear localisation signal; TNOS—transcription termination region of the agrobacterial nopaline synthase gene; TOCS—transcription termination region of octopine synthase gene.
FIG. 16 depicts schematically vectors pICH15830, pICBV2, and pICH15840.
FIG. 17 depicts schematically vectors pICH13630, pICH15760 in (A), and pICH10881, pICH15770 in (B). The adipt3 and adipt4 adapters shown in (A) correspond to SEQ ID NOS: 7 and 8, respectively.
FIG. 18 . Generation of tobacco transformants on nonselective hormone-free medium. Morphology of regenerated shoots containing T-DNA with an IPT gene (A, B) and without an IPT gene (C).
DETAILED DESCRIPTION OF THE INVENTION
In this invention we describe a process of rapid, inexpensive in planta assembly of a DNA sequence of interest designed for stable integration into a plant chromosome. This approach allows inter alia for fast optimization of the sequences to be expressed by testing various transcription, translation assembled units, units with different protein fusions or different protein targeting or post-translational modification, etc. It can be efficiently used for screening libraries of coding or regulatory sequences of interest. Another application of the invention is the design of safer vectors which are unable to transfer the sequence of interest through an illicit gene transfer. Also, difficult cloning can be avoided during the design of complex DNA regions (e.g. showing instability during cloning procedures in bacterial cells) for stable nuclear transformation, as two or more complex DNA fragments can be linked together in planta prior to integration into plant nuclear DNA.
Current methods of transient or constitutive transgene expression in plants usually employ introducing into plant cell assembled vector(s) with the gene(s) of interest. Transient expression of a sequence of interest is beyond the scope of this invention. The differences between transient and constitutive transgene expression are best exemplified, e.g. within the frame-work of plant functional genomics, where the use of viral vectors can relatively fast provide some initial information about a possible function of a transgene in some cases (WO993651; Kumagai et al., 1995, Proc. Natl. Acad. Sci. USA, 95, 1679-1683). In many other cases, no information or artefacts are obtained. Further, use of viral vectors does not allow further study of the function of a transgene, e.g. during plant development, etc. In addition, Agrobacteria or viral vectors as such cause severe changes in the plant cells, thus making it difficult to study, for example, the functions of genes involved in plant-pathogen interactions. Stably transformed transgenic plants with different expression patterns (e.g. inter- or intracellular compartmentalisation, tissue, organ or cell-specific expression) are required for detailed study of a gene of interest. According to the present invention, the assembly, optimization and identification of a desired DNA sequence of interest for stable nuclear transformation of plant cells can be performed with high efficiency in planta, thus be combined with plant transformation as a one step procedure. In the following, said at least two different vectors of the invention are also referred to as precursor vectors.
The general scheme of such assembly from two or more (precursor) vectors by site-specific DNA recombination is shown in FIG. 1 . The simplest scheme of such assembly is the creation of a DNA sequence of interest ab from two precursors vectors A and B by recombination using the recombination site RS ( FIG. 1A , I). Needless to say that such recombination event shall be selectable. This is easy to achieve e.g. if said recombination creates a functional gene providing for selection.
In one preferred embodiment of the invention, a T-DNA region ( FIG. 7 ) including said DNA sequence of interest is assembled from two precursor vectors represented by two other T-DNA regions ( FIGS. 4 and 6 , bottom) through integrase PhiC31-mediated recombination. Said T-DNA region may contain a functional BAR gene that is absent in the precursor vectors, thus making possible the selection for said recombination event. The integrase necessary for assembly for the T-DNA region of interest may be transiently provided by one of the precursor vectors, pICH11150 ( FIG. 4 ). Because of the irreversibility of the reactions catalyzed by PhiC31 integrase, said integrase can also be constitutively expressed by a genetically engineered plant or plant cell.
Many different site-specific recombinases/integrases that can be used for practicing this invention are known in the art. Suitable recombinases/recombination site systems include inter alia the Cre-Lox system from bacteriophage P1 (Austin et al., 1981, Cell, 25, 729-736), the Flp-Frt system from Saccharomyces cerevisiae (Broach et al., 1982, Cell, 29, 227-234), the R-RS system from Zygosaccharomyces rouxii (Araki et al., 1985, J. Mol. Biol., 182, 191-203), the integrase from the Streptomyces phage PhiC31 (Thorpe & Smith, 1998, Proc. Natl. Acad. Sci., 95, 5505-5510; Groth et al., 2000, Proc. Natl. Acad. Sci., 97, 5995-6000), and resolvases. In addition, other methods of DNA rearrangement are contemplated to be within the scope of the present invention. Other DNA modification enzyme systems can all be used to generate related but functionally distinct DNA sequences of interest inside of a wild-type or a genetically engineered plant cell: restriction endonuclease, transposase, general or specific recombinase, etc. The use of site-specific recombinases with irreversible mode of action is preferred in this invention, as this allows to create a stable recombination product containing said DNA sequence of interest with a predictable structure.
The choice of a suitable promoter to drive expression of the recombinase is of particular value, as it directly affects the performance of the process of the invention, e.g efficiency of assembly of the T-DNA regions and recovery of desired primary transformants in the plant species of choice. The combination of vector pICH15850 carrying a 5′ end of the BAR gene ( FIG. 14 ) with different complementing vectors (e.g. pICH15820, pICH17320, or 17330) produces different results in different plant species. For example, the Arabidopsis actin2 promoter performs better in Arabidopsis than in tobacco, while the promoter of the Arabidopsis gene HSP81.1 gives similarly good results in both plants, Arabidopsis and tobacco.
Different methods may be used for providing a plant cell or a plant with said at least two different vectors (precursor vectors). Said vectors may be transformed into plant cells by a Ti-plasmid vector carried by Agrobacterium (U.S. Pat. No. 5,591,616; U.S. Pat. No. 4,940,838; U.S. Pat. No. 5,464,763) or particle or microprojectile bombardment (U.S. Pat. No. 5,100,792; EP 00444882B1; EP 00434616B1). Other plant transformation methods can also be used like microinjection (WO 09209696; WO 09400583A1; EP 175966B1), electroporation (EP00564595B1; EP00290395B1; WO 08706614A1) or PEG-mediated transformation of protoplasts etc. The choice of precursor vector delivery, like transformation protocols, depends on the plant species to be transformed. For example, microprojectile bombardment is generally preferred for monocot transformation, while for dicots, Agrobacterium -mediated transformation gives better results in general.
In the embodiment described above, we used Agrobacterium -mediated delivery of vector precursors into Nicotiana cells. However, the heterologous DNA may be introduced into the plants in accordance with any of the standard techniques suitable for stable transformation of plant species of interest. Transformation techniques for dicotyledons are well known in the art and include Agrobacterium -based techniques and techniques which do not require Agrobacterium . Non- Agrobacterium techniques involve the uptake of exogenous genetic material directly by protoplasts or cells. These techniques include PEG or electroporation mediated uptake, particle bombardment-mediated delivery and microinjection. Examples of these techniques are described in Paszkowski et al., EMBO J 3:2717-2722 (1984), Potrykus et al., Mol. Gen. Genet. 199:169-177 (1985), Reich et al., Biotechnology 4:1001-1004 (1986), and Klein et al., Nature 327:70-73 (1987). In each case, the transformed cells are regenerated to whole plants using standard techniques.
Agrobacterium -mediated transformation is a preferred technique for the transformation of dicotyledons because of its high transformation efficiency and its broad utility with many different species. The many crop species which may be routinely transformed by Agrobacterium include tobacco, tomato, sunflower, cotton, oilseed rape, potato, soybean, alfalfa and poplar (EP 0 317 511 (cotton), EP 0 249 432 (tomato), WO 87/07299 ( Brassica ), U.S. Pat. No. 4,795,855 (poplar)). Agrobacterium transformation typically involves the transfer of the binary vector carrying the foreign DNA of interest to an appropriate Agrobacterium strain which may depend on the complement of vir genes carried by the host Agrobacterium strain either on a co-resident plasmid or chromosomally (Uknes et al., Plant Cell 5:159-169 (1993). The transfer of the recombinant binary vector to Agrobacterium may be accomplished by a triparental mating procedure using E. coli carrying the recombinant binary vector, a helper E. coli strain which carries a plasmid such as pRK2013, which is able to mobilize the recombinant binary vector to the target Agrobacterium strain. Alternatively, the recombinant binary vector may be transferred to Agrobacterium by DNA transformation (Höfgen & Willmitzer, Nucl. Acids Res. 16, 9877 (1988)).
Transformation of the target plant species by recombinant Agrobacterium usually involves co-cultivation of the Agrobacterium with explants from the plant following protocols known in the art. Transformed tissue carrying an antibiotic or herbicide resistance marker present between the binary plasmid T-DNA borders may be regenerated on selectable medium.
Preferred transformation techniques for monocots include direct gene transfer into protoplasts using PEG or electroporation techniques and particle bombardment into callus tissue.
The patent applications EP 0 292 435, EP 0 392 225 and WO 93/07278 describe techniques for the preparation of callus and protoplasts of maize, transformation of protoplasts using PEG or electroporation, and the regeneration of maize plants from transformed protoplasts. Gordon-Kamm, et al., Plant Cell 2:603-618 (1990), and Fromm, et al., Biotechnology 11:194-200 (1993), describe techniques for the transformation of elite inbred lines of maize by particle bombardment.
Transformation of rice can also be undertaken by direct gene transfer techniques utilizing protoplasts or particle bombardment. Protoplast-mediated transformation has been described for Japonica-types and Indica-types (Zhange, et al., Plant Cell Rep. 7:739-384 (1988); Shimamoto, et al., Nature 338:274-277 (1989); Datta, et al., Biotechnology 8:736-740 (1990)). Both types are also routinely transformable using particle bombardment (Christou, et al., Biotechnology 9:957-962 (1991)). Agrobacterium -mediated rice transformation is also applicable (Chan et al., 1993, Plant Mol. Biol., 22, 491-506).
EP 0 332 581 describes techniques for the generation, transformation and regeneration of Pooideae protoplasts. Furthermore, wheat transformation is described by Vasil, et al., Biotechnology 10:667-674 (1992) using particle bombardment into cells of type C long-term regenerable callus. Vasil, et al., Biotechnology 11:1553-1558 (1993) and Weeks, et al., Plant Physiol. 102:1077-1084 (1993) describe particle bombardment of immature embryos and immature embryo-derived callus.
Transformation of monocot cells such as Zea mays may be achieved by bringing the monocot cells into contact with a multiplicity of needle-like bodies on which these cells may be impaled, causing a rupture in the cell wall thereby allowing entry of transforming DNA into the cells (see U.S. Pat. No. 5,302,523). Transformation techniques applicable to both monocots and dicots are also disclosed in the following U.S. Pat. No. 5,240,855 (particle gun); U.S. Pat. No. 5,204,253 (cold gas shock accelerated microprojectiles); U.S. Pat. No. 5,179,022 (biolistic apparatus); U.S. Pat. Nos. 4,743,548 and 5,114,854 (microinjection); and U.S. Pat. Nos. 5,149,655 and 5,120,657 (accelerated particle mediated transformation); U.S. Pat. No. 5,066,587 (gas driven microprojectile accelerator); U.S. Pat. No. 5,015,580 (particle-mediated transformation of soy bean plants); U.S. Pat. No. 5,013,660 (laser beam-mediated transformation); U.S. Pat. Nos. 4,849,355 and 4,663,292.
Transgenic plant cells or plant tissue transformed by one of the methods described above may then be grown to full plants in accordance with standard techniques. Transgenic seeds can be obtained from transgenic flowering plants in accordance with standard techniques. Likewise, non-flowering plants such as potato and sugar beets can be propagated by a variety of known procedures. See, e.g., Newell et al. Plant Cell Rep. 10:30-34 (1991) (disclosing potato transformation by stem culture).
The assembly of a DNA sequence of interest in planta from precursor vectors can be greatly facilitated by the presence of helper (auxiliary) sequences A′ and B′ ( FIG. 1A , II) which are preferably absent in the assembled DNA sequence of interest AB ( FIG. 1A , II). These helper sequences may end up in recombination products that do not contain said DNA sequence of interest. Such auxiliary sequences can provide genes of interest that are necessary for assembly of the DNA sequence of interest (e.g. recombinases), removal of transformants carrying a precursor vector stably integrated into chromosomal DNA (e.g. using counter-selectable marker genes), transiently provide for gene products necessary for early stages of tissue culture (e.g. genes responsible for biosynthesis of phytohormones), etc.
In one preferred embodiment of the invention, the generation of a DNA sequence of interest for monocotyledonous plants ( FIG. 9 ) from precursor vectors ( FIG. 8 ) is described. Said precursor vectors may contain two types of auxiliary sequences—one may provide for the site-specific integrase PhiC31 and another may provide for isopentenyl transferase (IPT) altering endogenous cytokinins in affected plant cells (Medford et al., 1989, Plant Cell, 1, 403-413). The IPT gene, in an addition to being used as inducer of axillary bud formation, can be used as selectable marker gene causing plant morphological abnormality, once stably integrated into chromosomal DNA (Ebinuma et al., 1997, Proc. Natl. Acad. Sci. USA, 94, 2117-2121). In this embodiment, the IPT gene can be used as counter-selectable marker allowing for identification and removal of the transformed plant tissues containing precursor vector sequences stably integrated into genomic DNA. FIG. 18 shows tobacco regenerants that contain the IPT gene in T-DNA. They are clearly distinct from the regenerants not having the IPT gene. Other examples of counter-selectable markers (CSM) for use in the present invention are the gene coding for conditionally lethal cytosine desaminase (cod A) (Gleave et al., 1999, Plant Mol. Biol., 40, 223-235) or a gene coding for bacterial cytochrome P-450 (O'Keefe et al., 1994, Plant Physiol., 105, 473-482).
In another preferred embodiment, a mixture of more than two different precursor vectors is used for assembling various DNA sequences of interest. Said DNA sequences of interest may be the result of random site-specific recombination events between two sets of precursor vectors (set A n and set B n , FIG. 1B , I). Actually, a set of DNA sequences of interest of the type A n B n may be generated in a plant cell by site-specific recombination of a set of precursor vectors (A 1 , A 2 , . . . , A n ) with a set of precursor vectors (B 1 , B 2 , . . . , B n ), wherein n is the number of precursor vectors of type A or type B. At least three different precursor vectors are needed to endow the cell with at least two different DNA sequences of interest. The number of all possible combinations of DNA sequences of interest that can be assembled from the plurality of precursor vectors A and the plurality of precursor vectors B may be calculated by multiplying the number of precursor vectors of type A times number of precursor vectors of type B.
Examples for nucleic acid sequences represented as part of A or B and joint together by site-specific recombination may be coding sequences or parts thereof or any genetic elements. Herein, such a genetic element (or regulatory element) may be any DNA element that has a distinct genetic function on DNA or RNA level, said function is other than coding for a structural part of a gene. Examples include: transcriptional enhancers, promoters or parts thereof, translational enhancers, recombination sites, transcriptional termination sequences, internal ribosome entry sites (IRESes), restriction sites, autonomously replicating sequences or origins of replications.
In this invention, the recombination product containing said DNA sequence of interest can consist of components of more than two precursor vectors. In FIG. 1B , II, the assembly of such a DNA sequence of interest containing sequence portions from three different precursor vectors A, B and C, is shown. However, for efficient assembly of said DNA sequence of interest, the use of more than one type of recombinase and/or integrases may be required.
The assembly of a DNA sequence of interest for stable integration into a chromosome of a plant cell allows for the selection of plant cells with said DNA sequence of interest integrated into the chromosomal DNA. One possible mechanisms of selection for said DNA sequence of interest is the assembly of a functional selectable marker gene as is described in detail in examples 1-3 and shown in general in FIG. 10 . The use of a counter-selectable marker gene (CSM) in all precursor vectors ( FIGS. 10 and 11 ) allows for easy removal of plant cells carrying precursor vectors stably integrated into chromosomal DNA. In some cases, the assembly of a DNA sequence of interest together with the assembly of a functional gene of interest might be an advantage, e. g. when the gene of interest is toxic for bacterial cells. The selectable marker in such cases can be a part of a bicistronic construct under control of an IRES element ( FIG. 11 ). The site-specific recombination of precursor vectors (A and B in FIG. 11 ) may lead to the formation of DNA sequence of interest carrying the functional bicistronic construct with the gene of interest followed by an IRES-controlled selectable marker gene. The use of IRES elements in plants is known in the prior art (WO9854342; WO0246440; Dorokhov et al., 2002, Proc. Natl. Acad. Sci. USA, 99, 5301-5306) and can be routinely practiced in combination with the present invention.
The assembly of complex vectors in planta from precursor vectors that are of simpler structure can be a further advantage, allowing to avoid complex cloning steps and/or manipulation with unstable DNA structures in bacterial cells. The assembly of the DNA sequence of interest for generating different derivative vectors in allelic position toward each other is shown in FIG. 12 . Said DNA sequence of interest (FIG. 12 ,C) stably integrated into the plant chromosomal DNA can be further exposed to a transposase of choice (Ac or Spm, FIG. 13 ), allowing to remove the targeted sequences (flanked by Ds sequences for Ac or dSpm sequences for Spm). The final derivative vectors B and C ( FIG. 13 ) are allelic in relation to each other and encode different parts of a gene of interest (GOI) that can be assembled through intein-mediated trans-splicing. This approach addresses biosafety issues, e.g. the control of trangene segregation, as the two fragments of the same gene providing for a trait of interest would always segregate to different gametes due to their allelic location. Details on biologically/environmentally safe transgenic plants having fragments of a transgene in allelic relation can be found in WO03/102197.
The transgenic plants or plant cells produced according to the invention may be used for many different purposes, some of which have been mentioned above. In a further application, the DNA sequence of Interest assembled in planta may in turn also be used as a precursor vector for downstream processes. Said DNA sequence of interest may e.g. be induced to form an extrachromosomal DNA like an independently maintained episomal vector. This inducing may e.g. be achieved by crossing a transgenic plant of the invention carrying said DNA sequence of interest with another plant that provides a factor capable of exerting the inducing function or triggering the formation of said extrachromosomal/episomal DNA. Alternatively, the formation of such an episomal DNA can be caused e.g. by transient expression of a factor (e.g. transposase, viral replicase, etc.) capable of triggering formation of the extrachromosomal/episomal DNA from said DNA sequence of interest. Said episomal DNA may be capable of further reintegration (e.g. it may be or have properties of a transposable element) or be capable of independent maintenance during cell divisions (derivative of DNA viral vector).
The present invention is preferably carried out with higher, multi-cellular plants. Preferred plants for the use in this invention include any plant species with preference given to agronomically and horticulturally important species. Common crop plants for the use in present invention include alfalfa, barley, beans, canola, cowpeas, cotton, corn, clover, lotus, lentils, lupine, millet, oats, peas, peanuts, rice, rye, sweet clover, sunflower, sweetpea, soybean, sorghum triticale, yam beans, velvet beans, vetch, wheat, wisteria, and nut plants. The plant species preferred for practicing of this invention are including but not restricted to: Representatives of Gramineae, Compositeae, Solanaceae and Rosaceae.
Additionally, preferred species for use the invention, as well as those specified above, plants from the genera: Arabidopsis, Agrostis, Allium, Antirrhinum, Apium, Arachis, Asparagus, Atropa, Avena, Bambusa, Brassica, Bromus, Browaalia, Camellia, Cannabis, Capsicum, Cicer, Chenopodium, Chichorium, Citrus, Coffea, Coix, Cucumis, Curcubita, Cynodon, Dactylis, Datura, Daucus, Digitalis, Dioscorea, Elaeis, Eleusine, Festuca, Fragaria, Geranium, Glycine, Helianthus, Heterocallis, Hevea, Hordeum, Hyoscyamus, Ipomoea, Lactuca, Lens, Lilium, Linum, Lolium, Lotus, Lycopersicon, Majorana, Malus, Mangifera, Manihot, Medicago, Nemesia, Nicotiana, Onobrychis, Oryza, Panicum, Pelargonium, Pennisetum, Petunia, Pisum, Phaseolus, Phleum, Poa, Prunus, Ranunculus, Raphanus, Ribes, Ricinus, Rubus, Saccharum, Salpiglossis, Secale, Senecio, Setaria, Sinapis, Solanum, Sorghum, Stenotaphrum, Theobroma, Trifolium, Trigonella, Triticum, Vicia, Vigna, Vitis, Zea , and the Olyreae, the Pharoideae and many others.
Within the scope of this invention the plant species, which are not included into the food or feed chain are specifically preferred for pharmaceutical and technical proteins production. Among them, Nicotiana species are the most preferred, as the species easy to transform and cultivate with well developed expression vectors (especially viral vectors) systems.
Genes of interest, their fragments (functional or non-functional) and their artificial derivatives that can be expressed in plants or plants cells using the present invention include, but are not limited to: starch modifying enzymes (starch synthase, starch phosphorylation enzyme, debranching enzyme, starch branching enzyme, starch branching enzyme II, granule bound starch synthase), sucrose phosphate synthase, sucrose phosphorylase, polygalacturonase, polyfructan sucrase, ADP glucose pyrophosphorylase, cyclodextrin glycosyltransferase, fructosyl transferase, glycogen synthase, pectin esterase, aprotinin, avidin, bacterial levansucrase, E. coli gIgA protein, MAPK4 and orthologues, nitrogen assimilation/methabolism enzyme, glutamine synthase, plant osmotin, 2S albumin, thaumatin, site-specific recombinase/integrase (FLP, Cre, R recombinase, Int, SSVI Integrase R, Integrase phiC31, or an active fragment or variant thereof, isopentenyl transferase, Sca M5 (soybean calmodulin), coleopteran type toxin or an insecticidally active fragment, ubiquitin conjugating enzyme (E2) fusion proteins, enzymes that metabolise lipids, amino acids, sugars, nucleic acids and polysaccharides, superoxide dismutase, inactive proenzyme form of a protease, plant protein toxins, traits altering fiber in fiber producing plants, Coleopteran active toxin from Bacillus thuringiensis (Bt2 toxin, insecticidal crystal protein (ICP), CryIC toxin, delta endotoxin, polyopeptide toxin, protoxin etc.), insect specific toxin AaIT, cellulose degrading enzymes, E1 cellulase from Acidothermus celluloticus , lignin modifying enzymes, cinnamoyl alcohol dehydrogenase, trehalose-6-phosphate synthase, enzymes of cytokinin metabolic pathway, HMG-CoA reductase, E. coli inorganic pyrophosphatase, seed storage protein, Erwinia herbicola lycopen synthase, ACC oxidase, pTOM36 encoded protein, phytase, ketohydrolase, acetoacetyl CoA reductase, PHB (polyhydroxybutanoate) synthase, acyl carrier protein, napin, EA9, non-higher plant phytoene synthase, pTOM5 encoded protein, ETR (ethylene receptor), plastidic pyruvate phosphate dikinase, nematode-inducible transmembrane pore protein, trait enhancing photosynthetic or plastid function of the plant cell, stilbene synthase, an enzyme capable of hydroxylating phenols, catechol dioxygenase, catechol 2,3-dioxygenase, chloromuconate cycloisomerase, anthranilate synthase, Brassica AGL15 protein, fructose 1,6-biphosphatase (FBPase), AMV RNA3, PVY replicase, PLRV replicase, potyvirus coat protein, CMV coat protein, TMV coat protein, luteovirus replicase, MDMV messenger RNA, mutant geminiviral replicase, Umbellularia californica C12:0 preferring acyl-ACP thioesterase, plant C10 or C12:0 preferring acyl-ACP thioesterase, C14:0 preferring acyl-ACP thioesterase (luxD), plant synthase factor A, plant synthase factor B, D6-desaturase, protein having an enzymatic activity in the peroxysomal b-oxidation of fatty acids in plant cells, acyl-CoA oxidase, 3-ketoacyl-CoA thiolase, lipase, maize acetyl-CoA-carboxylase, 5-enolpyruvylshikimate-3-phosphate synthase (EPSP), phosphinothricin acetyl transferase (BAR, PAT), CP4 protein, ACC deaminase, protein having posttranslational cleavage site, DHPS gene conferring sulfonamide resistance, bacterial nitrilase, 2,4-D monooxygenase, acetolactate synthase or acetohydroxyacid synthase (ALS, AHAS), polygalacturonase, Taq polymerase, bacterial nitrilase, many other enzymes of bacterial or phage including restriction endonucleases, methylases, DNA and RNA ligases, DNA and RNA polymerases, reverse trascryptases, nucleases (Dnases and RNAses), phosphatases, transferases etc.
The present invention also can be used for the purpose of molecular farming and purification of commercially valuable and pharmaceutically important proteins including industrial enzymes (cellulases, lipases, proteases, phytases etc.) and fibrous proteins (collagen, spider silk protein, etc.). Human or animal health protein may be expressed and purified using described in our invention approach. Examples of such proteins of interest include inter alia immune response proteins (monoclonal antibodies, single chain antibodies, T cell receptors etc.), antigens including those derived from pathogenic microorganisms, colony stimulating factors, relaxins, polypeptide hormones including somatotropin (HGH) and proinsulin, cytokines and their receptors, interferons, growth factors and coagulation factors, enzymatically active lysosomal enzyme, fibrinolytic polypeptides, blood clotting factors, trypsinogen, a1-antitrypsin (AAT), human serum albumin, glucocerebrosidases, native cholera toxin B as well as function-conservative proteins like fusions, mutant versions and synthetic derivatives of the above proteins.
The above proteins and others can optimised for a desired purpose by introducing random mutations into their coding sequence or by gene shuffling methods. Screening for a protein having optimised properties for the desired purpose may then be done using the process of the present invention.
EXAMPLES
The following examples are presented to illustrate the present invention. Modifications and variations may be made without departing from the spirit and scope of the invention.
Example 1
Vector Design for the Stable Transformation of Dicotyledonous Plants with Split BAR Gene
Design of pICH11150
This construct was done on the basis of binary vector pICBV-19 ( FIG. 2 ). As a first step of cloning, the target BsaI restriction sites for the intron insertion were introduced into the BAR gene (construct pICH10605, FIG. 2 ). The BsaI enzyme cuts DNA outside of the recognition site making 4 nucleotides overhang. In the case of pICH10605, the BsaI enzyme was used to introduce splicing acceptor and donor sites for the consequent intron insertion. As a next step, PCR fragment amplified on pICH7410 ( FIG. 3 ) construct with oligos int-ad-9 (5′-tttttggtc cgacctgcaa caataagaac aaaaagtcat aaatt-3′; SEQ ID NO: 1) and attbpr11 (5′-tttaagcttg agctctttcc taggctcgaa gccgcggtgc gggtg-3′; SEQ ID NO: 2) was inserted into pICH10605 using BsaI and HindIII restriction sites. The PCR fragment containing AttB and 3′ part of intron as well as AvrII and SacI restriction sites replaced the GUS expression cassette and 5′part of BAR expression cassette. The T-DNA part of the resulting construct (pICH11140, FIG. 4 ) contained the 3′ part of BAR expression cassette: AttB, 3′part of the intron, 3′ part of BAR-gene and OCS terminator as well as AvrII and SacI restriction sites. As a final step of 3′ construct cloning, a PhiC31 integrase expression cassette containing Arabidopsis actin 2 promoter, PhiC31 integrase and NOS terminator was introduced into pICH11140 using AvrII and SacI restriction sites. The final construct pICH11150, containing 3′ end of BAR gene with AttB, recombination site together with the 3′ end of the intron, as well as PhiC31 integrase expression cassette is shown in FIG. 4 .
Design of pICH11170
This construct was done on the basis of binary vector pICBV-16 ( FIG. 5 ). The PCR fragment amplified from pICH8430 ( FIG. 5 ) with oligos int-ad-10 (5′-tttaagcttg aattcttttg gtctcaggta agtttcattt tcataattac aca-3′; SEQ ID NO: 3) and attppr14 (5′-tttttcaatt ggagctccta cgcccccaac tgagagaac-3′; SEQ ID NO: 4) was cut with HindIII and MfeI restriction enzymes and introduced into pICBV-16 digested with HindIII and EcoRI. PCR fragment containing 5′ part of intron and AttP as well as BsaI and EcoRI restriction sites replaced the GUS expression cassette in intermediate construct pICH11160 ( FIG. 6 ). As the final step of the cloning, EcoRI/BsaI fragment of pICH10605 ( FIG. 2 ) containing a NOS promoter and 5′ part of BAR gene was inserted into pICH11160. The T-DNA region of the final construct pICH11170 is shown in FIG. 6 .
Further vectors for use in the invention are described in the following.
Design of pICH17330
The AvrII/NcoI DNA fragment containing the Arabidopsis Hsp81.1 promoter and fragment of PhiC31 integrase ORF was transferred into the pICH15820 ( FIG. 14 ) construct linearised with AvrII and NcoI enzymes yielding pICH 17330 ( FIG. 15 ).
Design of pICH17320
The Spe/NcoI DNA fragment containing the complete Spm promoter and the fragment of PhiC31 integrase ORF was transferred into pICH15820 ( FIG. 14 ) construct linearised with AvrII and NcoI enzymes yielding pICH17320 ( FIG. 15 ).
Design of pICH15850
The NotI/SacI fragment of pICH11170 ( FIG. 6 ) was fused with adapters adipt1 (5′ ggccgctttt tatgcattt tttgagctct cgcgaggatc ctagct 3′; SEQ ID NO: 5) and adipt2 (5′ aggatcctcg cgagagctca aaaaatgcat aaaaagc 3′; SEQ ID NO: 6) that destroyed the original SacI site and introduced BamHI, SacI and NsiI sites, producing pICH15830 ( FIG. 16 ). For pICH15840 cloning, the NotI/NsiI fragment of pICBV2 ( FIG. 16 ) was transferred to the pICH15830 ( FIG. 16 ) construct, reintroducing T-DNA left border region which was excised in the first step of cloning. The BamHI/SacI fragment of pICH15820 ( FIG. 14 ) containing complete IPT gene was transferred to pICH15840, resulting in pICH15850 ( FIG. 14 ).
Design of pICH15820
The cloning of 3′ split-BAR construct with isopenthenyl transferase (IPT) gene (pICH15820) comprised several steps. In the pICH13630 construct (FIG. 17 ,A), adapter adipt3/adipt4 that destroyed original AvrII and SacI sites and introduced SacI and AvrII sites in reverse orientation replaced AvrII/SacI fragment. In addition, this adapter introduced SpeI and XhoI sites for the insertion of IPT gene (pICH15760, FIG. 17 , A). The AvrII/SacI fragment containing a PhiC31 integrase expression cassette ( Arabidopsis actin 2 promoter-PhiC31 integrase ORF with C-terminal nuclear localization signal-nos terminator) was transferred from pICH10881 to pICH15760 resulting in pICH15770 ( FIG. 17 , B)
Isopenthenyl transferase (IPT) gene (including original promoter and terminator regions) of Agrobacterium strain C58 (appr. 2 kb) was amplified by PCR as 4 fragments flanked by BsaI restriction sites. PCR fragments were subcloned into pGEM-T vectors and then isolated using BsaI enzyme having its recognition site outside of the digestion site. This allows to create 4 bp overhangs with any nucleotide sequence enabled to assemble the entire IPT gene and insert it into the pICH15770 ( FIG. 17 ) contruct linearised with XhoI/SpeI in one ligation step. This cloning resulted in pICH15820 ( FIG. 14 ).
Example 2
Agrobacterium -Mediated Transformation of the Dicotyledonous Plant Nicotiana tabacum (cv Petit Havana) and Arabidopsis thaliana with in planta Assembled T-DNA Region
The constructs pICH11150 and pICH11170 were immobilized into A. tumefaciens (GV3101) and used for Agrobacterium -mediated leaf discs transformation of Nicotiana plants (Horsh et al., 1985, Science, 227, 1229-1231) using 10 mg/L of phosphinothricin (PPT) as selectable marker. Arabidopsis thaliana plants were transformed using a vacuum infiltration protocol (Bechtold et al., 1993, C. R. Acad. Sci. Paris Life Sci. 316, 1194-1199). Phosphinothricine-resistant (PPT R ) transformants were selected by spraying one-week-old plantlets with a 2.5 ml/L of Harvest™ (Agrevo) solution (active ingredient glufosinate, commercially available PPT-analogous compound).
Regenerated tobacco plants and selected A. thaliana primary transformants were PCR analysed for the presence of an in planta assembled T-DNA region stably integrated into chromosomal DNA ( FIG. 7 ) and for the absence of the T-DNA regions of pICH11150 and pICH11170. PCR analysis demonstrated that approximately 8% of all Arabidopsis transformants contained the desired T-DNA region ( FIG. 7 ) without co-integrated T-DNA regions of pICH11150 and pICH11170. The same analysis of tobacco regenerants revealed a significantly lower frequency of plants with desired genotype than observed with Arabidopsis —less than 0.1%. Similar results described above were obtained with the complementing pair of constructs pICH15820 and pICH15850 ( FIG. 14 ). However, there were no primary transformants resulting from co-integration (and restoration of BAR activity by intron formation) of said T-DNA regions, but only from site-specific recombination. This might be explained by the presence of a large region separating the 3′ and 5′ parts of introns of co-integrated T-DNAs. New set of constructs using integrase under control of different promoters (either Zea mays Spm transposase (pICH17320, FIG. 15 ), or Arabidopsis heat shock protein Hsp81.1 (pICH17330, FIG. 15 ) was generated. These vectors in combination with complementary vector pICH15850 ( FIG. 14 ) showed much better results than vector pICH15820 ( FIG. 14 ). For example, the frequency of tobacco transformants carrying correctly recombined T-DNA regions without co-integrated T-DNAs were approx 10% or more depending on experiments. This demonstrates that the efficiency of the process can be affected by controlling the efficiency of integrase expression and can be adjusted to any plant species of interest. The regenerating tobacco phenotypes with and without IPT gene are shown in FIG. 18 .
Example 3
Vector Design and Agrobacterium -Mediated Transformation of Monocotyledonous Plants with Split BAR Gene
For the design of constructs using a split BAR gene to monitor desired T-DNA region assembly in planta, the original constructs pICH11150 and pICH11170 (see EXAMPLE 1) were used. The construct pICH11150 was modified by replacing the Arabidopsis actin2 (PACT2-i,) promoter with rice actin1 (PACT1) promoter (McElroy D, et al., 1991, Mol Gen Genet., 231, 150-160) yielding construct pICH12022 ( FIG. 8 ). The construct pICH11170 was modified by replacing the nopaline synthase promoter (PNOS) driving expression of the BAR gene fragment with the rice actine1 promoter (PACT1) and the NPTII expression cassette with IPT (isopentenyl transferase, Gene Bank Acc. No.: X14410) expression cassette under control of maize ubiquitin gene promoter (PUBQ) (Christensen A H & Quail P H., 1996, Transgenic Res., 5, 213-218) yielding construct pICH12031 ( FIG. 8 ). All manipulations for construct design were performed using standard cloning procedures (Sambrook, Fritsch & Maniatis, 1989, Molecular cloning: A laboratory manual, 2nd ed. Cold Spring Harbor, N.Y.: CSH Laboratory Press).
The line PEN3 of Pennisetum glaucum was used for Agrobacterium -mediated transformation with plasmids pICH12022 and pICH12031. Aliquotes of Agrobacterium tumefaciens AGL1 strain carrying either pICH12022 or pICH12031 were mixed together in equal proportions and used for transformation as described below.
The culture medium included Murashige and Skoog (MS) salts and vitamins: (Reference: Murashige, T. & Skoog, F. A 1962, Physiol. Plant., 15, 473-497) with 2.0 mg/L of 2,4-D, which is 2,4-Dichlorophenoxyacetic acid, 30 g/l sucrose and 0.3% gelrite. Regeneration medium contained a half-strength MS salts and vitamins with 20 g/L maltose, 1 mg/L IAA, 1 mg/L Zeatin and 0.6% gelrite.
Infection medium (IM) contained a half-strength MS salts and vitamins with 2 mg/L 2,4-D, 10 g/L glucose, 60 g/L maltose, 50 mg/L ascorbic acid, 1 g/L MES (2-N-morpholinoethanesulfonic acid) and 40 mg/L Acetosyringone (AS). The pH of the medium was adjusted to 5.2 by 1 N KOH. Cocultivation medium (CM) was same as the IM (excluding ascorbic acid) and was solidified by adding 0.6% gelrite.
Infection medium was filter sterilized, whereas all other media were autoclaved. AS, dissolved in DMSO (400 mg/mL), was added after sterilization.
Agrobacterial cultures (strains AGL1, EHA105, A4 etc.) with the appropriate binary plasmids were grown for 3 days at room temperature on LB2N (LB medium with 2 g/L NaCl and 1.5% agar) plates supplemented with the appropriate antibiotics. Bacteria were scraped from the plates and resuspended in IM in 50-mL falcon tubes. The tubes were fixed horizontally to a shaker platform and shaken at low speed for 4 to 5 h at room temperature. Optical density of the suspension was measured and OD600 was adjusted to 1.0.
Callus pieces were incubated in the Agrobacterial suspension for 3 hours at room temperature and transferred to the gelrite-solidified CM with 60 g/L maltose.
After 3 days of cultivation on CM, the calli were washed five times by half-strength MS medium with 60 g/L sucrose and transferred to the gelrite-solidified CM with 60 g/L sucrose and 5 mg/L phosphinothricin (PPT) and, in some cases, 150 mg/L Timentin. Phosphinothricin-resistant calli developed under selection were plated to the regeneration medium with 5 mg/L PPT.
The regenerating PPT R plant tissues were initially visually tested for the absence of functional IPT gene causing adventitious formation of shoots in hormone-free media (Ooms et al., 1983, Theor. Appl. Genet., 66, 169-172; Smigocki, A C & Owens, L D., 1989, Plant Physiol., 91, 808-811; Smigocki, A C & Owens, L D. 1988, Proc. Natl. Acad. Sci. USA, 85, 5131-5135). Secondary screening for plants carrying in planta assembled T-DNA region ( FIG. 9 ) and for the absence of T-DNA regions from pICH12022 and pICH12031 were carried out by using PCR analysis of PPT R plant tissue for the presence of integrase PhiC31 and IPT gene sequences.
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A process of producing transgenic plants or plant cells stably transformed on a chromosome with a DNA sequence of interest capable of expressing a function of interest, said process comprising (a) providing plant cells or plants with at least two different vectors that are adapted to recombine with each other between site-specific recombination sites compatible with a site-specific recombinase that is also provided in order to produce a non-replicating recombination product containing said DNA sequence of interest, (ii) said at least two different vectors are adapted for integrating said DNA sequence of interest into said chromosome, (iii) said DNA sequence of interest contains sequence portions from at least two of said at least two different vectors, said sequence portions being necessary for expressing said function of interest from said DNA sequence of interest; and (b) selecting plants or plant cells expressing said function of interest.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a mobile communications system, and in particular to a micro-cellular communications system which performs call connections between mobile terminals.
2. Description of the Related Art
In mobile communications, a user having a mobile terminal therewith may move from one cell to another or between different service areas. Therefore, it is important to inform the user through the mobile terminal where it is located. A navigation system using GPS (Global Positioning System) has been known as such a location displaying system.
Further, a mobile navigation system combining a mobile communications system with the navigation system has been proposed in Japanese Patent Unexamined Publication No. 1-142899. More specifically, in the mobile navigation system, a mobile switching center is provided with a map information memory. When receiving the location information of a mobile terminal, the mobile switching center reads map information based on the location information from the map information memory and transmits it to that mobile terminal. Therefore, the mobile terminal can display the map information appropriate for the location on screen and the user can easily be informed where the user is.
SUMMARY OF THE INVENTION
In the case of calling, however, the calling user cannot know where the destination terminal is located. In other words, the conventional system cannot provide the location information of both sides of connection. Therefore, the calling and called users cannot be informed whether they are near. Further, the conventional mobile terminal needs the GPS receiver, resulting in increased amount of hardware and complicated circuit in the mobile terminal.
An object of the present invention is to provide a mobile communications system and a mobile terminal which can provide the location information of both the mobile terminal and another mobile terminal with reduced size and weight.
Another object of the present invention is to provide a mobile terminal which can receive and display the map information including the location of another mobile terminal.
According to the present invention, in a mobile communications system comprising a plurality of radio cell stations each forming a micro cell and performing call connections between mobile terminals, location data and map data for each of the radio cell stations are stored onto a database. When receiving a data request from a first mobile terminal through a first radio cell station, the data request including designation of a second mobile terminal, the database is searched for first location data of the first radio cell station, second location data of a second radio cell station forming a micro cell in which the second mobile terminal is located, and map data for at least one of the first and second radio cell stations. Then the first and second location data and retrieved map data are transferred to the first mobile terminal through the first radio cell station.
The first mobile terminal, when receiving the first and second location data and retrieved map data from the mobile communications system through the first radio cell station, displays a map and two locations corresponding to the first and second mobile terminals on screen based on the retrieved map data and the first and second location data.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a mobile communications system according to an embodiment of the present invention;
FIG. 2 is a diagram showing an example of a table stored in the location information database;
FIG. 3 is a block diagram showing a mobile terminal of the embodiment;
FIG. 4 is a sequence diagram showing an operation of the mobile communications system of FIG. 1;
FIGS. 5A-5D are signal formats of data request messages used in the mobile communications system;
FIG. 6A is a schematic diagram showing an example of display screen in the mobile terminal PS 2 ;
FIG. 6B is a schematic diagram showing an example of display screen in the mobile terminal PS 3 ; in the case as in FIG. 6A;
FIG. 6C is a schematic diagram showing an overlapped area of two adjacent map areas;
FIGS. 7A and 7B are signal formats of map data request messages used in the mobile communications system;
FIG. 8A is a schematic diagram showing another example of display screen in the mobile terminal PS 2 ;
FIG. 8B is a schematic diagram showing another example of display screen in the mobile terminal PS 3 ; in the case as in FIG. 8A; and
FIG. 9 is a schematic diagram showing a map area arrangement to be retrieved in the case where two map areas are separated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a micro-cellular communications system is composed of a location information database 101 , a plurality of mobile switching centers 102 , 103 , . . . , each having a plurality of radio cell stations connected thereto. Each radio cell station CS forms a micro cell of the order of 100 to 500 meters in which a mobile terminal (or a personal station) communicates with that radio cell station by radio. The radio cell stations are placed to cover the service area with their micro cells and each mobile terminal can move freely between micro cells. As will be described later, the location of a mobile terminal can be detected depending on which micro cell the mobile terminal is located in. Since each micro cell is of 100 to 500 meters diameter, the detected location of the mobile terminal has an error of 100-500 meters at the maximum.
It is assumed for simplicity that the location information database 101 can be shared between the mobile switching centers 102 and 103 and that radio cell stations CS 1 and CS 2 are connected to the mobile switching center 102 and radio cell stations CS 3 and CS 4 are connected to the mobile switching center 103 . Further, it is assumed that mobile terminals PS 1 , PS 2 and PS 3 are located in the micro cells of the cell stations CS 1 , CS 3 and CS 4 , respectively.
Referring to FIG. 2, the location information database 101 stores a location information table containing the location data, the map data, and the located terminal data for each cell station. In this embodiment, the location data is absolute location data of each cell station, such as a set of Longitude and Latitude, the map data is bitmap data of a predetermined area map on a scale of 1 to 50,000 in the vicinity of each radio cell station, and the located terminal data is the identification list of mobile terminals which are located in the micro cell of each radio cell station. For example, the absolute location of the radio cell station CS 1 is Longitude 140° 6′ 52″ E and Latitude 34° 56′ 50″ N, the map in the vicinity of the radio cell station CS 1 is formed with the bitmap data MAP 1 , and the mobile terminal located in the micro cell of the radio cell station CS 1 is the mobile terminal PS 1 .
The area size of each map is preferably set to more than 50 times the radius of each micro cell so as not to influence the error of location of each mobile terminal. As shown in FIG. 2, the radio cell stations CS 3 and CS 4 are relatively close to each other and the radio cell station CS 1 is far away from the radio cell stations CS 3 and CS 4 . Therefore, the map areas of the radio cell stations CS 3 and CS 4 are overlapped and those of the radio cell station CS 1 and the radio cell station CS 3 or CS 4 are separate from each other.
Referring to FIG. 3, a mobile terminal PS is comprised of an antenna and a radio transceiver 201 which transmits and receives a radio signal to and from a nearby radio cell station through the antenna. A processor 202 performs the operations of the mobile terminal including coding/decoding and other necessary operations for radio communication. An ID ROM (read-only memory) 203 stores an identification number such as a subscriber telephone number which is used to received data from the nearby radio cell station. A RAM (random access memory) 204 stores the map data and the absolute location data received from the location information database 101 through the mobile switching center and the nearby radio cell station.
As will be described later, the processor 202 performs the calling and called operations using the ID ROM 203 and the RAM 204 according to instructions received from a telephone section 205 . The telephone section 205 includes a speech encoder/decoder, a speaker, a microphone and a keypad for dialing. The processor 202 further controls a display driver 206 to display the received map data and absolute location data on a display 207 such as a liquid-crystal display (LCD).
Operation
The respective radio cell stations CS 1 to CS 4 broadcast control signals in their micro cells at all times. The control signals include cell station identification numbers (CD-ID 1 to CS-ID 4 ) which are previously assigned to the radio cell stations CS 1 to CS 4 , respectively.
Referring to FIGS. 4 and 5, when a mobile terminal (here, PS 1 ) moves from outside the service area into the micro cell of the radio cell station CS 1 or when the mobile terminal is powered on within the service area, the mobile terminal PS 1 receives the control signal from the radio cell station CS 1 and then transmits a location registration request message to the radio cell station CS 1 . As shown in FIG. 5A, the location registration request message conveys the cell station ID number CS-ID 1 and the self ID number PS-ID 1 .
When receiving the location registration request message, the radio cell station CS 1 transfers it to the mobile switching center 102 which uses the location information database 101 to perform the location registration of the mobile terminal PS 1 . This causes the database 101 to be updated such that the mobile terminal PS 1 is added to the located terminal field for the radio cell station CS 1 . After that, the mobile switching center 102 reads the absolute location data of the radio cell station CS 1 from the database 101 and then transmits a location registration response message back to the mobile terminal PS 1 . The location registration response message includes the absolute location data (here, Longitude 140° 6′ 52″ E and Latitude 34° 56′ 50″ N) as shown in FIG. 5 B. When receiving the location registration response message from the radio cell station CS 1 , the processor 202 of the mobile terminal PS 1 stores the absolute location data included in the location registration response message as the location data thereof onto the RAM 204 .
In the case where a user wants to know the location of another mobile terminal, the user uses the keypad to designate the ID number of the mobile terminal (for example, PS 2 ) and start calling, which causes a location data request message to be transmitted to the radio cell station CS 1 . The first terminal is the calling terminal and the second terminal is the called terminal. As shown in FIG. 5C, the location data request message conveys the cell station ID number CS-ID 1 , the self ID number PS-ID 1 , and the designated ID number PS-ID 2 .
When receiving the location data request message, the radio cell station CD 1 transfers it to the mobile switching center 102 which in turn inquires from the location information database 101 whether the designated terminal PS 2 is now located in the service area, that is, the designated ID number PS-ID 2 is registered in the location information database 101 .
If the designated terminal PS 2 is located in the service area, the absolute location data of the designated terminal PS 2 (here, Longitude 139° 36′ 11″ E and Latitude 35° 43′ 58″ N) is read from the database 101 and then a location information response message is transmitted back to the mobile terminal PS 1 . The location information response message includes the absolute location data of the designated terminal PS 2 as shown in FIG. 5 D. When receiving the location information response message from the radio cell station CS 1 , the processor 202 of the mobile terminal PS 1 stores the absolute location data included in the location information response message as the location data of the designated terminal PS 2 onto the RAM 204 . If the designated terminal PS 2 is not located in the service area, another location information response message indicating that the designated terminal is outside the service area is transmitted back to the mobile terminal PS 1 .
After the location data of the self terminal and the designated terminal are received, the map data MAP 1 in the vicinity of the radio cell station CS 1 is downloaded from the database 101 to the mobile terminal PS 1 . In this case, the mobile terminal PS 1 may transmit a map data request message and receive a map data response message conveying the map data MAP 1 (see FIGS. 7 A and 7 B). The processor 202 of the mobile terminal PS 1 stores the received map data onto the RAM 204 and then displays the map together with the locations of the self terminal PS 1 and the designated terminal PS 2 on the display 207 .
The other mobile terminals can perform the same sequence as described above. In FIG. 4, the sequence performed by the mobile terminal PS 2 is shown as an example. The mobile terminal PS 2 can display the map in the vicinity of the radio cell station CS 3 together with the locations of the self terminal PS 2 and another terminal on screen.
FIG. 6A shows a displayed map in the mobile terminal PS 2 when it designates the mobile terminal PS 3 and FIG. 6B shows a displayed map in the mobile terminal PS 3 when it designates the mobile terminal PS 2 . In the displayed map of the mobile terminal PS 2 as shown in FIG. 6A, the location of the mobile terminal PS 2 itself is displayed in the approximate center of the screen and the location of the designated mobile terminal PS 3 is displayed in the lower-right portion of the same screen. On the other hand, in the displayed map of the mobile terminal PS 3 as shown in FIG. 6B, the location of the mobile terminal PS 3 itself is displayed in the approximate center of the screen and the location of the designated mobile terminal PS 2 is displayed in the upper-left portion of the same screen. The displayed maps as shown in FIGS. 6A and 6B are obtained in the case where both the mobile terminals PS 2 and PS 3 are located in the overlapped area of the respective map areas of the radio cell stations CS 2 and CS 3 as shown in FIG. 6 C.
A mobile terminal can receive not only the map data in the vicinity of the radio cell station connected thereto but also the map data in the vicinity of another radio cell station connected to a designated mobile terminal. And a desired map can be selected and displayed on screen by a user's instruction.
As shown in FIGS. 7A and 7B, in the case where a user of the mobile terminal PS 2 wants to receive the map of another radio cell station connected to a designated mobile terminal PS 3 , the user uses the keypad to designate the ID number of the mobile terminal PS 3 and start calling, which causes a map data request message to be transmitted to the radio cell station CS 3 . The map data request message conveys the cell station ID number CS-ID 3 , the self ID number PS-ID 2 , the designated ID number PS-ID 3 , and a map data type. The map data type is used to select one of the self map, the designated terminal map, and a combination thereof.
When receiving the map data request message, the radio cell station CS 3 transfers it to the mobile switching center 103 which in turn inquires from the location information database 101 whether the designated terminal PS 3 is now located in the service area, that is, the designated ID number PS-ID 3 is registered in the location information database 101 . If the designated terminal PS 3 is located in the service area, the absolute location data of the designated terminal PS 3 and its map data MAP 4 are read from the database 101 and then are transmitted back to the mobile terminal PS 2 . The processor 202 of the mobile terminal PS 2 stores the absolute location data and the map data of the designated terminal PS 3 onto the RAM 204 . It is the same with the mobile terminal PS 3 . In this manner, the same map is displayed on the respective displays of the mobile terminals PS 2 and PS 3 as shown in FIGS. 8A and 8B.
FIG. 8A shows a displayed map in the mobile terminal PS 2 when it receives the map data MAP 4 in the vicinity of the radio cell station CS 4 connected thereto. FIG. 8B shows a displayed map in the mobile terminal PS 3 when it receives the map data MAP 4 in the vicinity of the radio cell station CS 4 connected to the designated mobile terminal PS 3 .
In this case, since the same map is displayed on the respective displays of the mobile terminals PS 2 and PS 3 , each mobile terminal can easily display route information such as required time and distance between these locations using the absolute location data with an error of 100-500 meters at the maximum. Needless to say, such concurrent displaying is obtained in the case where both the mobile terminals PS 2 and PS 3 are located in the overlapped area of the respective map areas of the radio cell stations CS 2 and CS 3 as shown in FIG. 6 C. Usually, these mobile terminals are located in different areas which are not overlapped.
Referring to FIG. 9, the mobile terminal PS 1 is away from the mobile terminal PS 3 and therefore the area map MAP 1 in the vicinity of the radio cell station CS 1 does not overlap with the area map MAP 4 in the vicinity of the radio cell station CS 4 . In this case, the mobile terminal PS 1 can display one selected from the area map MAP 1 and the area map MAP 4 on screen as described above.
Further, the mobile terminal PS 1 can display the reduced maps of the area map MAP 1 and MAP 4 on screen. Since the absolute locations of the radio cell stations CS 1 and CS 4 have been received, the processor 202 of the mobile terminal PS 1 can calculate route information such as a distance and a required time between them.
Furthermore, in the case where the location information database 101 stores the area maps between the radio cell stations CS 1 and CS 4 as shown in FIG. 9, the location information database 101 can reduce these area maps and transmit the reduced area map to the mobile terminal PS 1 together with the corresponding absolute locations. In this case, the mobile terminal PS 1 can display the reduced map between the area maps MAP 1 and MAP 4 on screen and further can calculate route information such as a traveling distance and a required time between them.
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A mobile communication terminal includes a location information database storing location data and map data for each of the radio cell stations. When receiving a data request including an identification of a second mobile terminal from a first mobile terminal through a first radio cell station, the database is searched for first location data of the first radio cell station, second location data of a second radio cell station forming a micro cell in which the second mobile terminal is located, and map data for at least one of the first and second radio cell stations. Then the first and second location data and retrieved map data are transferred to the first mobile terminal through the first radio cell station and thereby a map and two locations corresponding to the first and second mobile terminals are displayed on screen based on the retrieved map data and the first and second location data.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a solvent condenser arrangement for a solvent recovery apparatus.
2. Description of the Prior Art
In many industrial processes, for instance, in the drying of articles such as audio tapes or video tapes, solvent vapors are formed which have to be collected and recovered so that they do not enter the atmosphere but can be recycled. Moreover, in such a recovery apparatus usually the inert gas, in general, nitrogen is processed, which serves the purpose of screening the manufacturing apparatus, where the solvent vapors are formed, against the ambient air. In order to prevent such solvent vapors from leaving this apparatus all openings, in general, the inlet and the outlet of this apparatus are provided with transfer chambers which are constantly flushed with the inert gas, in particular, nitrogen to avoid any contact of the atmosphere in the apparatus with the outside air and thus, in particular, emission of the solvent vapors.
Hence, a modern solvent recovery apparatus usually comprises two circuits partially independent of each other, i.e.
an inert gas circuit from which the solvent is condensed, and
a cryogenic part which supplies the transfer chambers of the manufacturing apparatus, for instance, a drier.
The basic construction of such a recovery apparatus for the supply of a drier can be seen from FIG. 1. The drier shown there is continuously or charge-wise charged with the articles to be dried, e.g. video tapes or audio tapes and is provided with transfer chambers 1a, 1b at its inlet and outlet, which are supplied with nitrogen and therefore form a protective curtain between the solvent atmosphere in the inside of the drier 1 and the ambient air.
The solvent-charged nitrogen present in the drier 1 is supplied to a heat exchanger 2 of the solvent recovery apparatus where this gas mixture is precooled. High-boiling components are condensed in the heat exchanger 2 in accordance with the vapor pressure curve. Moreover, the heat exchanger 2 serves the purpose of heat recovery.
The precooled solvent/nitrogen mixture not containing the high-boiling components is supplied from the heat exchanger 2 into a condenser, in which the main portion of the solvent is condensed against external refrigeration. The latter is supplied by the vaporizer 3 of a refrigerating machine 4.
From the vaporizer 3, which also serves as condenser, the two-phase mixture consisting of liquid solvent/purified nitrogen is supplied into a solvent separator 5, where the solvent is separated from the nitrogen; the latter flows from the separator 5 back into the heat exchanger 2 and is heated there in heat exchange with the gas mixture consisting of solvent/nitrogen drained from the drier 1. A fan 6 sucks off the nitrogen from the heat exchanger 2 and returns it into the drier 1.
The recovered solvent present in the separator 5 is intermediately stored in a container 7 and usually repumped to the storage tank for the solvent by means of a pump (not shown).
To prevent oxygen from penetrating into the drier 1 and the solvent from leaving the drier 1 nitrogen is supplied to the transfer chambers 1a, 1b of the drier to produce a positive flow in both directions, namely to the outside of the transfer chambers (the ambient air) and to the inside towards the drier 1.
The flushing nitrogen required therefor is taken partially from the recirculation nitrogen and partially from a tank 8. To guarantee a positive flow from the transfer chambers 1a, 1b into the drier 1 nitrogen is permanently withdrawn from the nitrogen circuit downstream of the separator 5; in accordance with the vapor pressure curve this withdrawn nitrogen, however, still contains so much solvent that this gas mixture may not yet be dissipated into the environment. For this purpose, the gas mixture is heavily supercooled in a cryogenic apparatus 9 and thus purified of the solvent to such a degree until the solvent portion of this gas mixture lies below the regulatory values, so that it is suited for the supply of the transfer chambers. The refrigeration necessary for this purpose is taken from the nitrogen which is used in addition for the flushing of the transfer chambers.
After heating in another heat exchanger 10 the nitrogen passes from the cryogenic apparatus to the transfer chambers 1a, 1b.
In such a solvent recovery apparatus frequently temperatures of -25° C. and below are necessary to condense the solvents used. In this connection, difficulties may arise in the vaporizer 3 of the refrigerating machine, which vaporizer serves as solvent condenser, if a solvent having a high melting point or a solvent mixture comprising components having high melting points have to be condensed. This leads to the sublimation of the components with high melting points and thus to closing of the solvent circuit in the vaporizer 3. The solvent very frequently contains water as well, which sublimes on the cold surfaces of the vaporizer 3 and thus leads to icing of the vaporizer 3.
SUMMARY OF THE INVENTION
Therefore, the invention has as its object to provide a solvent condenser arrangement of the specified category, in which the disadvantages mentioned in the above do not occur. In particular, a solvent condenser arrangement is to be proposed, in whcih operating troubles due to closing of the solvent circuit by crystallizing components are securely avoided.
According to the invention this is achieved by providing at least two solvent condensers of which one is in operation at a time, while the other one is defrosted and by alternately supplying the solvent condensers via a pump from a refrigerant container under vaporization pressure.
Expedient forms of embodiment are defined by the features of the subclaims.
The advantages achieved by the invention are based on the use of at least two separate solvent condensers which are operated alternately, that is one after the other, so that always one solvent condenser is operated and the other one can be defrosted in order to thus avoid closing of the solvent circuit by crystallization of components of the solvent.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic showing of the prior art solvent recovery system.
FIG. 2 is a schematic showing of the improved solvent recovery system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention is described in more detail on the basis of an embodiment by referring to the enclosed FIG. 2 which shows a schematic view of the structure of such a solvent recovery apparatus. As far as possible, the reference numerals used are the same as in FIG. 1, so that the corresponding components do not have to be described one more time. The drier 1 comprising the transfer chambers 1a, 1b and the nitrogen supply is not shown again in FIG. 2.
In the solvent recovery apparatus according to FIG. 2 the mixture consisting of solvent/nitrogen reaches a circuit which can be interrupted by means of valves 3.12, 3.13, 3.22 and 3.23. The two left-hand valves 3.13 and 3.12 according to the representation shown in FIG. 2 are allocated to a first solvent condenser 3.1 and the two right-hand valves 3.22 and 3.23 according to the representation of FIG. 2 are allocated to a second solvent condenser 3.2. The mixture consisting of solvent/nitrogen is fed into this circuit between the two valve groups; furthermore, each solvent condenser 3.1 and 3.2 is connected to the circuit between its two associated valves.
Between the two solvent condensers 3.1 and 3.2 there is provided a liquid separator 3.6 effective in both flow directions of the gas mixture, which collects any condensing solvent. Said liquid separator 3.6 is connected to the two condensers 3.1 and 3.2.
The outlets of the two solvent condensers 3.1 and 3.2 are connected to each other and to the refrigerant vaporizer 3 of the refrigerating machine 4. A pump 3.5 sucks off the liquid refrigerant from the refrigerant vaporizer 3 and feeds it to the solvent condenser 3.2 via a valve 3.21 or to the solvent condenser 3.1 via a valve 3.11, respectively.
The two-phase mixture consisting of liquid solvent/purified nitrogen flows to the separator 5, where it is further processed in the manner described above.
Of the two solvent condensers 3.1 and 3.2 one is in operation at a time, while the other one is being defrosted.
If, for instance, the solvent condenser 3.1 is defrosted, valve 3.11 is closed, so that the pump 3.5 supplies only the solvent condenser 3.2 with liquid refrigerant from the refrigerant vaporizer 3 via the opened valve 3.21. At the same time valves 3.12 and 3.23 are opened and valves 3.22 and 3.13 are closed, so that the solvent condenser 3.1 is supplied with carrier gas and thus receives the enthalpy necessary for its defrosting.
The carrier gas then flows via the liquid separator into the operating solvent condenser 3.2 and, furthermore, via the opened valve 3.23 to the liquid separator 5, where further processing takes place as usual.
For inverting this function valve 3.11 is opened, valve 3.21 is closed and valves 3.12, 3.13, 3.22 and 3.23 are switched over accordingly, so that the solvent condenser 3.2 is defrosted and at the same time the solvent condenser 3.1 is operated.
Due to this "tandem method" the refrigerant vaporizer 3 is separated from the solvent condensers and it is simultaneously guaranteed that due to regular defrosting without interruption, any possible solidifying of solvents cannot lead to operating troubles.
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A solvent condenser arrangement for a solvent recovery apparatus comprises at least two solvent condensers of which one is in operation at a time, while the other is defrosted; the at least two solvent condensers are supplied via a pump from a refrigerant container under vaporization pressure.
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FIELD OF THE INVENTION
The present invention relates to cigarette filters and more particularly to a cigarette filter with air dilution means.
BACKGROUND OF THE INVENTION
It is well known in the cigarette filter art to provide air ventilation or air dilution means for introducing ambient air into the filter to dilute the mainstream smoke passing from the tobacco rod through the filter. As used herein, "air dilution" or "air ventilation" refers to ambient air as a diluent, and is the ratio usually expressed as a percentage, of the volume of air drawn through the air dilution means to the total volume of air and aerosol drawn through the cigarette and exiting the mouth end of the cigarette. Dilution of the mainstream smoke reduces the quantity of particulate matter and gas phase components of the smoke that is delivered to the smoker.
Ventilating air has heretofore been introduced into the filter in several ways, but primarily by the use of porous or perforated wrappers for the tobacco rod and/or filter. The most common means for introducing ventilating air into a cigarette has been by means of mechanical or laser perforations of the tipping paper and the filter plug wrap. Typically, a plurality of perforations or openings are provided in one or more rows arranged circumferentially about the filter adjacent the tobacco rod end thereof. The openings may be provided in the tipping paper and plug wrap prior to or during assembly of the cigarette.
Cigarette filters may be made with many different types of filtration materials, one of the most common materials being a rod of fibrous material, such as a cellulose acetate fiber tow. When a smoker draws on the mouth end of a cigarette with a conventional air diluted cellulose acetate filter, air flows through the air dilution openings in the tipping paper and plug wrap in a direction generally transversely to the longitudinal axis of the filter until it meets the flow of mainstream smoke from the tobacco rod. The diluting air flow is diverted by the pressure drop across the filter in a longitudinal direction toward the mouth end of the filter. In this conventional air diluted filter construction, the mainstream smoke flow is usually concentrated in a central or core portion of the filter and the dilution air flows primarily in the annular portion of the filter surrounding the central portion and between such central portion and the filter plug wrap.
Such flow of mainstream smoke and diluting air is evident from a visual inspection of the staining pattern at the mouth end of the filter. Since the dilution air forces the mainstream smoke toward the longitudinal axis of the filter, the "tar" or particulate matter in the smoke will be concentrated in the central or core portion of the filter leaving a stained or discolored core portion and an annular or peripheral portion of the filter unstained or substantially unstained. In the case of a conventional cellulose acetate filter, this flow pattern results in a concentrated stain or discoloration in the core portion of the mouth end of the filter surrounded by a white or substantially white peripheral region which does not discolor significantly as the cigarette is smoked. The greater the percentage of air dilution, the lesser the staining or discoloration in the core portion and the greater the peripheral unstained or white peripheral region.
Many factors affect the flavor and taste of cigarette smoke including filtration and air dilution. An increase in filtration efficiency (i.e., an increase in pressure drop across the filter element) or an increase in air dilution ordinarily will reduce the flavor perceived by the smoker. It would be desirable, however, to provide a filter for a cigarette which has sufficient air dilution to significantly reduce the particulate matter and gas phase components delivered to the smoker while retaining the taste and flavor of the smoke to the greatest extent possible.
SUMMARY OF THE INVENTION
It has been discovered according to the present invention that the flavor of a highly air diluted cigarette can be improved by altering the flow paths of the air and mainstream smoke through the filter. In particular, the circumferentially arranged air dilution holes or openings in the filter element are extended radially into the filter material. Ambient air is thus drawn into and flows to the mouth end of the filter through the central core region of the filter thereby forcing the mainstream smoke to flow to the mouth end of the filter through the annular or peripheral region of the filter around the core region. In this way, the mainstream smoke flows to the filter mouth end over a greater cross-sectional area of the filter than in the conventional air diluted filters. Conversely, the dilution air flows to the filter mouth end over a smaller cross-sectional area of the filter than in the conventional air diluted filters. Although the reasons are not presently understood, this alteration of the flow paths and flow path areas of the dilution air and mainstream smoke yields a filter cigarette with improved flavor and taste compared to a filter cigarette with a conventional cellulose acetate filter with equivalent air dilution.
The air dilution holes are preferably made in the filter during assembly of the filter cigarette by a conventional laser perforator, the settings of which have been adjusted to cause the laser beam to penetrate into the fibrous filter material rather than to perforate only the tipping paper and filter plug wrap as in conventional air diluted filters.
One or more circumferential rows of perforations or holes are provided in the filter plug depending on the amount of air dilution desired. Typically, at least eight holes are provided, however, the number of holes will be dependent upon the air dilution and the staining pattern desired. Air dilution may be any desired percentage up to about 85-95% with a preferred range of about 30-85% and a most preferred range of about 50-80% depending on the type of cigarette to be designed. The depth of the holes into the filter material is preferably in the range of 1.0 to 4.0 millimeters. The holes may be of any suitable cross-section (e.g., round, oval, oblong, rectangular, etc.) and the number and cross-sectional area of the holes in each row may vary depending on the amount of air dilution selected for the cigarette design. The area and depth of the holes in one row may also be different from the area and depth of the holes in another row to achieve the desired flow paths for air and mainstream smoke.
Each configuration of hole arrangements and air dilution percentage, i.e., number, depth and cross-sectional area of the holes, will yield a unique flow pattern of air and mainstream smoke for that arrangement which can be identified by the location and coloration of the staining pattern at the mouth end of the filter. These staining patterns can be helpful to identify the hole arrangements that provide the most improved taste and flavor of the cigarette.
With the foregoing and other advantages and features of the invention that will 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 views illustrated in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a cigarette incorporating the cigarette filter of the present invention;
FIG. 2 is a cross-sectional view of the cigarette of FIG. 1 schematically showing the major flow paths of the dilution air and mainstream smoke;
FIG. 3 is a broken perspective view of the cigarette of FIGS. 1 and 2 also schematically showing the flow paths of the dilution air and mainstream smoke; and
FIG. 4 is an end elevation view of the filter end of the cigarette of the present invention showing a typical staining pattern for the filter.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings there is illustrated in FIG. 1 a cigarette 10 comprising a cigarette filter 12 made according to the invention and a conventional tobacco rod 14 overwrapped by paper wrapper 15 and attached to the filter 12 by means of tipping paper 16. The filter 12 is made of a fibrous material 17, such as a polypropylene or polyester tow, but preferably a cellulose acetate tow in a conventional manner.
Two circumferential rows of radial slots or holes 18, 20 are formed in the filter adjacent the tobacco rod 14 for admitting diluting air into the filter. The holes 18, 20 are preferably formed after the tobacco rod and filter have been assembled together with tipping paper 16. The holes 18, 20 are preferably made with a conventional laser perforator set to penetrate the filter to a desired depth as described hereinafter. The number of rows, the number of holes in each row and the cross-sectional area of the holes determines the percentage of air dilution of the cigarette according to known principles.
The percentage of air dilution of a cigarette incorporating the filter of the invention may be any desired value up to about 85-95% air dilution. However, the filter of the invention is believed to be most useful for cigarettes with relatively high air dilutions, e.g., ultra low tar cigarettes with 50-80% air dilution, because such cigarettes tend to have less flavor and taste than higher tar cigarettes.
FIGS. 2 and 3 illustrate the flow paths of the diluting air and mainstream smoke in one embodiment of the invention employing two rows of blind holes 18, 20 which extend through the tipping paper 16, the filter plug wrap 22 and into the fibrous filter material 17 to different depths. In this embodiment the holes 20 closest to the mouth end 13 of the filter 12 extend into the fibrous filter material 17 to a depth of about 2.0 millimeters and the holes 18 closest to the tobacco rod 14 extend into the fibrous filter material 17 to a depth of about 4.0 millimeters. It will be understood that the depths of the holes 18, 20 may vary from those set forth above.
When a smoker draws on the mouth end 13 of the filter 12 of cigarette 10, ambient air depicted by arrows 24 is drawn into the holes 18, 20, flows through each of the holes and exits therefrom into the fibrous filter material 17 near the longitudinal axis A of the filter. From this point, the flows from each hole combine into a large dilution air flow that travels in a generally longitudinal direction along the core portion of the filter toward the mouth end 13 as depicted by arrow 26.
Flow of the mainstream smoke through the tobacco rod 14 is depicted by arrow 28 in FIG. 2. As mainstream smoke passes into the fibrous filter 12 from the tobacco rod 14, the pressure of the dilution air in the core portion of the filter causes the mainstream smoke to diverge from the axis A and separate into a plurality of flow paths depicted generally by arrows 30. Mainstream smoke flows to the mouth end of the filter generally parallel to the flow of dilution air 26. It will be appreciated by those skilled in the art that the flows of mainstream smoke and dilution air do not separate into discrete flows as shown in FIGS. 2 and 3 for illustration purposes only by the arrows 24-30. Rather, there is some mixing and commingling of the smoke and air with a substantially greater concentration of dilution air along the central flow path depicted by arrow 26 and a substantially greater concentration of mainstream smoke along the annular flow paths depicted by arrows 30.
Referring to FIG. 4 which illustrates a typical staining pattern on the mouth end 13 of a filter constructed according to the invention, the staining pattern is depicted by a substantially clear or unstained core region 32 in the center of the mouth end and by a peripheral or annular stained region 34 surrounding the region 32.
The staining pattern and degree of discoloration shown in FIG. 4 will vary depending on a number of factors, including the percentage of air dilution (higher air dilution will result in less total discoloration than a lower air dilution), location, number and depth of the holes 18, 20. Some minor discoloration and staining may also occur in the central region 32 of the mouth end. An important feature of the invention is the redirection of a substantial portion of diluting air flow into the core region of the filter and the redirection of a substantial portion of mainstream smoke flow into the annular region surrounding the core region of the filter.
Another benefit of the present invention is possible when it is used with a specialty plug wrap such as carbon-filled paper which is used to remove gaseous phase irritants from the smoke. Since the smoke flows to the peripheral regions of the filter, there will be more reaction between the gas phase of the smoke and the plug wrap.
EXAMPLE 1
An 85 mm cigarette is prepared using an American tobacco blend having the following proportions: flue-cured 40.0%, cased burley 26.3%, Turkish 18.7%, expanded tobacco 15.0%. The cigarette has the following properties:
______________________________________Tobacco rod length, mm 57.0Total cigarette length, mm 84.0Tape circumference, mm 24.75Total weight, g 0.748Firmness, 0.1 mm 9.9Cigarette paper StandardTipping paper StandardAir dilution, % 56+/-2Cigarette Pressure Drop, mm 115+/-4Depth of holes into filter, mm 3-4Hole location, mm from mouthend 13Cellulose acetate tow type 2.1/42,000Filter length, mm 27Filter circumference, mm 24.43Filter pressure drop, mm 125Plasticizer, % 8%Plug wrap (non-porous) Standard______________________________________
The holes are made in the filter by a Korber on-line laser with the following settings:
______________________________________Laser power, watts 200Number of perforations 8Pulse time setting 115Beam control setting 910______________________________________
The cigarette FTC smoking yield is as follows:
______________________________________Number of puffs 10.1"Tar" mg/cigarette 6.3Nicotine mg/cigarette 0.68CO mg/cigarette 8.0CO.sub.2 mg/cigarette 29.0Butt length, mm 34______________________________________
EXAMPLE 2
An 85 mm cigarette is prepared using an American tobacco blend having the following proportions: flue-cured 35%, cased burley 21%, Turkish 18%, expanded tobacco 7%, reconstituted sheet 19%. The cigarette has the following properties:
______________________________________Tobacco rod length, mm 57.0Total cigarette length, mm 84.0Tape circumference, mm 24.71Total weight, g 0.95Cigarette rod wt., g 0.734Firmness, 0.1 mm 8Cigarette paper StandardTipping paper StandardAir dilution, % 84+/-1Cigarette Pressure Drop, mm 84+/-4Cellulose acetate tow type 2.1/42,000Filter length, mm 27Filter circumference, mm 24.43Filter pressure drop, mm 125Plasticizer, % 8%Plug wrap (non-porous) Standard______________________________________
Two rows of holes are made in the filter by a Korber laboratory laser with the following settings:
______________________________________ Row 1 Row 2______________________________________Hole location from mouth end, mm 17 13Laser power, watts 100 100Number of perforations 10 10Pulse time setting 198 198Beam control setting 423 423Depth of holes into filter, mm 1.5-3.0 1.3-2.0______________________________________
The cigarette FTC smoking yield is as follows:
______________________________________Number of puffs 10.3"Tar" mg/cigarette 0.6Nicotine mg/cigarette 0.10CO mg/cigarette 1.1CO.sub.2 mg/cigarette 9.9Butt length, mm 34______________________________________
Although only preferred embodiments are specifically illustrated and described herein, it will be appreciated that many modifications and variations of the present invention are possible in light of the above teachings and within the purview of the appended claims without departing from the spirit and intended scope of the invention.
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A cigarette filter connected to a tobacco rod is provided with air dilution holes which extend radially into the fibrous material of the filter to a depth of about 1.0 to about 4.0 millimeters. When a smoker draws on the cigarette, air admitted into the air dilution holes flows to a central or core region of the filter and thence to the smoker's mouth. Mainstream smoke from the tobacco rod flows into the filter and is diverted to an annular region surrounding the core region.
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FIELD OF THE INVENTION
This invention relates to the field of high-speed division hardware for general purpose computer systems. In particular, it relates to the class of S.R.T. dividers capable of producing multiple bits of quotient per clock cycle through cascaded divider stages.
BACKGROUND OF THE INVENTION
Classical binary (radix-2) restoring, nonperforming, and nonrestoring dividers typically require one iteration or cycle, or one full divider stage, per bit of quotient generated. With these dividers, 32 cycles are required for division of a 64-bit dividend by a 32-bit divisor to produce a 32-bit quotient.
Dividers that operate in a radix greater than two, such as in radix 4 or radix 8 offer the possibility of performing division in fewer cycles or stages than radix 2 dividers. Radix 4 dividers can divide a 64-bit dividend by a 32 bit divisor to produce a 32 bit quotient in 16 cycles or stages, plus overhead, by producing two bits of quotient in each cycle. A radix 8 divider can perform this division in 11 cycles or stages, plus overhead, by producing three bits of quotient per cycle or divider stage.
Dividers that implement two or more cascaded divider stages can produce more than one quotient bit per cycle. These dividers can be challenging to build because of the amount of logic required.
SRT division has been in the news because a look-up-table having an incorrect entry in early Pentium processors. This division method, named after D. Sweeney, J. Robertson, and K. Tocher, is a nonrestoring division algorithm using a signed quotient digit set.
Prabhu, et al., describe an effectively radix 8 SRT divider in U.S. Pat. No. 5,870,323. Radix 8 SRT dividers like that of Prabhu, et al., may be used in high speed processors to produce more than one quotient bit per clock cycle.
SRT division is performed by iterating a sequence of
a. estimating one or more digits of quotient, based on the most significant bits, including sign, of the dividend or partial remainder and the divisor. The quotient digit may represent one or more bit positions in the eventual quotient.
b. subtracting a product of the quotient digit times the divisor from the dividend or partial remainder to form a new partial remainder. This subtraction is often performed in carry-save form in the least significant bits, but carry must be propagated in the most significant bits during either the subtraction or during the estimation of the next one or more digits of quotient.
c. shifting the quotient digit into a quotient register.
d. shifting the new partial remainder by at least one bit position(s) and iterating steps a, b, and c until sufficient digits of quotient have been obtained.
The divider of Prabhu, et al., has several, preferably three, overlapped stages of radix-2 SRT division to provide the effect of a high radix, preferably radix-8, divider. Three bits of quotient are generated in each clock cycle, one bit from each of the overlapped stages.
In each stage, a quotient selection logic look-up table, which may be implemented as logic gates, ROM or PLA, generates each estimate of quotient bits. Multiple quotient bit estimation logic circuits operating in sequence are provided to produce several quotient digits in each clock cycle. In parallel with the estimation of a first, a second, and a third digit, the divisor is multiplied by all possible values of the digit estimates, and these values are subtracted from the dividend or partial remainder to form a set of differences in carry-save form. A multiplexor, controlled by the estimates, then selects a new partial remainder from the set of differences. This computation of several possible differences, followed by selection of the difference corresponding to the digit generated, is speculative execution. In Prabhu's divider, the partial remainder is recycled in carry-save form, and speculative execution is used to achieve high-speed execution at the cost of many more carry-save adders than would be required without speculative execution.
It is known that SRT division can be performed with less speculative execution than in the divider of Prabhu, et. al. In this technique, quotient digit estimates are computed as described. The digit estimate is used to control a multiplexor that selects the divisor multiple corresponding to the digit, the selected divisor multiple is then subtracted from the dividend or partial remainder to form a new partial remainder.
One-hot encoding is known to be an alternative method of representing numbers or parts of numbers. One-hot encoding requires a number of lines equal to two raised to the power of the number of equivalent binary bits of the number or part of a number to be represented; hence one-hot encoding three binary bits requires eight lines, one-hot encoding four bits requires sixteen lines, etc. One-hot encoding is therefore rarely used to represent large numbers.
It is known that adding to one-hot encoded numbers is equivalent to shifting the one-hot encoded number by a number of bit positions equal to the number added to the one-hot encoded number. For example, two in eight-line one-hot encoded form is 0000 0100. Adding three to this is equivalent to left shifting by three places, to produce 0010 0000, or five in one-hot form.
SUMMARY OF THE INVENTION
It has been found that, if the most significant bits of partial remainder are generated initially in one-hot encoded form, it is possible to reduce the number of logic levels, and hence the time required for generation of each successive partial remainder. The one-hot encoded form of the most significant bits of the partial remainder is then recoded into a binary form when carry is propagated to produce a final remainder.
The reduction of logic levels occurs in part because one-hot encoded addition or subtraction is equivalent to a shift operation, with no need to separately propagate a carry signal, and in part because with a one-hot encoded partial remainder, few levels of logic are necessary to estimate each quotient digit.
It has also been found that with the most significant bits of the partial remainder in one-hot encoded form, the quotient digit estimate can be computed quickly enough that it is possible, in some dividers, to avoid using speculative execution logic during computation of the binary encoded less bits of each partial remainder.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a generalized computer system;
FIG. 2 a block diagram of the processor of the generalized computer system;
FIG. 3 an illustration of the bit fields of a floating point number as often used in typical computer systems;
FIG. 4 a block diagram of a portion of a floating point pipeline, showing an SRT divider generating one quotient bit per cycle;
FIG. 5 a block diagram of the core of an SRT divider embodying the present invention and generating two quotient bits per cycle with speculative execution;
FIG. 6 a block diagram of the core of a high-speed SRT divider embodying the present invention, generating two quotient bits per cycle, and having a merged datapath section with speculative execution;
FIG. 7 a block diagram of an integer divider embodying an SRT divider having one-hot encoded most significant bits of each partial remainder; and
FIG. 8 a block diagram of a high speed SRT divider embodying the present invention, generating two quotient bits per cycle, but without speculative execution.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Many computer systems used today, such as those portrayed in FIG. 1, have a processing element 100 . One or more additional processing elements 101 may also be present, as is supported by symmetric multiprocessing operating systems including Solaris, Linux, and Windows NT. Each processing element usually has a processor 102 , a Cache memory 103 , and a memory manager 104 that determines which memory addresses are cacheable and translates memory addresses from a virtual address space to a physical address space.
Each processing element 100 communicates over one or more data busses 105 to a main memory 106 , which may include additional memory management and caching functions, and, often through a bus bridge 107 and an additional bus 108 , to I/O devices 109 , including disk memory devices 110 . There are many ways of implementing such computer systems, for example some of the I/O functions 109 , including the Disk Memory 110 , may communicate directly with the main memory.
In the processor 102 of each processing element, as shown in FIG. 2, there is usually a unit for fetching instructions and tracking instruction addresses 200 , an instruction decoder and dispatcher 201 , and a data fetch and store unit 202 that conducts data transfers between a multiport register file 203 and the various memory and I/O devices of the system, including the cache memory 103 , main memory 106 , disk memory 110 and I/O devices 109 . There are also usually a floating point execution pipeline 204 and an integer execution pipeline 205 that receive data from the multiport register file 203 , operate upon it, and write results back to the multiport register file 203 . The floating point execution pipeline 204 and integer execution pipeline 205 may alternatively be combined into one unit; or a single divider may be shared by both units to perform integer division and division of floating point mantissas.
Floating point numbers, as shown in FIG. 3, are usually comprised of three separate fields. A sign bit 300 represents whether the number is positive or negative. The magnitude of the floating point number is that of the mantissa field value 301 multiplied by a base value raised to the power indicated by an exponent field 302 . The base value is fixed for each floating point format, two being a common base value. The IEEE 754 specification provides detailed descriptions of a single precision floating point format, where all three fields fit in a 32-bit word and having 24 bits (including one hidden bit) of mantissa, and a double precision floating point format where all three fields fit in a 64-bit word and having 52 bits allocated to the mantissa. One extra, or hidden, mantissa bit is available because of the way in which normalization is performed, so the mantissa is effectively a 53 bit number. The mantissa portion of the number is always positive, negative numbers are represented through the sign bit; hence the product of a pair of mantissas is always positive.
The bits of the operand are numbered for purposes of this discussion such that bit 0 is the least significant bit of the mantissa. For a single precision operand, bit 31 is the sign bit, and bit 22 the most significant bit of the mantissa (there is one additional “hidden” bit). Similarly, for double precision operands, bit 63 is the sign bit, the hidden bit is the most significant bit of the mantissa, and bit 51 the second most significant bit of the mantissa with bit 0 the least significant bit of mantissa.
FIG. 4 illustrates the functions performed by a floating point pipeline, embodying the present invention, during execution of a floating point division. Pipeline registers are not shown. This figure illustrates a single-stage divider.
A floating point divisor 400 is split into an exponent, a sign, and a mantissa field by exponent/mantissa splitter 401 . Similarly, a floating point dividend 402 is split into its exponent, sign, and mantissa fields by exponent mantissa splitter 403 . The sign path is not shown. An exponent subtractor 404 subtracts the divisor exponent from the dividend exponent to produce a raw quotient exponent 405 .
The dividend mantissa is fed through an MSB recoder 410 to a Dividend/recycled remainder register 411 . MSB recoder 410 operates on the most significant three bits of the dividend, recoding these bits in one-hot form, while passing less significant bits unaltered.
The most significant bits of the dividend mantissa from the dividend/recycled remainder register 411 and the most significant bits of the divisor mantissa 412 (for radixes greater than two) from the divisor exponent/mantissa splitter are fed to a quotient digit predictor 413 . Simultaneously, the divisor mantissa 412 is fed to a carry-save-adder (CSA) based, multiplier & subtractor array 414 . For speed, the multiplier and subtractor array 414 has two sections, a first section generates products of all possible values of quotient digit 413 times the divisor 412 , and a second section subtracts these products from the dividend/recycled remainder register 411 , generating a set of outputs of all possible differences of the dividend/recycled remainder register and products of the divisor times a quotient digit. Multiplexor array 415 selects the member of the set of all possible differences corresponding to the predicted quotient digit 416 from quotient digit predictor 413 . The selected difference from multiplexor array 415 is shifted left by shifter 417 , recoded as necessary such that the equivalent of its most significant three bits are in one-hot form, and recycled into the dividend/recycled remainder register 411 as a partial remainder (PR).
Each predicted quotient digit 416 is assembled in a quotient assembly register 420 . This process is iterated until all desired quotient bits have been assembled. When all desired quotient bits are assembled, redundancy in the quotient is removed by propagating carry in the quotient assembly register 420 to form a raw mantissa quotient 420 a ; and carry may optionally be propagated by carry propagator 421 on the contents of the dividend/recycled remainder register 411 to form a remainder 422 . The raw mantissa quotient 420 a and the raw quotient exponent 405 are then normalized by Normalizer and Exception Generator 425 to form a floating point quotient 426 . In event of divide overflow or other error conditions, Normalizer and Exception Generator 425 generates an exception or error flag and an error or not-a-number code for the floating point quotient 426 according to the rules of IEEE 754.
The MSB recoder 410 , Dividend/recycled remainder register 411 , quotient digit predictor 413 , CSA Multiplier and Subtractor array 414 , multiplexor array 415 , shifter 417 , quotient assembly register 420 , and carry propagator 421 , with associated control logic including an iteration counter to control iteration of the division, together comprise the SRT divider 430 .
The primary advantage of this SRT divider is that, with one-hot coding of the most significant bits of dividend/recycled remainder register 411 , fewer levels of logic are required for paths through the quotient digit predictor 413 , CSA Multiplier & subtractor array 414 , Multiplexor array 415 , and shifter 417 than with ordinary binary coding. This results in part because carry propagation is inherent during subtraction of the one-hot encoded most significant bits of the dividend/recycled remainder, the only bits over which carry must be propagated during each cycle. A multiplexor array, or barrel, shifter is used for this one-hot encoded subtractor.
FIG. 4 portrays a basic SRT divider that produces one quotient bit per cycle of the iterative division process. The iterative process may be, and preferably is, unrolled to provide for generation of two, three, or more bits of quotient per cycle.
The core of an SRT divider embodying one-hot coding of the most significant bits of the dividend and unrolled to generate two bits of quotient per cycle is detailed in FIG. 5 . The divisor 500 enters a divisor multiplier 501 that generates the possible products of possible quotient digits times the divisor, including negative one times the divisor 502 and one times the divisor 503 . A third possible product, zero, equal to a possible quotient digit of zero times the divisor, is optimized out of the logic. The divider is divided into a control section 504 that operates upon the one-hot coded portion 506 of the dividend or partial remainder 515 , and a datapath section 504 a that operates upon the binary encoded portion 507 of the dividend or partial remainder.
A dividend 505 enters with its most significant binary three bits recoded into eight lines of one-hot encoded form 506 . Remaining bits of dividend 505 remain in binary-encoded form 507 . A top few bits 508 of the divisor 500 may, but are not required to, enter each of two quotient selection logic blocks 509 and 510 in the control section 504 of the divider, these divisor bits are necessary for quotient digit estimation for all radixes greater than two and are optional in the radix-two divider stages of FIG. 5. A pipeline latch for the dividend during a first iteration and for a partial remainder during further iterations of the division is shown at 515 and 516 .
The one-hot encoded portion 517 of the dividend enters the first quotient selection logic 509 , which generates a quotient digit 519 , here q(i+1), selected from the set {−1,0,+1}, as this embodiment comprises two cascaded stages of radix-2 SRT division. The dividend enters the control section 504 of the divider through a one-hot pipeline register 515 , the output 517 of which enters the first quotient selection logic 509 . A group of one-hot adders 520 subtract the upper portion of the possible divisor products 502 and 503 from the dividend or partial remainder 517 upper portion, the outputs of which are fed to partial remainder selection multiplexor 521 , with the output 517 of pipeline register 515 that is the sum when the quotient digit 519 is zero. A barrel shifter array of multiplexers is used for one-hot addition and subtraction, with output remaining in one-hot form. Partial remainder selection multiplexor 521 produces a partial remainder 522 most significant portion.
The low, binary encoded, portion of the dividend enters the datapath 504 a section of the divider through quotient/partial remainder low portion pipeline register 516 . The quotient digit 519 also controls a partial remainder selection multiplexor 525 in the datapath 504 a portion of the divider. Multiplexor 525 selects between the pipeline register 516 and the sums of the possible products 526 (formed by subtracting the lesser bits of the divisor products 502 and 503 from the contents of the pipeline register 516 in an array of carry-save adders 527 ). This multiplexor 525 produces a low, binary encoded, portion of a partial remainder 528 .
The most significant bit, both of the sum vector and carry vector, of the low portion partial remainder 528 are considered by the second stage quotient selection logic 510 .
The most significant bit portion 522 of the first partial remainder enters the second quotient selection logic 510 , generating a second quotient digit 530 . A one-hot adder array 531 produces a set of possible partial remainders 532 , which, along with the most significant bit portion 522 of the first partial remainder, are selected according to the second quotient digit 530 by a second high portion partial remainder selection multiplexor 533 to produce a second partial remainder high portion 534 .
The low, binary encoded, partial remainder portion 528 also enters a set of adders 540 that produce a set of possible differences 541 of quotient digit times the divisor. The second quotient digit 530 selects between these possible differences 541 in multiplexor 542 to produce a low, binary encoded, portion of a second partial remainder 543 . This low portion of the second partial remainder is shifted by a partial remainder shifter (not shown) and redeposited in the dividend/partial remainder low portion pipeline register 516 . Since the partial remainder shifter need shift only by a constant number of bit positions, it is implemented by wiring partial remainder 543 bits N to input bits N+n of dividend/partial remainder register 516 .
A few upper bits 544 of the low portion of the second partial remainder 543 , together with the second partial remainder high portion 534 , are processed into a shifted, one-hot encoded top portion 545 by a propagator 546 , and deposited into one-hot pipeline register 515 .
The quotient digits 519 and 530 are assembled into a quotient by a quotient assembly register (not shown).
An alternative embodiment having a two-bit merged datapath section is portrayed in FIG. 6 . In this embodiment, divisor 600 enters through a multiplier array 601 that provides all the possible products of a pair of single quotient digits times the divisor 602 : minus three times the divisor, minus two times the divisor, minus the divisor, the divisor, two times the divisor, and three times the divisor. Zero times the divisor is optimized out of the logic.
The dividend 605 enters the alternative embodiment of FIG. 6 into dividend/partial remainder high part one-hot encoded pipeline register 606 and dividend/partial remainder low portion pipeline register 607 . The most significant three bits 608 of dividend 605 enter the pipeline register 606 through a one-hot encoder 609 .
As with the embodiment of FIG. 5, the most significant bits 615 (FIG. 6) of the divisor 600 may enter the control section 616 of the embodiment of FIG. 6 into a first 617 and a second 618 quotient selection logic element. The contents 620 of the high part pipeline register 606 also enter the first 617 quotient selection logic and a one-hot encoded adder array 621 . Adder array 621 adds the high portions of the minus divisor and plus divisor terms of the possible products of a pair of single quotient digits times the divisor 602 to the contents 620 of the high part pipeline register 606 , producing an array of sums 622 .
The first quotient selection logic 617 produces a first quotient digit 625 , that controls a first partial remainder top portion multiplexor 626 to generate a first partial remainder top portion 627 . Unlike the embodiment of FIG. 5, no first partial remainder lower portion is produced.
The first partial remainder top portion 627 is fed to the second quotient digit selection logic 618 to generate a second quotient digit 630 , and to a one-hot encoded adder barrel shifter array 631 that adds the high portions of the minus divisor and plus divisor terms of the possible products of a pair of single quotient digits times the divisor 602 , producing an array of sums 632 .
The second quotient digit 630 then controls a second partial remainder top portion multiplexor 635 to generate a second partial remainder top portion 636 .
In the datapath 640 portion of the divider of FIG. 6, a binary-encoded portion of the low portion pipeline register 607 is fed to a carry-save adder array 641 and to a low portion partial remainder selection multiplexor 642 . The array of possible products of a pair of single quotient digits times the divisor 602 is also fed to carry-save adder array 641 , which produces an array of all the possible differences 643 of the low portion pipeline register 607 and the possible products of a pair of single quotient digits times the divisor 602 .
The first 625 and second 630 quotient digits are combined 645 to control the low portion partial remainder selection multiplexor 642 , which selects a low portion partial remainder 646 . The low portion partial remainder 646 is shifted by a shifter 647 , before being latched in the low portion pipeline register 607 . The most significant bits of the low portion partial remainder 646 and the second partial remainder top portion 636 are combined and shifted in propagator 650 to produce a new one-hot encoded partial remainder high portion 651 that is latched into the high part pipeline register 606 .
In operation, in a preliminary cycle, the dividend mantissa portion from an exponent/mantissa splitter has its most significant bits one-hot encoded by encoder 609 and is latched into the pipeline registers 606 and 607 , and the divisor 600 is presented to the multiplier array 601 .
In a first iteration, a first two, most significant, bits of quotient are generated by quotient selection logic elements 617 and 618 , these quotient bits then generate a first iteration partial remainder one-hot encoded high portion at propagator 650 and a binary-encoded first iteration partial remainder low portion at shifter 647 , these first iteration partial remainders are latched into pipeline registers 606 and 607 . This quotient bit pair is latched into the quotient assembly register most significant bits.
In a second and subsequent iterations, additional quotient bit pairs are generated by quotient selection logic elements 617 and 618 , these quotient bits being used to generate further iteration partial remainder one-hot encoded high portions at the output of propagator 650 and a binary-encoded further iteration partial remainder low portions at the output of shifter 647 . The further iteration partial remainders are latched into the pipeline registers 606 and 607 . These quotient bit pairs are latched into the quotient assembly register next most significant bits. A counter and appropriate control logic (not shown) control which bits of the quotient assembly register are loaded in each iteration and the number of iterations.
In this implementation, the second quotient selection logic 618 requires information equivalent to the result of the most significant bits of the lower portion subtraction. This is obtained by duplication logic 650 , that uses the most significant two bits of the lower section dividend/partial remainder register 607 , a few bits from the −D and +D possible digit products times the divisor 602 , and the first quotient selection logic 617 output 625 , to generate the equivalent 651 of the most significant bit of an intermediate partial remainder lower portion.
Upon completion of sufficient iterations, an assembled quotient is present in the quotient assembly register. The redundancies in the assembled quotient are reduced by carry propagation logic of the type known in the art of SRT dividers and normalized as required.
A one-hot encoded SRT divider embodying the present invention may also be used to perform integer division, as shown in FIG. 7 . In this embodiment, positive integers are assumed, signed integers may be converted to positive integers by logic well known in the art, or the divider may be designed to handle signed integers by converting the one-bit detectors disclosed to detectors of the first bit that does not match the sign bit.
An integer divisor 700 enters through a one-bit detector 701 , that detects the identity of the most significant bit that does not match the sign (zero for positive integers) of the divisor. A barrel shifter 702 left-shifts the divisor 700 such that the most significant bit that does not match the sign is in the most significant bit position of a shifted divisor 703 .
Similarly, an integer dividend 705 enters through a one-bit detector 706 , that detects the identity of the most significant bit that does not match the sign (zero for positive integers) of the dividend. A barrel shifter 707 left-shifts the dividend 705 such that the most significant bit that does not match the sign is in the most significant bit position of a shifted dividend 708 .
The shifted divisor 703 and shifted dividend 708 then enter a divider core 710 , such as the divider core of FIG. 6, that performs the division iterations and produces a sequence of quotient digits 711 . The quotient digits 711 are assembled in a quotient digit assembler 712 , and redundancy is removed to form a binary quotient in carry propagator 713 to form a raw quotient 714 .
An adjustment calculator and exception generator 720 examines the bit count of the most significant bits of both divisor and dividend as reported by the one-bit detectors 701 and 706 . The adjustment calculator determine a count 721 of bit positions by which the raw quotient 714 must be shifted by a barrel shifter 722 to form a correct integer quotient 723 . The adjustment calculator and exception generator 720 also determines when a divide by zero error condition must be reported.
The core of an SRT divider embodying one-hot coding of the most significant bits of the dividend, unrolled to generate two bits of quotient per cycle, and without speculative execution in subtraction to form the next partial remainder is detailed in FIG. 8 . The divisor 800 enters a divisor multiplier 801 that generates the possible products of possible quotient digits times the divisor, including negative one times the divisor 802 and one times the divisor 803 . A third possible product, zero, equal to a possible quotient digit of zero times the divisor, is optimized out of the logic. The divider is divided into a control section 804 that operates upon the one-hot coded portion 806 of the dividend or partial remainder 805 , and a datapath section 804 a that operates upon the binary encoded portion 807 of the dividend or partial remainder.
A dividend 805 enters with its most significant binary three bits recoded into eight lines of one-hot encoded form 806 . Remaining bits of dividend 805 remain in binary-encoded form 807 . A top few bits 808 of the divisor 800 may enter each of two quotient selection logic blocks 809 and 810 in the control section 804 of the divider, these bits must enter the quotient selection logic in divider stages having radix greater than two, the may optionally enter the quotient selection logic in the divider having two cascaded radix-two stages illustrated in FIG. 8. A pipeline latch for the dividend during a first iteration and for a partial remainder during further iterations of the division is shown at 815 and 816 .
The one-hot encoded portion 817 of the dividend enters the first quotient selection logic 809 , which generates a quotient digit 819 , here q(i+l), selected from the set {−1,0,+1}, as this embodiment comprises two cascaded stages of radix-2 SRT division. The quotient enters the control section 804 of the divider through a one-hot pipeline register 815 , the output 817 of which enters the first quotient selection logic 809 . A group of one-hot adders 820 add the most significant bits of the possible divisor products 802 and 803 , the outputs of which are fed to partial remainder selection multiplexor 821 , with the output 817 of pipeline register 815 that is the sum when the quotient digit 819 is zero. A barrel shifter array of multiplexers is used for one-hot addition or subtraction, as required, with output remaining in one-hot form. Partial remainder selection multiplexor 821 produces a partial remainder 822 most significant portion. This embodiment therefore uses speculative execution in computing the high, one-hot encoded, bits of each partial remainder.
The low, binary encoded, portion of the dividend enters the datapath 804 a section of the divider through quotient/partial remainder low portion pipeline register 816 . The quotient digit 819 also controls an operand selection multiplexor 825 in the datapath 504 a portion of the divider. Multiplexor 825 selects between the possible products of the quotient digit times the divisor, including minus the divisor 802 , zero, and the divisor 803 . The selected product of the quotient digit times the divisor is subtracted from the partial remainder low portion in the pipeline latch 816 by a carry save adder 826 . Carry save adder 826 produces a low, binary encoded, portion of a partial remainder 828 without speculative execution of the subtraction. The most significant bits of the low portion partial remainder 828 are considered by the second quotient selection logic 810 .
The most significant bit portion 822 of the first partial remainder enters the second quotient selection logic 810 , generating a second quotient digit 830 . A one-hot adder array 831 produces a set of possible partial remainders 832 , which, along with the most significant bit portion 822 of the first partial remainder, are selected according to the second quotient digit 830 by a second high portion partial remainder selection multiplexor 833 to produce a second partial remainder high portion 834 .
The second quotient digit 830 selects between the possible products −D, 802 , zero, and +D 803 of a quotient digit and the divisor 800 in a multiplexor 840 to form a selected product 841 . Selected product 841 is subtracted by a carry-save adder 842 from the intermediate partial remainder 828 to produce a low, binary encoded, portion of a second partial remainder 843 . This low portion of the second partial remainder is shifted by a partial remainder shifter (not shown) and redeposited in the dividend/partial remainder low portion pipeline register 816 . Since the partial remainder shifter need shift only by a constant number of bit positions, it is implemented by wiring partial remainder 843 bits N to input bits N+n of dividend/partial remainder register 816 .
A few upper bits 844 of the low portion of the second partial remainder 843 , together with the second partial remainder high portion 834 , are processed into a shifted, one-hot encoded top portion 845 by a propagator 846 , and deposited into one-hot pipeline register 815 .
The quotient digits 819 and 830 are assembled into a quotient by a quotient assembly register (not shown).
The invention has been shown with reference to particular preferred embodiments. It will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention. For example, the number of dividend and partial remainder most significant bits that are one-hot encoded may be increased from three to a higher number such as six (for radix four operation), as may be desirable in operating at an effective radix. The number of bits of quotient, divisor, and dividend may vary from the embodiments set forth, the effective radix may be some other value than two or four, and the number of iterations will vary with effective radix and operand lengths. Further, the multiport register file may be divided into separate register arrays for the integer and for the floating point pipelines. It is understood that the invention is defined by the scope of the following claims.
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A Sweeney, Robertson, Tocher (SRT) divider for use in a computer system has recoding circuitry to recode the three most significant bits of the dividend into one-hot form as the dividend is loaded into a quotient/partial remainder register. With each clock, a partial remainder is generated also having its most significant three bits in one-hot form and the remaining bits in binary encoded form.
The divider has several stages permitting it to generate several bits of quotient in each clock cycle. Each stage has circuitry for estimating a quotient digit, and for computing a partial remainder by subtracting the product of the quotient digit times the divisor from either the dividend or a previous partial remainder. This subtraction is performed upon a one-hot code in the most significant bits and in binary code on the least significant bits. The divider also has circuitry for assembling a plurality of quotient digits into a quotient.
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TECHNICAL FIELD
The present invention relates to a switching device for transporting packets of data, particularly for IP (Internet Protocol), ATM (Asynchronous Transfer Mode), parallel interconnects, and SAN (System and Storage Area Network), e.g. IBA (Infiniband Architecture). More particularly the invention relates to a switching device that receives packets based on flow-control information. Further, the invention relates to a method for generating the flow-control information. The invention is also related to a switching apparatus comprising one or more switching devices and a communication device.
BACKGROUND OF THE INVENTION
The unbroken popularity of the World Wide Web and its annual increase in size requires increasingly larger switching fabrics. To meet today's switching requirement of 1 Tb/s throughput and above, switches are growing not only in terms of port speed, but also in number of ports. With 5 Gb/s links, port sizes of 64, and today's link and fabrication technologies, multichip and even multishelf solutions are necessary. As a consequence, the input adapters with virtual output queuing (VOQ) are at a distance from the switching device such that the roundtrip time (RTT) bandwidth product is significantly greater than 1. On the other hand switch packet sizes in terms of bytes remain constant. This means that there are more packets on the link, which requires larger memories in the switch, for it to be able to accept all packets in transit. This is a necessity in order that the switch be work-conserving or loss-less, depending on the link-level flow-control scheme used.
A large amount of the expenses invested in switch design goes into link technology, i.e. links, cables, and connectors. Therefore bandwidth is expensive, but however the bandwidth is not used efficiently at present.
IBM's PRIZMA switch-chip family uses a grant flow-control scheme that returns to each input adapter a vector of stop and go signals per output. This scheme is described in the publication “A Combined Input- and Output-Queued Packet-Switch System Based on PRIZMA Switch-on-a-Chip Technology” by C. Minkenberg and T. Engbersen in IEEE Commun. Mag., vol. 38, no. 12, December 2000, pp. 70-77. For fabric sizes of N=64 for instance, with N the number of switch ports, a vector length and hence a flow control bandwidth of 8 bytes per packet cycle would be required. If there are not potentially complex optimization schemes applied, the grant flow-control scheme will prevent switches to grow to larger sizes.
The Atlas switch as described by G. Kornaros et al. in the publication “Implementation of ATLAS I: a Single-Chip ATM Switch with Backpressure” in Proc. IEEE Hot Interconnects VI Symposium, Stanford, Calif., USA, 13-15, Aug. 1998, pp. 85-96 represents the category of switches that use a flow-control scheme based on credits. The flow-control bandwidth is designed to return two credits per packet cycle. The storage, serialization, and return of credits is performed per input using a so-called credit-out FIFO (first-in first-out memory). The FIFO must be large enough to hold all credits that are allowed in the worst case to circulate per adapter/switch input pair. For reasons of correctness the FIFO size scales with the number of ports and the memory size assigned per switch input/output pair. Therefore, the FIFO size roughly scales with O(MN), where M signifies the assigned memory size per memory point, and N the number of switch ports. More importantly, each FIFO must provide N write accesses per packet cycle, because each switch row can have up to N parallel departures. For N≧16 this presents tough hardware design challenges. For ever larger switches it is nearly an impossible task. Therefore the FIFO concept for storage and serialization is not a scalable solution.
Further problems arise from the limited bandwidth of the in-band flow-control channel. An out-of-band flow-control is prohibitively expensive for terabit and betabit solutions. Flow-control bandwidth becomes a real bottleneck if one scales existing switches to ever larger sizes realized as single or multistage fabrics. Furthermore, for scalable multistage fabrics, there are severe restrictions that enforce a number of flow-control events per packet-cycle in the channel.
From the above follows that there is still a need in the art for a new kind of flow-control mechanism which is performant, efficient, robust, scalable, and has the potential to be used in future switching fabrics. The mechanism should be suitable for various switch environments such as communication systems and multiprocessor interconnects. It is therefore an object of the present invention to provide an improved flow-control mechanism for high and efficient packet throughput.
SUMMARY AND ADVANTAGES OF THE INVENTION
In accordance with the present invention, there is provided a switching device for transporting packets of data, the packets being received at the switching device based on flow-control information, the device comprising a memory for storing the packets, a credit counter coupled to the memory for counting a credit number of packets departing from the memory, and a scheduler unit coupled to the credit counter for deriving the flow-control information in response to the credit number.
In a second aspect, there is provided a switching device for transporting packets of data, the packets being received at the switching device based on flow-control information, the device comprising a memory for storing the packets, a credit counter coupled to the memory for counting a credit number of packets departing from the memory, an occupancy counter coupled to the memory for determining a packet occupancy level of the memory, and a scheduler unit coupled to the credit counter for deriving the flow-control information in response to the credit number and the packet occupancy level. The credit counter and the occupancy counter can be combined into one counter unit leading to a reduced chip size.
In general, a scalable flow-control mechanism can be achieved that driven by hardware limits future switching requirements to be applied between switching devices and adapters. In more detail, a credit-based flow-control mechanism with a flow-control link capacity of one so-called credit is proposed. The flow-control information comprising the credit is generated by the scheduler unit and sent to an adapter unit, also referred as to input adapter. As credit is contemplated the coding of an address or destination of a memory, e.g. a crosspoint memory. The scheduler unit within the switching device is able to prioritize the credits to be sent to the input adapter. The switching device is scalable to larger fabric sizes, because it is based on independent counters, rather than on a FIFO that performs N parallel writes and one read. The scheduler unit is also referred to as reception scheduler, because under high network loads, it schedules packets from the reception side.
Several reception scheduling strategies can be applied in order to use the switching device at its best performance. Depending on the size, the strategy can be selected. For example, enhanced performance can be achieved with a strategy that supports the forward progress of packets at the switch level, and therefore keeps switching device utilization low.
The memory within the switching device can comprise memory units, e.g. crosspoint units, which form a switch row. Those defined memory units allow partitioning per input and per output of the switching device. This provides decoupling of input- and output work-conservingness functions. Each memory unit within the switch row is connected to the scheduler unit. Such a structure has the advantage that a centralized arbitor can be avoided.
The scheduler unit may comprise a credit-number-determination unit for determining the credit number of each memory unit within the switch row. The scheduler unit may further comprise an occupancy-determination unit for determining the packet occupancy level of each memory unit within the switch row. One of the mentioned determination units or the combination of both determination units allows a pre-ordering of return credits for the generation of the flow-control information. As the flow-control information comprising the return credit is sent serially, the order of return credits can be determined in advance.
The scheduler unit can comprise reception means for receiving communication-device-input information which indicates a communication-device status. Based on the communication-device status, the decision about which return packet is sent first can be based. This allows to consider the status of the communication-device at the switching device in order to guarantee a continuous packet flow. The communication-device can be any device, e.g. an input adapter, a switch, or an upstream node.
The scheduler unit can further comprise a logic unit for determining the memory unit to which a further packet may be directed based on the determined credit numbers, the packet occupancy levels, and the communication-device-input information. The communication-device status reflects the status of virtual output queues (VOQ), for example, at an input adapter. The communication-device-input information can be used as a filtering mask in the logic unit to define a final-ordering of credits in the generation process of the flow-control information. The scheduler unit can also work with vacancy levels which depends on the definition.
A plurality of the switch rows can form a switch matrix and each switch row is assigned to one scheduler unit. This leads to a simple structure and allows a scalable design, in particular of larger switch fabric or even multistage fabrics.
A switching apparatus comprises the switching device and the adapter unit. The adapter unit is connected to the switching device via known connecting means. Usually long links between the adapter unit and the switching device are no rarity.
In another aspect of the present invention, there is provided a method for generating flow-control information in a switching apparatus. The method comprising the steps of storing packets of data in a memory that comprises memory units, counting a counter-value of packets leaving the memory, and deriving the flow-control information in response to the number of stored packets and the counter-value.
In one embodiment, the counter-value of the counter is incremented when one packet leaves the corresponding memory unit. The counter-value is decremented when one flow-control information is sent out. Thus, each counter performs as a kind of bookkeeper for its corresponding memory unit. The counter-value can be used as an indication of available credits.
It is easy to implement when one flow-control information within one packet is sent to the adapter unit.
Various other objects, features, and attendant advantages of the present invention will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views.
DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described in detail below, by way of example only, with reference to the following schematic drawings.
FIG. 1 shows a schematic illustration of a switch arrangement according to the state of the art.
FIG. 2 shows a schematic illustration of a switching apparatus with a switching device according to the present invention.
FIG. 3 shows a schematic illustration of a scheduling unit according to the present invention.
FIG. 4 shows an embodiment for the evaluation of a flow-control information.
The drawings are provided for illustrative purpose only and do not necessarily represent practical examples of the present invention to scale.
DETAILED DESCRIPTION OF THE INVENTION
In the following the embodiments of the invention are addressed. The number of modules and units is chosen for sake of example only and can be varied without leaving the scope of the invention. For sake of clarity in FIGS. 1 and 2 for a number of identical units arranged in parallel only some of these units are depicted.
Before embodiments of the present invention are described, a schematic illustration of a switch arrangement of the state of the art is addressed. FIG. 1 shows a switching device 1 that is connected via connecting means 4 , 5 , 6 , 7 and switching device outputs 8 , 9 to a communication unit 70 , 72 , hereafter referred to as adapter unit 70 , 72 . Each adapter unit 70 , 72 comprises virtual output queues (VOQN), as indicated in the boxes labeled with 70 , 72 . The switching device 1 has a memory that here comprises memory units 10 , also labeled with M. The memory is assumed as a shared memory with the defined memory units 10 . These memory units 10 are arranged within a matrix structure, forming rows and columns. The input of each memory unit 10 is connected to its respective adapter unit 70 , 72 . The output of each memory unit 10 leads column wise to respective switching device outputs 8 , 9 . As the figure is a schematic illustration only, it is understood that in practice the switching device outputs 8 , 9 are connected to the respective adapter units 70 , 72 or that the switching device outputs 8 , 9 are identical to the reverse channel of the connecting means 5 , 7 . Each row of memory units 10 and in particular each memory unit 10 within the row is connected to a FIFO (first-in first-out memory) 3 , also referred to as credit-out FIFO 3 , for buffering credits. The memory size numbers are equivalent to the number of credits available per input/output pair at initialization. Packets arrive via a data channel of the connecting means 4 , 6 after RTT/2, i.e. half roundtrip time, at the switching device 1 and are stored in the memory unit 10 identified by its destination address. Once the packet has been scheduled for departure and has left the switching device 1 , a memory address is freed and stored as a credit in the respective credit-out FIFO 3 . It takes another RTT/2 until it arrives at the corresponding VOQ of the respective adapter unit 70 , 72 . A credit is the coding of the address of the respective memory unit 10 . The shown structure has the disadvantage that it is not scalable. At the observation level, it can not be determined from which memory units 10 the credits originate.
The same reference numbers or signs are used to denote the same or like elements.
FIG. 2 shows a schematic illustration of a switching apparatus 2 according to the present invention. The switching apparatus 2 comprises the illustrated switching device 1 and the adapter unit 70 , 72 . The switching device 1 comprises here crosspoint memory units 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , hereafter short memory units 10 - 18 . These memory units 10 - 18 are arranged within a matrix structure, forming rows and columns. The output of each memory unit 10 - 18 leads column wise to the respective switching device outputs 8 , 9 . Several memory units 10 - 12 form a switch row 60 . For the sake of simplicity only one switch row is indicated in the figure by reference number 60 . For practical purposes, one adapter unit 70 is assigned to a defined switch row 60 . Each memory unit 10 - 12 , 13 - 15 , 16 - 18 within its switch row 60 is connected to a scheduler unit 30 , 40 , 50 , also referred to as reception scheduler. In general, each scheduler unit 30 , 40 , 50 per switch row implements a strategy of returning credits to the respective adapter unit 70 , 72 . Moreover, to each memory unit 10 - 18 is arranged a credit counter 20 - 28 , i.e. each memory unit 10 - 12 , 13 - 15 , 16 - 18 has its assigned credit counter 20 - 22 , 23 - 25 , 26 - 28 . Each credit counter 20 - 28 counts a credit number indicating the number of available credits. For example, the credit number is incremented (add operation) when one packet leaves the memory unit 10 - 18 . On the other hand, the credit number is decremented (subtract operation) when one flow-control information comprising the credit is sent out via the reverse channel to the adapter unit 70 , 72 . The credit counters 20 - 22 , 23 - 25 , 26 - 28 belonging to the respective memory unit 10 - 12 , 13 - 15 , 16 - 18 within the switch row 60 are connected to the respective scheduler unit 30 , 40 , 50 .
The generation of the flow-control information is performed by the scheduler unit 30 , 40 , 50 in response to the credit number. The decision is based on local, i.e. per memory unit information. The decision of which credit to prefer, i.e. which credit should be returned, can further be based on memory occupancy level, on memory vacancy level, departure rate, arrival rate, and the total number of credits to be returned.
FIG. 3 shows a schematic illustration of the scheduling unit 30 according to the present invention. The task of the scheduling unit 30 is to prioritize available credits and to sent flow-control information comprising the prioritized credit to the adapter unit 70 (not shown in this figure). The scheduling unit 30 comprises here a credit-number-determination unit 32 , an occupancy-determination unit 33 , and a logic unit 34 . Further, the scheduling unit 30 comprises a reception means 31 that receives and provides communication-device-input information. The logic unit 34 is coupled to the reception means 31 , the credit-number-determination unit 32 , and the occupancy-determination unit 33 . The credit-number-determination unit 32 is connected to credit counters 20 . 1 - 22 . 1 which are further connected to the switch row 60 containing the memory units 10 - 12 . Each credit counter 20 . 1 - 22 . 1 has its assigned memory unit 10 - 12 . Moreover, the occupancy-determination unit 33 is connected to occupancy counters 20 . 2 - 22 . 2 which are further connected to the switch row 60 . Each occupancy counter 20 . 2 - 22 . 2 has its assigned memory unit 10 - 12 . The logic unit 34 outputs the generated flow-control information labeled with F C I. As the scheduling unit 30 receives the communication-device-input information via the data channel of the connecting means 4 , this communication-device-input information indicating the status of the communication device can therefore be provided to the scheduling unit 30 , in particular to the logic unit 34 , for the decision process. The communication-device-input information can be used as a hint to schedule the return credits accordingly. The consideration of such scheduling hints leads to an enhanced performance of the switching apparatus 2 . For the decision, the credit counters 20 . 1 - 22 . 1 are considered by the logic unit 34 as indicated by arrows from the respective credit counters 20 . 1 - 22 . 1 . The occupancy-determination unit 33 determines the packet occupancy level of each memory unit 10 - 12 within the switch row 60 . In the present example, the packet occupancy level of one memory unit 10 is “2” and of another memory unit 12 the occupancy level is “9”. These packet occupancy levels are stored in the occupancy counters 20 . 2 - 22 . 2 and are retrieved from each occupancy counter 20 . 2 - 22 . 2 as indicated by the interrupted arrows. The scheduler unit 30 determines the memory unit 10 - 12 within the switch row 60 to which a further packet may be directed. In the example, the decision is based on the determined credit numbers provided by the respective credit counters 20 . 1 - 22 . 2 and the packet occupancy levels, e.g. “2”-“9”. In a further example, the received communication-device-input information from the adapter unit 70 is used for the decision process. In general, each measure, i.e. the credit number, the packet occupancy level, the communication-device-input information, and a combination thereof can be used to derive the flow-control information. The communication-device-input information can comprise the virtual output queue (VOQN) which has received many packets and wants to send these packets next to the switching device 1 . As there can be a round robin mechanism implemented in the adapter unit 70 also the round status can be contained in the communication-device-input information. A more detailed evaluation and decision process as performed by the scheduling unit 30 is described with reference to FIG. 4
FIG. 4 shows an embodiment for the evaluation of a flow-control information. There are various ways and strategies to prioritize credits. Two strategies to prioritize credits based on static properties are described below.
FIG. 4 indicates the switch row 60 with several memory units 10 - 12 . The memory occupancy levels of the memory units 10 - 12 as shown in the figure are as follows: “2”, “3”, “9”, “1”, “4”, and “9.” In a first step, the occupancy levels are read by the occupancy-determination unit 33 and written, for example, into a register labeled with I. In a second step, the memory units 10 - 12 having the lowest occupancy level are marked by a logic “1”. The respective register is labeled with II. Another register labeled with III reflects the received communication-device-input information indicating that the first and the last virtual output queue of the adapter unit 70 have a need to send the next packets. The next step, is performed by the logic unit 34 . A simple logical AND operation of the content of the registers II and III leads to the result as shown in a result register IV. The result shows that a future packet can be sent to the determined memory unit that here is labeled with reference number 12 as it has one of the lowest occupancy levels and the corresponding virtual output queue is prepared to send a further packet to this determined memory unit 12 . The information of the result register IV is sent as flow-control information to the adapter unit 70 .
In a further example the scheduling decision is based solely on the memory occupancy level. Each switch row 60 with its scheduling unit 60 runs independently from the others. The counters 20 - 22 , 23 - 25 , 26 - 28 that do the bookkeeping per memory unit 10 - 12 , 13 - 15 , 16 - 18 are incremented whenever a packet leaves the switching device 1 . The same counters 20 - 22 , 23 - 25 , 26 - 28 are decremented whenever one of its local credits is scheduled on the reverse channel via the connecting means 5 , 7 , 8 , 9 . An ideal prioritization scheme would schedule credits such that they arrive at the virtual output queue (VOQ) of the adapter unit 70 , 72 when a packet stream comes alive or continues to send. It should cease to deliver credits if there are no packets to send. On the other hand, packets should preferably be sent to the switching device 1 if it is ensured that they will make forward progress.
The two strategies to prioritize credits are described in the following.
The first strategy, called highest memory occupancy first (HMF), focuses on the first aspect, namely to keep existing flows alive. The second strategy, called highest memory vacancy first (HVF), focuses on the second aspect, namely to support flows that make forward progress at switch level. The names are chosen to reflect the fact hat the decision of returning credits is taken from the occupancy level of each memory unit 10 - 18 . The names do not reflect queue levels, because queues typically implement quality of service disciplines such as priorities.
HMF endeavors to deliver credits as fast as possible to these virtual output queues (VOQ) of the adapter unit 70 , 72 which are soon to suffer credit underrun. The reasoning is that those memory units 10 - 18 that have the highest occupancy also tie up most of the local credits materialized as packets in their crosspoint memories, i.e. in their memory units 10 - 18 . Therefore, their corresponding VOQs are likely to experience credit underrun. Hence, the HMF strategy favors the return of those local credits, whose memory unit 10 - 18 has the highest memory occupancy. There can be built into the scheme an implicit round-robin to provide fairness in the case of equal memory occupancy. The strategy tries to reduce the waiting time of newly born flows at the input side.
HVF endeavors to return local credits from those memory units 10 - 18 first that are close to data underrun. The reasoning is from a switch perspective, which strives for optimal performance to fill its memory equally. The memory units 10 - 18 that have a high occupancy level are likely to maintain a certain departure rate if an output scheduler allows it. Therefore, the return of these credits is not a priority. However, memory units 10 - 18 that have a low memory pressure should urgently return their credits because a certain output rate may not be maintainable. Moreover, memory units 10 - 18 that have lower occupancy are more likely to make forward progress. Therefore, the current forward progress of packets should be supported, meaning that these credits should be returned with priority.
Any disclosed embodiment may be combined with one or several of the other embodiments shown and/or described. This is also possible for one or more features of the embodiments.
It is to be understood that the provided illustrative examples are by no means exhaustive of the many possible uses for my invention.
From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.
It is to be understood that the present invention is not limited to the sole embodiment described above, but encompasses any and all embodiments within the scope of the following claims:
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The present invention discloses a scalable flow-control mechanism. In accordance with the present invention, there is provided a switching device for transporting packets of data, the packets being received at the switching device based on flow-control information, the device comprising a memory for storing the packets, a credit counter coupled to the memory for counting a credit number of packets departing from the memory, and a scheduler unit coupled to the credit counter for deriving the flow-control information in response to the credit number. Moreover, a switching apparatus and a method for generating flow-control information is disclosed.
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BACKGROUND
[0001] RFID-polling devices exist for inventory and shopping related purposes. For example U.S. Pat. No. 8,305,192 RFID reader with automatic near/far field interrogation mode switching, and related operating methods U.S. Pat. No. 7,336,177 RFID system and method for tracking individual articles. U.S. Pat. No. 7,253,717 Armstrong Method and system for communicating with and tracking RFID transponders.
[0002] However they lack apparatus and methods for Homing, and homing through thousands of competing RFID fields of communications.
SUMMARY
[0003] The present invention solves these and other problems of the prior art by more fully exploiting the highly and inexpensively useful electrodynamic properties of convenient antennas easily available for mobile products. Such properties include, as a non-limiting example, frequency-dependent attenuation, side band communications and extremely precise and predictable propagation directions.
[0004] MFQRFID, (Multi-Frequency RFID, for purposes of this document) utilizes legacy RFID circuitry adding at least a second transmitter (xmit) and receiver (rec) tuned to a second frequency, through a second antenna array allowing a single core modem, power management and processing/memory to share the at least two xmit/rec channels. Thereafter, the two channels, being on different frequencies, may be independently selected by the RFID circuitry based on signal strength of the communicating external device. Alternatively, all channels are used simultaneously.
[0005] Through creative spacing of the frequencies in use, an external device seeking to communicate with the RFID circuitry (through the RFID modem) allows the remote device to establish communications on one frequency and channel first, thereafter providing some guidance (homing) to the RFID circuitry due to attenuation field strength and the remote device being optimized to provide a vector, a direction to the RFID circuitry. The accuracy of the vector plays in much less in this scenario because of the following phenomena. As the remote device seeking further communications and direction to the RFID circuitry moves closer, a second frequency comes into range providing a new vector in similar fashion and communications. Because the frequencies will be higher and higher as the device seeking communications and direction moves closer and closer, other RFIDs in proximity play in less and less based on the simple phenomena of attenuation diminishment over distance which may be further based on frequency (a barring effect is thus cited and referenced with the term “barring effect”). Higher frequencies require shorter transmission antenna and as such, if the amplifier is maintained as linear, the field density will diminish as the frequency selected is higher. To further enhance the effect, we need only set the xmit power level to a lower level for each successive higher frequency and we achieve the net sum desired effect. The external device seeking communications with the MFQRFID finds the lowest frequency generates the strongest field, while each successive higher frequency from the same RFID “core” generates weaker and weaker fields at set values which are controlled by the manufacturing process and any selective permanent load we wish to add to the transmission line, or software controls or both hardware and software limiters. in embodiments, this scheme is used if the field strengths are the same or even reversed. The select frequencies can take into account the anticipated environment to enhance the effect of the invention. Homing, and homing through thousands of competing RFID fields of communications is one feature of this invention. Selective communications with only one RFID, ignoring other RFID beacons is another feature. Moving up the frequencies assures the field strength from competing RFID marked items diminishes as to move closer and closer to the one RFID marked item we wish to maintain communications with. RFIDs emit unique identifiers which explains how the device knows it is homing to a fixed position.
[0006] Loading the push amplifier, the transmitting amp that sends RF out of the chip so the higher the frequency the lower the strength, preset of course, provides the effect desired for the present invention. in an alternative embodiment, this technique is used in reverse, where the higher the frequency the higher the strength and the lower the frequency, the lower the strength.
[0007] As the user walks through a warehouse with 100 billion items, the wifi routers can provide general direction to the area where items of the class being sought are generally stored. Then, the user's device will “see” and communicate with perhaps 1000 of the billion items in this warehouse because the RFID channels are limited through the methods of the present invention. As a result, the user can ask the 1000 widgets, which, for example, is the blue one? The user is homed to a blue one. A lookup table of RFID unique identifiers versus description of the item tagged with the RFID comes into play, across the WiFi or even a carrier channel. The desired item is literally singled out because the frequency ultimately homed to is only good for 3 feet, then yet another only good to 2 feet and so on, Through a process of layering and revectoring. The device of the present invention can even ask the other RFIDs synced to me to stop communicating if literally, the user has singled out the one he wants to find or the user can rule out RFID tagged items and electronically ask their RFIDs to go silent.
[0008] Using several frequencies the present invention can thus home in a user to literally touch the item tagged with the rfid tag of this invention. The device seeking communications with the RFID tag can be a proprietary device, or, alternatively, an appropriately equipped cellular telephone or tablet, a peripheral apparatus to a cell phone/laptop/tablet, laptop or wrist watch, wearable electronics or just another RFID chip with the prerequisite communications capability to the user. (eg with a display and software, processing to guide the user).
[0009] Single Side Band (SSB) technology is proposed, in an embodiment to share the transmission line of a given RFID. In an embodiment, MFQRFID and SSBRFID are used simultaneously, in a single RFID chip. In this embodiment, the present invention has two or more transmission lines and within each line, as many higher or lower side band channels as is necessary for a given application. Here again, attenuation of transmitted signal is dependent upon any loading scheme we wish to apply, causing the homing effect and the barring effect of communications to other RFIDs in proximity to apply.
[0010] In accordance with this aspect of the present invention, the homing effect literally guides a user through countless millions of other RFIDs to reach the one RFID they are seeking, presuming only that the physical access pathway is clear or able to be traversed by the user.
[0011] An object of the invention is auto tracking of a given set of objects, because they changed from static to mobile, or even in another person's cart, to your cart. If they move in sync with you (with one or more of your devices), they automatically form a list. The user can see and modify the list. The user can also scan items assuring the list polled automatically matches precisely, that which is in their physical cart.
[0012] A further object of the invention is auto polling, I can poll and take inventory better if I can selectively talk to RFID groups within RFID groups. So, by logically arranging the tag frequencies, I can talk to different classes of inventory and get a head count. (auto inventory) A further object of the invention is far superior homing, allowing someone with a hand held cell, for example, to walk right up to a needle in a haystack with no wasted time. eg works as fast as we can walk around, solving for homing down to a unique item. A further object of the invention is auto mapping with more accurate depiction of where my inventory is sitting and in three dimensions, X, Y and Z. (Z being above at or below sea level)
[0013] A further object of the invention is cost reduction: as 3-D printers become more capable, the cost to do this per tag approaches less than a cent. As such, tagging everything, every least common denominator will become popular. Even parts in a machine. (so disassembly, assembly and trouble shooting is enhanced)
[0014] A further object of the invention is the far more accurate depiction of a user's location, with an appropriately equipped device within a RFID field.
[0015] A further object of the invention is the far more accurate depiction of a device′ identity within an RFID field. A further object of the invention is the far more accurate permanent placement of permanent electronic devices such as wifi routers, cctv cameras, other forms of router or data communications device intended to be static, mapped as to its location in three dimensions, X, Y and Z, and further, correlated to a known grid such as the GPS grid. (Global Positioning System/s)
[0016] A further object of the invention is the accurately placed static electronic device is enabled to generate a mapping of objects in its field, RFID objects, which can be mapped and tracked with extreme accuracy due to the specific attributes of this invention
[0017] A further object of the invention is the devices in the field of local static electronic devices, such as wifi routers, can be allowed to communicate or barred from communicating due to information and instructions passed to the device in the field, through RFID channels. We can thus bar communications in specific blocks of 3-D mapped space with given X, Y and Z coordinates for each point in the barred field. In embodiments, the field is a cube, rectangle or a more complex contiguous shape.
[0018] A further object of the invention is to add encryption and virus detection to the static devices to assure safer communications within the field.
[0019] A further object of the invention is to provide instructions to devices in the field to limit communications between devices to assure as traffic increases and more devices are in the field, intercommunication between devices is intelligently throttled to avoid latency.
[0020] A further object of the invention is to allow a device communicating with a plurality of RFIDs to send and receive commands allowing a selective ignore hereinafter “feature” and turn off RFID communications for a set time. Selected RFIDs in range stop responding to facilitate homing to a class of RFIDs in the field, or a single RFID in the field of communications based on these interchanged commands. The device can thus use any search and sort criteria to open or close RFIDs in range to further communication and homing functions.
[0021] A further object of the invention is to allow the first communications connection to thereafter, optionally, bar any further communications from the discrete RFID core until the communication session is released by the remote device, or it may be over-ridden by the RFID circuitry, such as when power fails and the RFID chip has to reboot from a new power source.
[0022] A further object of the invention is to allow the first communications connection, with proper security code and encrypted access, to thereafter reprogram the RFID chip in any manner the chip is capable of supporting. This may include allowing one or more simultaneous connections, liming functions, features or other communications thereafter, for any one connection or multiple connections.
DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 Passive Rfid (Radio Frequency Identification [Device]) connectivity between an Rfid “chip” and Rfid capable Cell Phone is depicted. Directional Antenna Arrays on the Cell Phones are also shown.
[0024] FIG. 2 Passive MFQ Rfid (Multi-Frequency Radio Frequency Identification [Device]) connectivity between an Rfid “chip” and Rfid capable Cell Phone is depicted.
[0025] FIG. 3 Passive MFQ Rfid (Multi-Frequency Radio Frequency Identification [Device]) connectivity between an Rfid “chip” and Rfid capable Cell Phone is depicted wherein, for each frequency channel, differing data is allowed or denied automatic passage and the MFQ Rfid Device acts as a router as well as a frequency dependent switch with hard impenetrable firewall present between all functions.
[0026] FIG. 4 Passive MFQ Rfid (Multi-Frequency Radio Frequency Identification [Device]) connectivity between an Rfid “chip” and Rfid capable Cell Phone is depicted wherein, for each frequency channel, connectivity is directly dependent upon distance between the Cell Phone and the MFQRfid Device (chip). Also introduced is the idea of a two antenna array on the Cell Phone enabling 2 dimensional Parallax.
[0027] FIG. 5 The idea of a 4 antenna array on the Cell Phone is introduced, wherein the antenna are formed in a dimensional structure so as to establish enough vectors to enable a highly accurate 3-Dimensional mapping of the distance and trajectory to a given MFQRfid target.
[0028] FIG. 6 Shows a redundant RFID chip 600 , where the two chips are interconnected by at least two communications pathways.
DETAILED DESCRIPTION
[0029] Referring now to FIG. 1 , Passive Rfid (Radio Frequency Identification [Device]) connectivity between an Rfid “chip” 104 and Rfid capable Cell Phone 100 is depicted. This is single channel Rfid so the pathways 102 , 102 a , 102 b and 102 c (5 pathways shown for 102 c ) represent only one frequency-connection to the Rfid Device ( 104 ) to Cell Phones 100 , 100 a and 100 b . Cell Phone 100 a is equipped with dual antenna 101 a and 101 b , allowing for two different vector connections to the target Rfid Device through which the use of Parallax (comparative analysis of signal strength received on each antenna) will improve the net sum vector data provided to the cell phone such that applications operated upon the cell phone will benefit from more accurate targeting for such sub applications as providing a user with a more accurate map to the target. Cell Phone 100 b furthers the concept of parallax, knowing that the applications are going to be mostly near field (objects within 1000 feet or less) a 5 antenna array is shown 101 c arranged along an arc 105 , wherein the sign of the arc determines the sensitivity of the array for pinpointing a target in two dimensions. The cell phone, used as the example for homing to an RFID tag or using RFID tagged objects for such things as ecommerce, is using 2 or more antenna. Through loss calculation and comparative analysis, calculating units, in embodiments of the invention, derive parallax and pinpoint the distance to the RFID tag and approximate trajectory. Then a higher frequency is contacted as the user moves closer and the same process repeats until the cell is proximate the tag.
[0030] Referring now to FIG. 2 , Passive MFQ Rfid (Multi-Frequency Radio Frequency Identification [Device]) connectivity paths 202 and 202 a between an MFQRfid “chip” 204 and an MFQRfid capable Cell Phone 100 are depicted. The antenna 201 and 203 , as well as 201 a and 203 a are tuned to one another according to a select fixed frequency differing for each channel. Pathway 202 is thus for one frequency and 202 a for a different frequency. It is known to those of skill in Rfid, generally, the lower frequency channels will connect and handshake at greater distances than the higher frequency channels due to basic fundamental electrical and physical properties of radio waves (free space propagation loss) Providing a threshold attenuation level in the Rfid (Device) to reject connectivity and handshake until signal strength and duration of signal passes preset minimum thresholds is advised and is not depicted in the drawings. This assures the Cell Phone is persistent in its positioning and desire to connect. When there are a large number of near field objects, this becomes paramount so as to limit polling and handshake to the minimum common denominator of close in objects. As the Cell Phone homes in on a given Rfid target, other targets may be auto-rejected. This is determinable by the identification of the target, acquiring and thus knowing its unique identifier and thereafter, rejecting communications from all but the one Rfid target by way of unique identifier, frequencies or other data the object emits embedded in its RF signal.
[0031] Referring now to FIG. 3 , Passive MFQ Rfid (Multi-Frequency Radio Frequency Identification [Device]) connectivity between an Rfid “chip” 304 and Rfid capable Cell Phone 300 is depicted wherein, for each frequency channel, 202 and 202 a , differing data is allowed or denied automatic passage and the MFQ Rfid Device acts as a router as well as a frequency dependent switch with hard impenetrable firewall present between all functions. Data contained in the Rfid chip such as Data A 308 , Data B 309 or Unique Identifiers 310 associated only and exclusively with this Rfid, are able to be routed only to the channel preset during the manufacturing process of MFQRfid 304 . Table 320 shows for device 300 , there are pathways present and based on the design intended, data 308 , 309 and 310 will be accessible to the Cell Phone 300 only through specific channels. These data are important to sequester so the Cell Phone, as it comes closer and connects with different frequency channels, can know what other signals it is receiving it may reject. Rejection of all unwanted signals quickens the homing and targeting function for applications dependent upon acquiring this data in real time or near real time, minimizing latency. Automating the polling through all near field MFQRfid devices allows and enables automated or automatic inventory counting. In this setting, the many objects in range, near field, can be counted with great rapidity through automation and the logical and creative use of these functions described herein.
[0032] FIG. 4 Passive MFQ Rfid (Multi-Frequency Radio Frequency Identification [Device]) connectivity between a MFQRfid “chip” 404 and MFQRfid capable Cell Phone 400 is depicted wherein, for each frequency channel, 401 - 403 , (a first frequency) 401 a - 403 a , (a second frequency) 401 b - 403 b (a third frequency) connectivity is directly dependent upon distance between the Cell Phone 400 and the MFQRfid Device (chip) 404 . Distance and frequency determine the order of connectivity. Also introduced is the idea of a five antenna array 430 on the Cell Phone 400 enabling 2 dimensional Parallax 420 using the values known for 420 a and 420 c which are acquired through attenuation signal strength plotting, and 420 b which is fixed. By way of example, said first, second and third frequencies are 1.121, 2.1466 and 6.1992 kHz, respectively.
[0033] FIG. 5 The idea of a 4 antenna array on the Cell Phone 500 is introduced, wherein the antenna array 530 are formed in a 3-Dimensional structure so as to establish enough vectors to enable a highly accurate 3-Dimensional mapping of the distance and trajectory to a given MFQRfid target 504 . Fixed Vectors 550 , 551 , 552 and 553 are used in combination with 530 , 531 , 532 and 533 , which are acquired through attenuation signal strength plotting to perform rapid-real time parallax calculations and make these data available to applications operated within the cell phone. It is noted that the use of channel connectivity to perform nested parallax calculation and, acquisition of data unique per channel connection, represent the novelty and uniqueness and taken as a whole, are not considered prior art to this invention.
[0034] In yet another embodiment, on first contact with a communications device with the proper passwords and encryption, the RFID is able to be reprogrammed or pre-programmed to allow or deny additional communications from devices and allow or deny access to any and all features. optionally, the RFID chip itself, though lacking self locator circuitry, holds its location in a memory where the location data is programmed into the RFID from other authorized surrounding communications devices. RFID communication-capable WiFi Routers represent one class of device which can program the RFID with its X, Y and Z coordinates. This will require the RFID to contain a unique identifier so external programming can track one RFID from another.
[0035] FIG. 6 Shows a redundant RFID chip 600 , where the two chips are interconnected by at least two communications pathways which can also share power, or, additional pathways between the redundant chips which are not shown, may also pass communications and power. The idea is one chip will be master and one slave, wherein, if the master is able to self detect any form of failure, it switches its on state and memory content to the other RFID chip and goes into a “communicate only with redundant chip” mode. Each redundant side has an antenna but only one is used at any given moment for transmission. The dormant antenna can be used for reception, allowing the off line chip to tell the on line chip if in truth, it is transmitting and thus is fully functional. Redundant chips are important because the extra cost to make the redundant version is very, very low, and this affords errors and physical failures to be self detecting, self-correcting and able to be reported to compatible external communications devices.
[0036] Also shown is another form of RFID chip ( 601 ) with dual capacitors ( 602 , 603 ) for power storage and use for power. Between the capacitors is a voltage regulator circuit ( 604 ) which can programmably share power between the two capacitors within the one RFID chip. One capacitor may be sized smaller than the other, such as 601 being about 1/10th the capacity of 602 . Also, the smaller capacitor ( 601 ) may charge from one electromagnetic frequency received optimally by antenna ( 610 ) while the other capacitor ( 603 ) charges from different antenna ( 611 ) and with the larger capacitor there may be more than one charging antenna to gather more energy as a function of time, when an electromagnetic field is present. Further, the second capacitor may charge from a different frequency to which the antenna array(s) ( 611 ) are tuned. The second frequency can be deliberately selected from ranges least likely to interfere with the primary frequency tuned to antenna 610 . Chips 601 as shown, may have interconnections as with the redundant RFID chip ( 600 ) which were omitted in the drawing of 601 for clarity.
[0037] RFID chip of type 601 is capable of charging other RFID chips in proximity. Because they are able to connect to one another through the RFID communications channels, each chip can inform another to rotate its use of its external antenna to the antenna which is charging the charging RFID chip with the greatest efficiency, As such, each chip carries sufficient circuitry to determine charging rate for its capacitors. Each chip of type 601 with multiple antenna 611 , has the ability to switch its outputs to one or more antenna allowing no signal or full signal strength to xmit through each transmission line independently. As such, a plurality of RFID chips each affixed to a different instance of item, can cascade charge one another with the greatest efficiency and without wasting signal strength down a transmission line that is not efficiently charging other RFID chips in proximity.
[0038] The functions of redundant chips remain the same. All forms of RFID chip in this specification may be equipped with memory and the memory may retain meta data passed from local devices which indicate interest in an item tagged with these RFID chips, or, may be selectively programmed from external devices to remember data provided during connections. Equally, the RFIDs may be polled for their data content which may or may not be protected with encryption, permission schemes, levels of access based on passcodes or, based on multibiometric signing and associated levels assigned to a given multibiometric. One interesting use of the larger capacitor as discussed above, is to allow for charging of many such RFIDs in reasonably close proximity to one another. A charging beacon, emitting wireless power within range of the antenna ( 611 ) charges the larger capacitor ( 603 ) much more quickly than the smaller capacitor ( 602 ). This will prove useful when communication to RFID chips is desirable en masse, such as when conducting an inventory, or, checking for tagged item aging, as but two non limiting examples. Eg the RFIDs can keep track of time/date and location data, again, as non limiting examples. Location data can be honed to greater accuracy by allowing the RFIDs to communicate with local WiFi routers, installed with calibrated internal location data which is intended to be ultra accurate, so, local RFIDs can estimate their location data from the WiFi routers and their relative distance between multiple calibrated WiFi routers.
[0039] Many modifications and other embodiments of the disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings, particularly with respect to the types of circuitry and software used. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed herein and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
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MFQRFID, (Multi-Frequency RFID, for purposes of this document) utilizes legacy RFID circuitry adding at least a second transmitter (xmit) and receiver (rec) tuned to a second frequency, through a second antenna array allowing a single core modem, power management and processing/memory to share the at least two xmit/rec channels. Thereafter, the two channels, being on different frequencies, may be independently selected by the RFID circuitry based on signal strength of the communicating external device.
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BACKGROUND OF THE INVENTION
(i) Field of the Invention
This invention relates to an improved hydrometallurgical process for treating nickel-copper mattes for the recovery of copper and nickel values. More particularly, the invention involves a process for treating iron and arsenic containing nickel-copper matte to thereby produce an essentially copper-free solution of nickel sulphate, from which metallic nickel can be recovered by processes such as electrowinning, and a copper sulphide concentrate containing low levels of iron, arsenic and nickel, from which copper can be recovered by a variety of conventional processes.
(ii) Description of the Related Art
Copper is recovered from copper sulphide concentrates by a variety of industrial processes including smelting and electrorefining, and roasting, leaching and electrowinning. In all cases it is desirable to ensure that nickel and arsenic, when present in the ore or concentrate, are separated from the copper prior to the electrolytic process step, in which they dissolve and accumulate in the electrolyte, with deleterious effect on cathode product quality and process economics. In the roast-leach-electrowinning process it is also desirable to minimize the level of iron in the copper sulphide concentrate to prevent the formation of acid-insoluble copper ferrites in the roasting step, which can significantly reduce the copper recovery attainable by this process route.
Copper frequently occurs in combination with nickel in sulphide ores, with the most common minerals being chalcopyrite, CuFeS 2 , and pentlandite, NiFeS 2 , in which the copper and nickel occur in combination with iron and sulphur. Arsenic is frequently present in low concentrations in nickel-copper sulphide ores. The conventional method for recovering nickel and copper from these ores is by flotation and smelting to produce a nickel-copper matte, typically containing 70 to 94% Ni+Cu, 5 to 22% S, and 0.2 to 5% Fe. Such mattes may also contain up to 5% arsenic, with lesser amounts of antimony and bismuth.
One well established industrial process for the recovery of nickel from nickel-copper mattes utilizes oxidative sulphuric acid leaching at atmospheric pressure to selectively leach nickel to form a relatively pure nickel sulphate solution, which after final purification, forms the feed to a nickel electrowinning process. In this process the copper is recovered as copper sulphide in the leach residue, but this residue also contains substantial amounts of nickel and significant amounts of iron, and in some cases, arsenic. Such a residue typically contains 45 to 55% Cu, 10 to 20% Ni, and up to 5% Fe and As. Before this copper sulphide residue can be processed by the conventional processes to copper metal, the levels of nickel, iron and arsenic must be reduced to less than about 1%.
A number of processes have been proposed to remove nickel, or nickel and arsenic, or nickel and iron from such copper sulphide containing leach residues, but none has yet succeeded in providing a process to remove all three of the metal contaminants. Prior art leach processes illustrative of the art are disclosed in U.S. Pat. No. 5,344,479 granted Sep. 6, 1994 to Sherritt Gordon Limited. PCT published application No. PCT/FI96/00432 filed Aug. 6, 1996, the assignees being Outokumpu Engineering Oy and U.S. Pat. No. 5,628,817 granted May 13, 1997 to Outokumpu Engineering Oy. Also of note, is U.S. Pat. No. 3,616,331 granted Oct. 26, 1971 to the International Nickel Company Inc. and U.S. Pat. No. 4,323,541 granted Apr. 6, 1982 to Outokumpu Engineering Oy.
In U.S. Pat. No. 5,344,479 issued to Kerfoot et al. there is disclosed a process for leaching a finely divided nickel-copper matte in acid solution under oxidizing conditions in an atmospheric leach step to produce a nickel sulphate solution and a copper-rich sulphide residue. The copper-rich sulphide residue is separated from the nickel sulphate solution and pressure leached under a non-oxidizing atmosphere in a sulphuric acid solution to produce a nickel sulphate solution containing iron and arsenic and a low-nickel copper sulphide product essentially free of iron and arsenic. The nickel sulphate solution is then treated in an iron-arsenic precipitation step in which the iron and arsenic are precipitated as ferric arsenate. The ferric arsenate precipitate is separated from the nickel sulphate solution and discarded. The nickel sulphate solution is recycled into the atmospheric leach step.
PCT application No. PCT/FI96/00432 discloses a modified process for recovering nickel and copper and separating iron from two pyrometallurgically produced nickel mattes containing different amounts of iron. The matte containing the lower amount of iron is leached in acid solution under oxidizing conditions at atmospheric pressure to selectively leach nickel from the matte to produce a nickel sulphate solution and a copper-rich sulphide residue. The copper-rich sulphide residue is separated from the nickel sulphate solution and pressure leached under a mildly oxidizing atmosphere in an acid solution to produce a low nickel copper sulphide product. The matte containing the higher amount of iron is treated in the solution from the pressure leach step in a combined oxidative atmospheric leach and iron hydrolysis step in which the solution pH is adjusted to at least 1.0 or higher. The nickel content of the high-iron matte is leached quantitatively, and iron is precipitated as a jarosite or goethite. The low-iron nickel sulphate solution is recycled back into the atmospheric leaching step.
U.S. Pat. No. 5,628,817 discloses a process for leaching nickel and copper from a high-sulphur low-iron nickel-copper matte by means of a multi-stage process. The nickel copper matte is leached in two atmospheric pressure leaching steps in the presence of oxygen using neutral or acidic leaching solutions containing copper sulphate, to produce a nickel sulphate solution and a precipitate of nickel and copper sulphides. The nickel is recovered from the nickel sulphate solution by electrowinning. The nickel and copper sulphide precipitate is then pressure leached in a substantially neutral copper sulphate solution, to produce a solution of nickel sulphate and a copper-rich precipitate. The iron in the nickel sulphate leach solution is then precipitated in an iron removal step and the residue proceeds to an oxidative pressure leach step in which the copper sulphide is quantitatively dissolved. The iron-free nickel sulphate solution from the iron removal step is recycled to the atmospheric leach circuits.
The commonality between these prior art processes resides in the fact that the iron and arsenic removal step is conducted following the non-oxidizing or mildly oxidizing pressure leach.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide an improved process for the treatment of nickel-copper mattes to produce an essentially copper-free solution of nickel sulphate, from which metallic nickel can be recovered by processes such as electrowinning or hydrogen reduction, and a copper sulphide concentrate from which copper can be recovered by a variety of conventional processes, including roast-leach-electrowinning or smelting-electrorefining.
More particularly, the objective of the invention is to produce copper sulphide concentrates containing low levels of nickel, iron and arsenic, from copper sulphide-rich leach residues which contain unusually high levels of iron or iron and arsenic.
Furthermore, one seeks to avoid the oxidation of sulphide sulphur to thereby minimize production of by-product sulphate. It is desirable, too, to produce a residue suitable for treatment by roast-leach-electrowinning but which may also be treatable by smelting-electrorefining. To achieve the desired low levels of iron and arsenic in the copper sulphide concentrate product, it is essential to prevent the precipitation of basic ferric sulphates or ferric arsenate in a non-oxidizing pressure leach. It is also sought to maximize nickel recovery concomitant with the production of a purer copper sulphide residue. Significantly, it is preferred to transfer the impurities from the copper sulphide product, by collecting them in an environmentally stable form in the iron residue waste stream.
The improvements in the process derive from the problems which arose when practising the process outlined in the U.S. Pat. No. 5,344,479 patent described supra, the disclosures of which are hereby incorporated by reference. In the original flowsheet (U.S. Pat. No. 5,344,479), it had been believed that in the non-oxidizing pressure leach, the iron and arsenic would be in their lower oxidation states i.e. Fe 2+ and As 3+ and therefore would remain in solution during the leach as desired. The discovery upon which the present improved process is derived arose when utilizing the '479 process with mattes having a higher iron concentration of 3 to 5% as opposed to the 0.3% of the matte originally being treated, and with leach residues containing up to 10% arsenic. It was found that insoluble ferric compounds such as ferric arsenate, or sodium jarosite could be formed in the non-oxidizing leach with consequent contamination of the copper sulphide product with iron and arsenic. This would indicate that some oxidation of Fe 2+ to Fe 3+ was occurring, under essentially non-oxidizing conditions.
Without being bound by same, it is believed that the iron may be reacting with Cu 2+ to form Cu + which is known to be more stable at 150° C., than at lower temperatures where it immediately disproportionates to copper powder and Cu 2+ . It is postulated that the reactions may be as follows:
At 150° C.:
Fe 2+ +Cu 2+ →Fe 3+ +Cu +
Fe 3+ +AsO 4 3- →FeAsO 4
Fe 2 (SO 4 ) 3 +3H 2 O→Fe 2 O 3 +3H 2 SO 4
Fe 2 (SO 4 ) 3 +Na 2 SO 4 +6H 2 O→2NaFe 3 (OH) 6 (SO 4 ) 2 +6H 2 SO 4
Below 130° C.:
2Cu + →Cu 0 +Cu 2+
Based on these discoveries, it has been determined that by conducting the iron and arsenic removal step ahead of the non-oxidizing pressure leach, in combination with a copper and iron dissolution step prior to the pressure leach, it is possible to significantly reduce the amount of iron and arsenic entering the non-oxidizing leach and thus minimize potential contamination of the copper sulphide product with said prementioned contaminants.
Broadly stated the invention relates to a process for separating and recovering nickel and copper values from a nickel-copper matte which may contain iron and arsenic which comprises leaching finely divided nickel-copper matte in an aqueous acidic solution under oxidizing conditions at atmospheric pressure with a deficiency of acid and at a minimum temperature of about 80° C. to selectively leach nickel from said matte to produce a nickel sulphate solution having a final pH in the range of about 3.0 to 6.5 and to produce a copper-rich sulphide residue containing a controlled amount of readily acid-soluble copper, separating the copper-rich sulphide residue from the nickel sulphate solution, and leaching said residue in an acid containing solution in a copper and iron dissolution step to provide a copper and iron containing sulphate solution and a copper sulphide residue rich in copper, separating the copper and iron containing sulphate solution from the residue, passing the copper and iron containing sulphate solution to an iron removal stage wherein said solution is reacted at a temperature of up to about 160° C. under pressure in an oxidizing atmosphere to produce an iron-rich residue and a substantially iron-free solution, separating the iron-rich residue and said iron-free solution, and leaching the copper sulphide-rich residue from the copper and iron dissolution step in an acidic solution containing an effective amount of acid-soluble copper under non-oxidizing pressure conditions at a temperature of at least about 130° C. to produce a nickel sulphate solution containing any iron and arsenic and a low nickel, copper sulphide product essentially free of said iron and arsenic. The copper sulphide-rich residue from the copper and iron dissolution step preferably is leached with the iron-free solution produced from the iron removal stage in an acidic solution. The iron removal stage may comprise an iron and arsenic removal stage or an iron, arsenic and antimony removal stage. Iron may be added either as dissolved iron or as acid soluble iron to the iron and arsenic removal stage or to the iron, arsenic and antimony removal stage.
The copper-rich residue from the copper and iron dissolution stage preferably is leached in an acidic solution selected from the group consisting of sulphuric acid, sulphuric acid solution containing nickel sulphate, sulphuric acid solution containing copper sulphate, and sulphuric acid solution containing nickel sulphate and copper sulphate.
Leaching of the finely divided nickel-copper matte preferably is conducted in an aqueous acidic solution sequentially in a first stage atmospheric leach and a second stage atmospheric leach with recycling of the solution from the second stage atmospheric leach to the first stage atmospheric leach.
The solution from the non-oxidizing pressure leach is recycled to said second stage atmospheric leach.
The copper-rich residue from the copper and iron dissolution stage together with the iron-free solution produced from the iron-removal stage may be leached under mildly oxidizing pressure conditions at a temperature of at least about 130° C. to produce a nickel sulphate solution and a low-nickel, copper sulphide product essentially free of said iron and arsenic.
Iron can be precipitated in the iron removal stage as jarosite (25 to 35% Fe) or hematite (50 to 60% Fe), depending on the feed solution sulphuric acid:iron mass ratio, temperature and oxygen pressure.
DESCRIPTION OF THE DRAWINGS
The embodiments of the process of the invention will be better understood having reference to the accompanying drawings, in which:
FIG. 1 shows a schematic flowsheet of the process illustrated in a preferred embodiment of the invention;
FIG. 2 shows a flowsheet of the process of the invention illustrating the inclusion of the roast-leach-electrowinning process for the recovery of cathode copper;
FIG. 3 demonstrates the recovery of nickel powder by hydrogen reduction from the nickel sulphate solution produced by the process of the invention; and
FIG. 4 is illustrative of a flowsheet involving partial copper dissolution from the upgraded copper sulphide residue product of the process of the invention, to augment the supply of soluble copper in the process when low copper:sulphide ratio nickel-copper matte is being treated.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Having reference to accompanying FIG. 1, there is depicted the flowsheet of the basic embodiment of present process. The process comprises a primary stage atmospheric oxidizing leach 12 followed by a secondary stage atmospheric oxidizing leach 14. Matte ground to about 90% passing 44 micrometers is fed to the oxidizing leach 12 for reaction in an aqueous sulphuric acid solution, preferably recycle leach solution from the secondary stage atmospheric oxidizing leach, together with nickel anolyte.
A typical matte composition could consist of, by weight, 30 to 75% Ni, 10 to 45% Cu, up to 10% Fe, 5 to 22% S and up to 5% As. Such impurities as Se, Te, Sb and Bi may also be present. Platinum group metals and precious metals which may also be present include Pt, Pd, Ru, Rh and Au. Typically the Cu:S mass ratio of the matte would be in the range of 1.5:1 to 4:1 and preferably would be in the range of 3:1 to 4:1. The process slurry in the atmospheric leach stage 12 is maintained at a temperature of above about 80° C. Air and/or oxygen is sparged into the process slurry, which is at atmospheric pressure, and the slurry is agitated for extraction of about 40-60% of the nickel with minimum oxidation of the sulphur. An excess of matte is provided relative to the acid to ensure controlled precipitation of the copper as metallic copper, copper sulphide, and basic copper sulphate. The residue may also contain copper oxide (Cu 2 O) formed by oxidation of metallic copper as well as any unreacted nickel compounds. A final pH in the range of 3.0 to 6.5, preferably about 6.5, is attained to ensure maximum precipitation of the iron, arsenic and other impurities.
The leach solution having up to 90 g/L nickel and less than 10 mg/L of each of copper and iron is passed to cobalt separation and nickel electrowinning (not shown). Nickel anolyte solution, typically containing 50 g/L Ni and 50 g/L H 2 SO 4 is returned as lixiviant to the leaching circuits.
The nickel-copper sulphide residue is separated from the leach solution in a liquid-solid separator 16 and passed to the secondary stage leach 14 under similar temperature and pressure conditions to those used in the primary stage leach 12 and reacted with a controlled amount of recycled acidic solutions, including nickel anolyte comprised of 50 g/L Ni and 50 g/L H 2 SO 4 , at a sulphuric acid to solids mass ratio in the range of 0.3:1 to 0.6:1, preferably about 0.5:1. The quantity of acid thus is controlled to provide an acid deficiency at the termination of the leach represented by a pH in the range of 4.0 to 6.5, preferably about 4.5, to leach most of the remaining nickel and to produce a leach residue of which about 60% by weight is in a readily acid-soluble form such as basic copper and nickel sulphates and basic iron and iron containing compounds. The acid balance in the circuit is maintained by distributing the nickel anolyte to the appropriate section/s of the circuit as required.
The leach solution containing about 70-80 g/L nickel and 10 g/L Cu at a pH of about 4.5 is recycled to the primary stage atmospheric leach 12. The copper-rich sulphide residue comprised of copper and nickel sulphides and nickel oxide, together with the acid-soluble basic copper sulphate (CuSO 4 .2Cu(OH) 2 ), basic nickel sulphate and basic iron and arsenic containing compounds, is separated from the leach solution by liquid-solid separator 18 and fed to the copper and iron dissolution stage 20.
In the agitated copper and iron dissolution tank 20, a controlled amount of nickel anolyte containing about 50 g/L H 2 SO 4 and 50 g/L Ni is added to obtain 20 to 30 g/L H 2 SO 4 and 5 to 20 g/L Cu in solution. The copper and iron dissolution slurry is fed to a liquid-solid separator 22 to yield a slurry containing about 45 per cent solids which is then transferred to an autoclave feed tank (not shown) and from there to the non-oxidizing pressure leach autoclave 24. The solution from the liquid-solid separation step 22 is passed to the iron removal stage 26. It is to be understood that the iron removal stage may be extended to include an iron and arsenic removal step or an iron, arsenic and antimony removal stage where appropriate. In certain instances it may be necessary to add additional iron, either in solution or dissolved in situ, to effect precipitation of the arsenic and/or antimony, as is well known to those skilled in the art.
The solution is passed to an autoclave in the iron removal stage 26, which contains up to 10 g/L iron and up to 10 g/L arsenic, and reacted with oxygen at a temperature of between 130 to 160° C., preferably 150° C., and pressure of between 450 to 1000 kPa for a retention time of between 1 to 3 hours to produce a solution containing less than 1 g/L iron and arsenic, and to precipitate the remaining iron as ferric arsenate (about 20 to 25% Fe), a jarosite (about 25 to 30% Fe) and/or hematite (about 50 to 60% Fe). The solution containing 5 to 20 g/L Cu, less than 1 g/L Fe and As, 10 to 40 g/L sulphuric acid and 40 to 50 g/L Ni is then fed to the non-oxidizing pressure leach autoclave 24. In the iron removal stage 26, when operated at about 150° C., hematite formation is favoured over jarosite formation at feed solution H 2 SO 4 :Fe mass ratios of about 2.5:1 or lower. At feed solution H 2 SO 4 :Fe mass ratios greater than 3:1, the formation of jarosite is favoured. At a feed solution H 2 SO 4 :Fe mass ratio of about 2:1, jarosite formation becomes more favourable with decreased temperature as shown in the test results given herebelow.
TABLE 1______________________________________ Feed Residue H.sub.2 SO.sub.4 :Fe Fe ContentTest mass ratio % Residue Type______________________________________1 1.7 55.3 Hematite2 2.0 51.1 Hematite3 2.3 54.1 Hematite4 3.1 39.9 Mixed5 3.3 30.6 Jarosite6 4.0 29.6 Jarosite7 5.0 30.8 Jarosite______________________________________
The pressure hydrolysis tests were carried out at 150° C., with a total pressure of 850 kPa, corresponding to an oxygen partial pressure of 375 kPa.
Table II below demonstrates the effect of temperature upon the type of residue obtained with a total pressure of 850 kPa.
TABLE II______________________________________ Feed ResidueTemperature H.sub.2 SO.sub.4 :Fe Fe Content ResidueTest °C. mass ratio % Type______________________________________ 8 130 1.7 46.7 Mixed 9 150 1.7 55.3 Hematite10 160 1.7 58.6 Hematite______________________________________
At lower temperatures (130° C.), jarosite formation is favoured even at low acid:Fe mass ratios.
In the non-oxidizing pressure leach 24, the non-oxidizing atmosphere is maintained by sparging steam or steam containing nitrogen into an autoclave to maintain the solution temperature at above 120° C., preferably in the range of 140° to 160° C. The upgraded copper sulphide residue, containing CuS as digenite having a Cu:S mass ratio of 3.6:1, and the platinum group metals together with some impurities such as Se, Te and Sb, are passed on to other circuits, not shown, for further treatment for the recovery of cathode copper. The solution containing less than 2 g/L Fe and As, 5 to 10 g/L Cu, 30 to 40 g/L sulphuric acid and 50 to 60 g/L Ni is passed back to the second stage atmospheric leach 14.
In an alternative embodiment, it is to be noted that the pressure leach may be conducted under mildly oxidizing conditions, namely by sparging air or oxygen into the autoclave in a manner known to one skilled in the art. Typically, mildly oxidizing conditions would comprise 500 kPa air or 100 kPa oxygen partial pressure.
In FIG. 2, there is depicted a flowsheet in which the upgraded copper sulphide residue produced by the process of the present invention is treated by a roast-leach-electrowinning process to produce copper cathode. The copper sulphide concentrate is roasted in a stream of air at 700° C. in a fluid bed roaster 30 to oxidize the copper sulphide to form copper oxide and sulphur dioxide which is utilized for the production of sulphuric acid. The roaster calcine, which contains copper oxide and iron oxide, is leached in recycled spent electrolyte containing sulphuric acid to dissolve the copper oxide as copper sulphate in an atmospheric leach 32. After solution purification steps (not shown) to remove any dissolved iron and other impurities, cathode copper is recovered from the copper sulphate solution by electrowinning 34. The concentration of nickel and arsenic in the electrowinning circuit is controlled by bleeding a portion of spent electrolyte back to the matte atmospheric leach circuits.
Having reference to FIG. 3, there is depicted a flowsheet in which the nickel sulphate solution produced by the first stage atmospheric leach 12 of the process of the present invention is treated by hydrogen reduction to produce metallic nickel powder. The solution is treated in an optional copper removal step 36, in which traces of copper are precipitated using nickel powder and sodium hydrosulphide. The copper sulphide precipitate is separated by filtration from the purified nickel sulphate solution. Ammonium sulphate and aqueous ammonia solution are added to the nickel sulphate solution in solution adjustment step 38 and the ammonia to nickel molar ratio adjusted to about 2:1, to form nickel diammine sulphate. The ammonium sulphate solution concentration is adjusted to the range 200 to 300 g/L. The nickel diammine sulphate solution is heated to 250° C. and reduced with hydrogen gas at a pressure of about 3.5 MPa in the nickel reduction step 40. The nickel powder production process is a batch process in which the powder particles are grown to the desired size, by reducing up to 60 consecutive charges of nickel diammine solution on to fine seed particles. The solution discharged from the reduction step 40, which typically contains about 1 g/L Ni and 1 g/L Co, and over 400 g/L ammonium sulphate, is treated with hydrogen sulphide to precipitate the nickel and cobalt as sulphides in the sulphide precipitation step 42 and recycled to the nickel-copper matte leach step 12. The barren solution is evaporated to crystallize ammonium sulphate, which is utilized as a fertilizer. In this flowsheet, the nickel anolyte normally used as leachant in the process of the invention is replaced by an aqueous solution of sulphuric acid.
Having reference to FIG. 4, there is illustrated a flowsheet wherein the upgraded copper sulphide residue produced by the non-oxidizing pressure leach of the process of the present invention is leached under oxidizing conditions in an atmospheric leach 24 step 44 at 80° C., to redissolve up to 50% of the copper content, as copper sulphate, and to provide soluble copper by recycle to the non-oxidizing pressure leach step 24, when copper deficient mattes (i.e. with a Cu:S mass ratio of less than 3:1) are to be processed.
The essentials of the invention comprise, in combination, the use of the copper dissolution step, the removal of the iron and arsenic prior to the non-oxidizing pressure leach, and the passage of the low iron and arsenic containing solution stream to the pressure leach.
The process of the invention will now be described having reference to the following non-limitative examples.
EXAMPLE 1
This example illustrates the prior art process disclosed in U.S. Pat. No. 5,344,479 applied to the treatment of a nickel-copper matte containing a high concentration of iron. A nickel-copper matte, containing by weight 48% Ni, 33.5% Cu, 12% S, and 3.0% Fe, was treated in two stages of oxidative atmospheric sulphuric acid leaching, according to the process disclosed in U.S. Pat. No. 5,344,479 to produce a leach residue analyzing 38.8% Cu, 12.7% Ni, 15% S and 7.5% Fe.
This residue was repulped in a sulphuric acid solution containing 51 g/L H 2 SO 4 , 48 g/L Ni, 4.9 g/L Cu and 120 g/L Na 2 SO 4 at a solid:solution ratio of 100 g/L and the resulting slurry was batch leached at 150° C. under non-oxidizing conditions for four hours. The resulting solid residue contained 68% Cu, 18.2% S, 0.66% Ni and 4.3% Fe. X-ray diffraction analysis of the residue indicated that the iron phase was sodium jarosite, NaFe 3 (SO 4 ) 2 (OH) 6 . The leach discharge solution contained 28 g/L H 2 SO 4 , 58 g/L Ni, 8.8 g/L Cu and 4.6 g/L Fe. Rate samples taken during the course of the pressure leach test showed that the iron content of the residue had increased from 1.0% at the start, to 4.6% at the end of the leach, confirming that the jarosite had been formed in the non-oxidizing pressure leach, and not in the prior atmospheric leach step. The maximum soluble iron level observed in the leach solution was 6.2 g/L.
A second pressure leach test was carried out to determine if sodium jarosite would precipitate from a leach solution containing a lower concentration of iron. A second stage atmospheric leach residue produced from the same nickel-copper matte, and analyzing 37% Cu, 13.9% Ni, 16.5% S, and 6.8% Fe, was pressure leached at 150° C. for four hours under non-oxidizing conditions, at a solids:solution ratio of 60 g/L. In this test, the highest iron concentration observed in solution was 4.3 g/L Fe, and after four hours leaching this had dropped only to 4.0 g/L Fe. The leach residue analyzed 73% Cu, 23% S, 0.73% Ni and 0.71% Fe.
This example indicated that the precipitation of sodium jarosite in the non-oxidizing pressure leach can be minimized or prevented by ensuring that the concentration of iron in solution remains below 4 g/L throughout the non-oxidizing pressure leach.
EXAMPLE 2
This example illustrates the removal of most of the iron content from a solution produced by repulping second stage atmospheric leach residue in sulphuric acid solution, and separating the acidic solution from the acid-insoluble residue.
A sample of second stage atmospheric leach residue, produced from the nickel-copper matte described in Example 1, was repulped in sulphuric acid solution containing 50 g/L H 2 SO 4 , 51 g/L Ni and 120 g/L Na 2 SO 4 , at a solids:solution ratio of 80 g/L. The resulting slurry was filtered, to provide a solution analyzing 4.1 g/L Fe, 17 g/L Cu, 20 g/L H 2 SO 4 , and 55 g/L Ni.
This solution was then treated to precipitate most of the iron, in a pressure hydrolysis step at elevated temperature and oxygen pressure, using a small quantity of a high-iron nickel-copper-cobalt alloy as an in situ neutralizing agent. The finely ground alloy, analyzing 39% Fe, 31% Ni, 13% Cu, 3.5% Co, and 7% S, was added to the product solution from the copper and iron redissolution step, and the slurry was heated in a batch autoclave at 150° C., under a 500 kPa oxygen partial pressure, for five hours. The iron concentration in the solution was reduced to less than 1 g/L after three hours, and to less than 0.5 g/L after five hours. The resulting solution analyzed 21 g/L Cu, 14 g/L H 2 SO 4 and 0.3 g/L Fe, which is very suitable as a feed solution to the non-oxidizing pressure leach. This solution was used to pressure leach the residue from the prior copper and iron redissolution step. The highest iron concentration observed in this non-oxidizing pressure leach test was 1.2 g/L Fe, and there was no indication that any sodium jarosite was precipitated.
EXAMPLE 3
This example illustrates the performance of the process flowsheet of the present invention in a miniplant circuit which was operated continuously for seven days. The circuit included the two atmospheric leach steps 12, 14, the copper and iron redissolution step 20, the iron removal step 26, and the non-oxidizing pressure leach step 24 as shown in FIGS. 1A, 1B.
A finely ground nickel-copper matte analyzing 48% Ni, 34.5% Cu, 11.7% S, and 2.9% Fe, was treated in the two stages of atmospheric leaching, to yield a second stage residue typically analyzing 48% Cu, 8.5% Ni, 15% S and 5.5% Fe. This residue was repulped in an acid solution containing 45 g/L H 2 SO 4 , 48 g/L Ni and 0.5 g/L Cu, to yield a product solution typically containing 24 g/L H 2 SO 4 , 50 g/L Ni, 17 g/L Cu and 3 g/L Fe. The residue typically contained 55% Cu, 14% Ni and 2% Fe.
The solution produced in the copper and iron redissolution circuit was treated at 150° C. with a 500 kPa oxygen overpressure, with a retention time of five hours. The high iron alloy as described in Example 2, was used as an in-situ neutralizing agent. The product solution contained 20 g/L Cu, 59 g/L Ni, 17 g/L H 2 SO 4 and 0.65 g/L Fe, while the hematite residue analyzed 55% Fe, 0.8% Ni and 0.8% Cu.
The product residue from the copper and iron redissolution step was repulped in the product solution from the iron removal step, and the resulting slurry was treated in the non-oxidizing pressure leach at 150° C., with a retention time of 5 hours. The copper concentrate product typically analyzed 74% Cu, 20% S, 0.3% Ni and 0.4% Fe, while the solution contained only 1.5 g/L Fe, together with 12 g/L Cu, 70 g/L Ni and 25 g/l, H 2 SO 4 .
EXAMPLE 4
This example illustrates the treatment of higher arsenic and iron containing material in the prior art process disclosed in U.S. Pat. No. 5,344,479 and in the improved process flowsheet of the present invention.
A high arsenic and iron containing leach residue analyzing 11% Ni, 31% Cu, 10% Fe, 11% As and 12% S was produced from atmospheric leaching of nickel-copper matte, according to the process disclosed in U.S. Pat. No. 5,344,479. A sample of this atmospheric leach residue was repulped in a sulphuric acid solution containing 50 g/L H 2 SO 4 , 51 g/L Ni, 5.1 g/L Cu and 120 g/L Na 2 SO 4 at a solids:solution ratio of 80 g/L and the resulting slurry was batch pressure leached at 150° C. under non-oxidizing conditions for four hours. The resulting solids residue analyzed 46% Cu, 14% S, 4.4% Ni, 5.7% Fe and 12% As. The leach discharge solution contained 35 g/L H 2 SO 4 , 51 g/L Ni, 3.0 g/L Cu, 4.8 g/L Fe and 2.3 g/L As.
A second sample of the same high arsenic and iron containing atmospheric leach residue was subjected to treatment in the improved process flowsheet of the present invention. The atmospheric leach residue was repulped in sulphuric acid solution containing 50 g/L H 2 SO 4 , 50 g/L Ni and 120 g/L Na 2 SO 4 , at a solids:solution ratio of 80 g/L, with the aim of redissolving copper, arsenic and iron. The resulting slurry was filtered, to separate solids analyzing 21% Ni, 44% Cu, 2.0% Fe, 0.4% As and 30% S from solution analyzing 7.0 g/L Fe, 8.3 g/L As, 11 g/L Cu, and 15 g/L H 2 SO 4 .
This solution was partially neutralized to 11 g/L H 2 SO 4 using NaOH and then treated to precipitate most of the arsenic and iron, in a batch pressure hydrolysis step at elevated temperature and oxygen pressure (150° C. and 500 kPa oxygen partial pressure) for five hours. The arsenic and iron concentrations in solution were reduced to less than 1 g/L each after two hours, and the final discharge solution after five hours analyzed 8.6 g/L Cu, 16 g/L H 2 SO 4 , 1.0 g/L Fe and 0.6 g/L As, which is suitable as a feed solution to the non-oxidizing pressure leach.
The low arsenic and iron containing solution from the pressure hydrolysis step was combined with the residue from the prior copper, arsenic and iron redissolution step. The repulped slurry was batch leached at 150° C. under non-oxidizing conditions for five hours. The resulting solids residue analyzed 73% Cu, 19% S, 0.7% Ni, 1.6% Fe and 0.5% As. The highest arsenic and iron concentrations observed in this non-oxidizing pressure leach test were 1.1 g/L Fe and 0.6 g/L As, and there was no indication that any arsenic or iron reprecipitation had occurred.
It will be understood, of course, that modifications can be made in the embodiments of the invention illustrated and described herein without departing from the scope and purview of the invention as defined by the appended claims.
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There is disclosed a process for separating and recovering nickel and copper values from a nickel-copper matte which may contain iron and arsenic. Finely divided nickel-copper matte undergoes one or more steps of sulphuric acid leaching at atmospheric pressure to produce a nickel sulphate solution and an iron and/or arsenic containing copper-rich sulphide residue. The copper-rich sulphide residue is repulped in sulphuric acid solution to selectively redissolve most of the iron and arsenic and the iron and arsenic containing solution is separated from the copper-rich residue. The iron and arsenic are largely precipitated from the leach solution in a pressure hydrolysis step and the iron and arsenic containing precipitate is separated and discarded. The iron and arsenic-depleted solution is recombined with the copper-rich sulphide residue from the acid repulp step and the resulting slurry is treated in a non-oxidizing pressure leach in which nickel arsenic and iron are extracted. The process produces a nickel sulphate solution containing low levels of copper, iron and arsenic and a copper sulphide product containing low levels of nickel, iron, arsenic and other impurities.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of International application no. PCT/CA2006/02912, filed 24 Feb. 2006 designating the United States, which is pending.
TECHNICAL FIELD
The invention relates to swimming aids and more particularly to snorkels for use as recreational and fitness training swimming aids.
BACKGROUND
Swimmers in a swimming pool or an open body of water often use the front crawl stroke, where in order to breathe, a swimmer must either lift his or her head or rotate it to one side, which also rotates and disrupts the body alignment. While diving snorkels have long been used to permit divers to breathe when near the surface of the water without lifting their heads from the water, snorkels have only recently been developed to allow swimmers to breathe while using the front crawl or other strokes without lifting or turning their heads.
The present inventor has disclosed and claimed a front-mounted snorkel in International application no. PCT/CA2006/02912, filed 24 Feb. 2006, and issued U.S. Pat. No. 7,047,965 issued May 23, 2006, which are incorporated herein by reference. A front-mounted swimmer's snorkel is also disclosed in U.S. Design Pat. No. Des 406,333 of Finis, Inc. It has a snorkel tube positioned in front of the user's forehead and secured by a head-brace, which extends above the water surface and has at its lower end a mouthpiece held in the user's mouth and a water purge valve. A problem with the Finis snorkel is that the head brace is at a fixed angle relative to the mouthpiece tube, so it does not accommodate swimmers with differently shaped foreheads.
There is a need therefore for a front-mounted swimming snorkel which adapts to different swimmers with varying head sizes and shapes.
SUMMARY OF INVENTION
The invention provides a swimming snorkel for use by a swimmer while swimming on or adjacent the surface of the water comprising means for releasably securing the snorkel to the head of the swimmer, whereby the mouth-piece of the snorkel is held in the mouth of the swimmer and the upper ends of the snorkel tube extends above the surface of the water when the head and body of the swimmer are on or adjacent to the surface of the water, wherein the means for securing the snorkel tube to the head of the swimmer is hingedly connected to the snorkel tube by hinge means pivotable about an axis perpendicular to said hollow airway.
BRIEF DESCRIPTION OF DRAWINGS
In drawings which describe preferred embodiments of the invention:
FIG. 1 is a side elevation view of a first embodiment of the invention in use by a swimmer.
FIG. 2 is an exploded perspective view of the embodiment of the invention shown in FIG. 1 .
FIG. 3 is a perspective view of a first embodiment of the invention.
FIG. 4 is an exploded side view of the embodiment of the invention shown in FIG. 1 .
FIG. 4A is a lower end view of the valve assembly shown in FIG. 4 .
FIG. 4B is a side view of the valve assembly shown in FIG. 4 .
FIGS. 4C , 4 D and 4 E are cross-sectional views of the breathing tube shown in FIG. 4 .
FIG. 4F is an end view, partially in cross-section, of the mouthpiece and hollow chamber shown in FIG. 1 .
FIG. 4G is a detail cross-section view of the valve assembly shown in FIG. 4 with the butterfly valve shown in the open position.
FIG. 4H is a cross-section of the valve assembly shown in FIG. 4 with the butterfly valve shown in the closed position.
FIGS. 4J and 4K are detail views of the headbrace connection of the invention.
FIG. 5 is a front view of the snorkel shown in FIG. 3 .
FIG. 6 is a perspective view of a second embodiment of the headbrace of the invention.
FIG. 7 is a front view of the embodiment of the headbrace shown in FIG. 6 .
FIG. 8 is a detailed perspective view of the embodiment of the headbrace of the invention shown in FIG. 6 in place on the snorkel tube.
FIG. 9 is a side view of the embodiment of the headbrace of the invention shown in FIG. 8 .
FIG. 10 is a cross-section taken along lines A-A of FIG. 9 .
FIG. 11 is an exploded view of the embodiment shown in FIG. 9 and 10 .
FIG. 12 is a front view of a third embodiment of the headbrace of the invention.
FIG. 13 is a side view of the embodiment shown in FIG. 12 .
FIG. 14 is a front view of the embodiment of the invention shown in FIG. 12 in place on the snorkel tube.
FIG. 15 is a side view of the embodiment of the invention shown in FIG. 12 in place on the snorkel tube.
FIG. 16 is a schematic side view of the embodiment shown in FIG. 12 showing two positions of the headbrace in dotted outline.
DESCRIPTION
Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
With reference to FIGS. 1 and 2 , a swimming snorkel 10 according to the invention is in use by a swimmer 12 . The snorkel 10 has a curved breathing tube 14 which is secured to the head 11 of the swimmer by a brace assembly 18 which comprises an adjustable, flexible rubber strap 20 , a forehead brace 22 which is secured to the strap 20 and bears against the swimmer's forehead 24 , and is hingedly connected to an adjustable tube-mounting element 26 secured to forehead brace 22 which slidingly receives the breathing tube 14 . Adjustable tube mounting element 26 is slidable with a friction fit on breathing tube 14 and is connected by hinge rod 23 with forehead brace 22 to form a hinge that allows rotation of mounting element 26 .
Tube 14 is connected to hollow chamber 28 , which has water purge exit passage 30 ( FIG. 2 ) and is connected to mouthpiece 32 which is held in the mouth 34 of the swimmer. Tube 14 , with a valve assembly 36 and an adjustable threaded butterfly valve 57 at its upper end, curves through an angle of approximately 90 degrees from chamber 28 to valve assembly 36 and is sufficiently long, generally about eighteen inches, so that the valve assembly 36 extends above the water line 38 when the swimmer's head 11 and body 17 are horizontally oriented during swimming.
With reference to FIG. 2 through 4 , tube 14 comprises hollow intake tube 13 and exhaust tube 15 . Valve assembly 36 is divided into intake chamber 35 and exhaust chamber 37 . Intake chamber 35 communicates with intake passage 51 and intake tube port 50 . Exhaust chamber 37 communicates with exhaust passage 53 and exhaust tube port 54 . Threaded hole 55 extends through the wall of exhaust chamber 37 and receives threaded butterfly valve 57 to form a compression seal along the surface of the threads that does not allow the entry of air or water. Intake tube port 50 and exhaust tube port 54 receive the upper ends of intake tube 13 and exhaust tube 15 . Intake passage 51 and exhaust passage 53 have one-way valves 58 , 60 respectively which comprise flexible silicone valve diaphragms 66 , 68 having central stems 62 , 64 which are secured in central apertures 74 , 76 of valve seats 70 , 72 . More than one one-way valve may be provided for either or both the intake or the exhaust passages.
Hollow chamber 28 communicates with mouthpiece passage 78 , purge exit passage 30 , intake tube port 52 and exhaust tube port 56 . Intake tube port 52 and exhaust tube port 56 receive the lower ends of intake tube 13 and exhaust tube 15 . Water purge exit passage 30 is closed by a one-way valve 40 comprising a flexible silicone valve diaphragm 42 having a central stem 44 which is secured in a central aperture 46 of valve seat 48 .
As shown in cross-section in FIG. 4C , 4 D and 4 E, while the upper and lower ends of inlet tube 13 are preferably circular in cross-section, the rest of inlet tube 13 has an arrowhead or bullet-shaped cross-section to reduce the hydrodynamic drag while swimming for reduced resistance through the water. Other shapes may be used to accomplish the same result. However the intake tube 13 should have a minimum cross-sectional area of about 0.44 square inch (0.75 inch circular diameter), so that a minimum amount of force is needed to inhale. FIG. 4G shows the valve assembly 36 , and FIG. 4H shows the threaded butterfly valve 57 in closed position.
As shown in FIGS. 4J and 4K , adjustable tube mounting element 26 is connected to forehead brace 22 by hinge rod 23 which extends through holes 27 in extending arms 25 and holes 21 in extending arms 19 and is secured with washers 16 and cotter pins 17 . The tube mounting element is thereby hinged on forehead brace 22 and moveable about the axis defined by hinge rod 23 .
The adjustable tube-mounting element 26 is attached by a hinge to the forehead brace 22 to allow pivoting only about an axis perpendicular to the breathing tube 14 so that the entire forehead brace will make contact with the swimmer's forehead and press more firmly against the forehead to prevent the forehead brace from moving when the breathing tube 14 jogs or veers to one side in the water. The hinged forehead brace will thus fit snugly against the swimmer's forehead independent of the shape of the forehead.
A second embodiment of the forehead brace is shown in FIG. 6 through 11 . In this embodiment, the forehead brace 60 has flexible arms 62 , 64 on which are provided cylindrical hinge pins 66 , 68 . Hinge pins 66 , 68 are rotatably received in cylindrical depressions 70 formed in the hollow snorkel tube 72 . Cylindrical depressions 70 are formed in two parallel rows on opposite sides of snorkel tube 72 so that the position of brace 22 can be adjusted along the length of snorkel tube 72 . The length and separation of the hinge pins 66 , 68 is such that when the pins are received in depressions 70 , the flexible arms 62 , 64 are parallel and retain the pins 66 , 68 in place, but when arms 62 , 64 are flexed apart the pins 66 , 68 can be removed from depressions 70 . A strap 74 is secured to brace 60 having strap connectors 76 to which a strap around the head of the swimmer can be adjustably secured. Thus the brace 22 is able to pivot about the axis formed by pins 66 , 68 and can be adjusted along the length of the snorkel tube.
A third embodiment of the forehead brace is shown in FIG. 12 through 16 . In this embodiment, a flexible material between the head brace and the tube or the tube-mounting element allows pivoting about an axis perpendicular to the breathing tube. The forehead brace 80 is connected to a connecting sleeve 82 by a living hinge 84 . Living hinge 84 is formed of a plastic material which returns to a rest configuration as shown in FIG. 13 when pressure is not applied to it, but when pressure is applied, living hinge 84 can pivot through angle E between the positions C and D shown in FIG. 16 . A slit 86 in brace 80 allows the two halves 87 , 89 of brace 80 to be separated to snap sleeve 82 around the snorkel tube 72 at the desired location. As in the other embodiments, a strap (not shown) is secured to brace 80 using strap connectors so that the strap around the head of the swimmer can be adjustably secured. Thus brace 80 is able to pivot in the direction of angle E and can be adjusted along the length of the snorkel tube.
As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. The invention will usefully operate on snorkel tubes of differing cross-sectional shapes, such as oval, square, star, rectangular, round or other shapes as well as single or multiple tubes. Also whereas a single axis hinge has been disclosed to allow movement of the head brace about the axis defined by the hinge rod, other means for hingedly connecting the head brace to the tube or the tube-mounting element would also be suitable, such as providing a flexible material between the head brace and the tube or the tube-mounting element which allows pivoting about an axis perpendicular to the breathing tube. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.
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A front-mounted swimming snorkel has a forehead brace which pivots about an axis perpendicular to the snorkel tube to adapt to different swimmers' heads.
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PRIOR APPLICATIONS
[0001] This is a continuation-in-part application that claims priority from U.S. patent application Ser. No. 12/933,421, filed 26 Nov. 2010 that claims priority from International Application No. PCT/SE2009/050288, filed 19 Mar. 2009 claiming priority from Swedish Patent Application No. 0800645-4, filed 20 Mar. 2008.
TECHNICAL FIELD
[0002] The present invention relates to a feed system for a continuous digester in which wood chips are cooked for the production of cellulose pulp.
BACKGROUND AND SUMMARY OF THE INVENTION
[0003] In older conventional feed systems for continuous digesters, high-pressure pocket feeders have been used as sluice feeders for pressurisation and transport of a chips slurry to the top of the digester.
[0004] The Handbook of Pulp, (Herbert Sixta, 2006) discloses this type of feeding with high-pressure pocket feeders (High Pressure Feeder) on page 381. The big advantage with this type of feed is that the flow of ships does not need to pass through pumps, but is instead transferred hydraulically. At the same time it is possible to maintain a high pressure in the transfer circulation to and from the digester without losing pressure. The system has however demonstrated some disadvantages in that the high-pressure pocket feeder is subjected to wear and must be adjusted so that the leakage flow from the high-pressure circulation to the low-pressure circulation is minimized. Another disadvantage is that during transfer, the temperature must be kept low so that bangs related to steam implosions do not occur in the transfer.
[0005] As early as 1957, U.S. Pat. No. 2,803,540 disclosed a feed system for a continuous chip digester where the chips are pumped from an impregnation vessel to a digester in which the chips are cooked in a steam atmosphere. Here, a part of the cooking liquor is charged to the pump to obtain a pumpable consistency of 10%. However, this digester was designed for small scale production of 150-300 tons pulp per day (see col. 7, r.35).
[0006] Also, U.S. Pat. No. 2,876,098 from 1959 discloses a feed system for a continuous chip digester without a high-pressure pocket feeder. Here the chips are suspended in a mixer before they are pumped with a pump to the top of the digester. The pump arrangement is provided under the digester and here the pump shaft is also fitted with a turbine in which pressurised black liquor is depressurised to reduce the required pump energy.
[0007] U.S. Pat. No. 3,303,088 from 1967 also discloses a feed system for a continuous chip digester without a high-pressure pocket feeder, where the wood chips are first steamed in a steaming vessel, followed by suspension of the chips in a vessel, whereafter the chips suspension is pumped to the top of the digester.
[0008] U.S. Pat. No. 3,586,600 from 1971 discloses another feed system for a continuous digester mainly designed for finer wood material. Here, a high-pressure pocket feeder not used either, and the wood material is fed with a pump 26 via an upstream impregnation vessel to the top of the digester.
[0009] Similar pumping of finer wood material to the top of a continuous digester is also disclosed in EP157279.
[0010] Typical for these embodiments of digester systems from the late 50's to the beginning of the 70's is that these were designed for small digester houses with a limited capacity of about 100-300 tons pulp per day.
[0011] U.S. Pat. No. 5,744,004 shows a variation of feeding wood chips into a digester where the chips mixture is fed into the digester via a series of pumps. Here, so called DISCFLO™ pumps are used. A disadvantage with this system is that this type of pump typically has a very low pump efficiency.
[0012] The previously mentioned Handbook of Pulp also discloses on page 382 an alternative pump feed of chips mixtures called TurboFeed™. Here three pumps are used in series to feed the chips mixture to the digester. This type of feed has been patented in U.S. Pat. No. 5,753,075, U.S. Pat. No. 6,106,668, U.S. Pat. No. 6,325,890, U.S. Pat. No. 6,336,993 and U.S. Pat. No. 6,551,462; however in many cases, U.S. Pat. No. 3,303,088 for example, has not been taken into consideration.
[0013] U.S. Pat. No. 5,753,075 relates to pumping from a steaming vessel to a processing vessel.
[0014] U.S. Pat. No. 6,106,668 relates specifically to the addition of AQ/PS during pumping.
[0015] U.S. Pat. No. 6,325,890 relates to at least two pumps in series and the arrangement of these pumps at ground level.
[0016] U.S. Pat. No. 6,336,993 relates to a detail solution where chemicals are added to dissolve metals from the wood chips and then drawing off liquor after each pump to reduce the metal content of the pumped chips.
[0017] U.S. Pat. No. 6,551,462 essentially relates to the same system already disclosed in U.S. Pat. No. 3,303,088.
[0018] A big disadvantage with the systems with multiple pumps in series is limited accessibility. If one pump breaks down, the whole digester system stops. With 3 pumps in series and a normal accessibility for each pump of 0.95, the total systems accessibility is just 0.86 (0.95*0.95*0.95=0.86).
[0019] Today's modern continuous digesters with capacities over 4000 tons pulp per day use digesters that are 50-75 meters high, where a gauge pressure of 3-8 bar is established in the top of the digester in the case of a steam phase digester, or 5-20 bar in the case of a hydraulic digester. The continuous digester systems are designed to, during the main part of operation, typically well over 80-95% of operation, run at nominal production, which makes it necessary, in regard to operational costs, for the pumps to be optimized for nominal production.
[0020] A typical digester system with a capacity of about 3000 tons with a feed system with the so called “ TurboFeed™” technology requires about 800 kW of pumping power. It is obvious that these systems must have pumps that run at an optimized efficiency close to their nominal capacity. Such a feed system requires 19,200 kWh (800*24) per 24 hours, and at a price of 50 Euro per MWh, the operational cost comes to 960 Euro per 24 hours or 336,000 Euro per year.
[0021] The systems must also be able to be operable within 50-110% of nominal production which places great demands on the feed system.
[0022] This means that a system supplier must offer pumps that are large enough to handle 4000 tons and that may also be operated within a 2000-4400 ton interval. Such a pump operated at 50% of its capacity is far from optimised, but it is necessary to at least temporarily be able to operate the pump at limited capacity in case of temporary capacity problems, for example further down the fibre line.
[0023] If this system supplier offers digester systems that can handle nominal capacities of 500-5000 tons, then pumps must be designed in a number of different pump sizes so that each individual installation can offer, from a power consumption and energy perspective, optimised transfer at nominal production. This makes the pumps very expensive, as normally a very limited series of pumps are manufactured in each size. To be able to meet demands of reasonably short delivery times, the system supplier must stock pumps in all pump sizes, which is very expensive.
[0024] The digester feed should also be able to guarantee optimal feeding to the top of the digester even if the flow in the transfer line is reduced to 50% of nominal flow.
[0025] This is difficult, because the flow rate in the transfer lines should be maintained above a critical level, as well-steamed chips have a tendency to sink against the direction of the transfer flow if the speed becomes too low.
[0026] A corrective measure that can be used at low rates, is to increase the dilution before pumping so that a lower chips concentration is established. This is however not energy efficient as it forces the feed systems to pump unnecessarily high volumes of fluid, which increases the pump energy consumption per produced unit of pulp.
[0027] Each pump has a construction point (Best Efficiency Point/“BEP”) at which the pump is intended to work. At this “BEP”, shock induced loss and frictional loss are, in the case of centrifugal pumps, at their lowest which in turn leads to that the pumps efficiency is highest at this point.
[0028] A first aim of the present invention is to provide an improved feed system for wood chips wherein optimal transfer can be achieved within a broader interval around the digesters design capacity.
[0029] Other aims of the present invention are;
improved efficiency of the feed system; improved accessibility; lower operational costs per pumped unit of chips; constant chip concentration during pumping regardless of production level; a limited range of pump sizes that can cover a broad span of the digesters production capacity; simplified maintenance; lower installation costs compared to feed systems with high-pressure pocket feeders or multiple pumps in series;
[0037] The above mentioned aims may be achieved with a feed system according to the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 shows a first system solution for feed systems for digesters with a top separator;
[0039] FIG. 2 shows a second system solution for feed systems for digesters without a top separator;
[0040] FIGS. 3-6 show different ways of attaching pumps to an outlet in a pre-treatment vessel;
[0041] FIG. 7 shows the feed system's connection to the top of a digester without a top separator; and
[0042] FIG. 8 shows a top view of FIG. 7 ;
[0043] FIG. 9 shows a third system solution for feed systems for digesters without a top separator;
[0044] FIG. 10 shows a fourth system solution for feed systems for digesters with a top separator, and
[0045] FIG. 11 shows how the transfer lines from each pump in the systems in FIGS. 9 and 10 may be combined to form one single transfer line.
[0046] FIG. 12 shows a second alternative of how the transfer lines from each pump may be combined to form one single transfer line, and
[0047] FIG. 13 shows a third alternative of how the transfer lines from each pump may be combined to form one single transfer line.
DETAILED DESCRIPTION OF THE INVENTION
[0048] In the following detailed description, the phrase “feed system for a continuous digester” will be used. “Feed system” herein means a system that feeds wood chips from a low-pressure chips processing system, typically with a gauge pressure under 2 bar and normally atmospheric, to a digester where the chips are under high pressure, typically between 3-8 bar in the case of a steam phase digester or 5-20 bar in the case of a hydraulic digester.
[0049] The term “continuous digester” herein means either a steam phase digester or a hydraulic digester even though the preferred embodiments are exemplified with steam phase digesters.
[0050] A basic concept is that a feed system comprises at least 2 pumps in parallel, but preferably even 3, 4 or 5 pumps in parallel. It has been shown that a single pump can feed a chips suspension to a pressurised digester, and it is therefore possible to exclude conventional high-pressure pocket feeders or complicated feed systems with 2-4 pumps in series.
[0051] The pumps are arranged in a conventional way on the foundation at ground level to facilitate service.
[0052] With the above outlined solution it is possible to provide feed systems for digester production capacities from 750 to 6000 tons pulp per day, with only a few pump sizes. This is very important, as these pumps for feeding wood chips at relatively high concentration are very specific in regard to their applications, and pumps that are able to handle production capacities of 4000-6000 tons pulp per day are very large and only manufactured in very limited series of a few pumps per year. The cost for these pumps therefore becomes a crucial factor for a digester system.
[0053] The table below shows an example of how it is possible to cover a production interval of 750-6000 tons with only two pump sizes optimised for 750 and 1500 tons pulp, respectively, per day;
[0000]
PUMP PROGRAM
Nominal Production
Capacity (ton per day)
750 pump
1500 pump
750
1 unit
1500
2 units
2250
1 unit
1 unit
(2250 alt)
(3 units *)
—
3000
—
2 units
(3000 alt)
(4 units *)
3750
1 unit
2 units
4500
—
3 units
(4500 alt)
(2 units *)
(2 units *)
5250
1 unit
3 units
6000
4 units
(X unit * = 1: st alternative)
[0054] This table clearly shows how it is possible, with the concept according to the present invention, to cover production capacities between 1500-6000 tons with only 2 optimised pump sizes while using a single pump installation in smaller digester systems with a capacity of 750 tons. Continuous digesters with a capacity of 750 tons are seldom used for new installations today, because batch digester systems are often more competitive for these capacities. A certain after market may exist for older digester systems with a low capacity where expensive feed systems with high-pressure pocket feeders are still used.
FIRST EMBODIMENT
[0055] FIG. 1 shows an embodiment of the feed system with at least 2 pumps in parallel. The chips are fed with a conveyor belt 1 to a chips buffer 2 arranged on top of an atmospheric treatment vessel 3 . In this vessel, a lowest liquid level, LIQ LEV , is established by adding an alkali impregnation liquid, preferably cooking liquor (black liquor) that has been drawn off in a strainer screen SC 2 in a subsequent digester 6 , and possibly adding white liquor and/or another alkali filtrate.
[0056] The chips are fed with normal control of the chip level CH LEV which is established above the liquid level LIQ LEV .
[0057] The remaining alkali content in the black liquor is typically between 8-20 g/l. The amount of black liquor and other alkali liquids that are added to the treatment vessel 3 is regulated with a level transmitter 20 that controls at least one of the flow valves in lines 40 / 41 . With this alkali impregnation liquor the wood acidity in the chips may be neutralised and impregnated with sulphide rich (HS − ) fluid. Spent impregnation liquor, with a remaining alkali content of about 2-5 g/l, preferably 5-8 g/l, is drawn off from the treatment vessel 3 via the withdrawal strainer SC 3 and sent to recovery REC. If necessary, white liquor WL may also be added to the vessel 3 , for example as shown in the figure, to line 41 . The actual remaining alkali content depends on the type of wood used, hardwood or softwood, and which alkali profile that is to be established in the digester.
[0058] In the case where a raw wood material that is easy to impregnate and neutralise is used, for example raw wood material such as pin chips or wood chips with very thin dimensions and a quick impregnation time, vessel 3 may in extreme cases be a simple spout with a diameter essentially corresponding to the bucket formed outlet 10 in the bottom of the vessel. Required retention time in the vessel is determined by the time it takes for the wood to become so well impregnated that it sinks in a free cooking liquor.
[0059] After the chips have been processed in vessel 3 they are fed out from the bottom of the vessel where also a conventional bottom scraper 4 is arranged, driven by a motor M 1 .
[0060] According to the invention, the chips are fed to the digester via at least 2 pumps 12 a, 12 b in parallel, and these pumps are connected to a bucket formed outlet 10 in the bottom of the vessel. The bucket formed outlet 10 has an upper inlet, a cylindrical mantle surface, and a bottom. The pumps are connected to the cylindrical mantle surface.
[0061] To facilitate pumping of the chips mixture, the chips are suspended in a vessel 3 to create a chips suspension, in which vessel is arranged a fluid supply via lines 40 / 41 , controlled by a level transmitter 20 which establishes a liquid level LIQ LEV in the vessel, and above the pump level by at least 10 meters, and preferably at least 15 meters and even more preferably at least 20 meters. Hereby a high static pressure is established in the inlet to pumps 12 a and 12 b so that one single pump can pressurise and transfer the chips suspension to the top of the digester without cavitation of the pump. The top of the digester is typically arranged at least 50 meters above the level of the pump, usually 60-75 meters above the level of the pump while a pressure of 5-10 bar is established in the top of the digester.
[0062] To further facilitate the feeding to the pumps, a stirrer 11 is arranged in the bucket formed outlet. The stirrer 11 is preferably arranged on the same shaft as the bottom scraper and driven by the motor M 1 . The stirrer has at least 2 scraping arms that sweep over the pump outlets arranged in the bucket formed outlet's mantle surface. Preferably a dilution is arranged in the bucket formed outlet, which may be accomplished by dilution outlets (not shown) connected to the upper edge of the mantle surface.
[0063] FIGS. 3-6 show how a number of pumps 12 a - 12 d may be connected to the outlet's cylindrical mantle surface and how the stirrer 11 may be fitted with up to 4 scraping arms. The pumps may preferably be arranged symmetrically around the outlets cylindrical mantle surface with a distribution in the horizontal plane of 90° between each outlet if there are 4 pump connections (120° if there are 3 pump connections and 180° if there are 2 pump connections). This way it is possible to avoid an uneven distribution of the load on the bottom of the vessel and its foundation. In practice, shut-off valves (not shown) are also arranged between the outlet's 10 mantle surface and the pump inlet and a valve directly after the pump to make it possible to shut off the flow through one pump if this pump is to be replaced during continued operation of the remaining pumps.
[0064] In FIG. 1 the chips are fed by pumps 12 a, 12 b via transfer lines 13 a, 13 b (only two shown in FIG. 1 ) to the top of the digester 6 . FIG. 1 shows a conventional top separator 51 arranged in the top of the digester. The transfer lines 13 a, 13 b, preferably 2, both open into the bottom of the top separator, where, driven by motor M 3 , a feeding screw 52 drives the chips slurry up under a dewatering process against the top separators withdrawal strainer SC 1 . Drained chips will then be fed out from the upper outlet of the separator in a conventional way and fall down into the digester. In the case a hydraulic digester is used, the top separator is turned up-side down, and feeds the chips down into the digester.
[0065] The drained liquid from the top separator 51 is led through a line 40 back to the processing vessel 3 , and may preferably be added to the bottom of the processing vessel, to there facilitate feeding out under dilution.
[0066] Alternatively, line 40 may be connected to the position for the outlet of line 41 in the processing vessel 3 and line 41 may be connected to the position for the outlet of line 40 in the processing vessel 3 , according to the concept CrossCirc™. In a variation, the flow of line 40 and 41 may be mixed at the intersection of lines 40 and 41 in FIG. 1 .
[0067] The digester 6 may be fitted with a number of digester circulations and the addition of white liquor to the top of the digester or to the digester's supply flows (not shown). The figure shows a withdrawal of cooking liquor via strainer SC 2 . The cooking liquor drawn off from strainer SC 2 is known as black liquor and may have a somewhat higher content of remaining alkali than black liquor that is normally sent directly to recovery and normally drawn off further down in the digester. The cooked chips P are then fed out from the bottom of the digester with the help of a conventional bottom scraper 7 and the cooking pressure.
Second Embodiment FIG. 2 shows an alternative embodiment which does not include a top separator. Instead the transfer lines 13 a, 13 b (only two are shown in FIG. 1 ) open directly into the top of the digester. Excess liquid is then drawn off with a digester strainer SC 1 arranged in the digester wall. FIGS. 7 and 8 show this in more detail. The remaining parts of this embodiment correspond to the digester system shown in FIG. 1 .
[0068] FIG. 8 shows how 4 transfer lines 13 a, 13 b, 13 c and 13 d may open directly into the top of the digester. These outlets may preferably be arranged symmetrically in the top of the digester with a distribution in the horizontal plane of 90° between each outlet if there are 4 outlets (120° if there are 3 outlets and 180° if there are 2 outlets). The outlets are suitably arranged at a distance of 60-80% of the digester radius. FIG. 7 shows how the transfer lines 13 a, 13 b and 13 c open directly down into the top of the digester and thereby distribute the chips over the cross section of the digester. In this case a steam phase digester is shown where steam ST and/or pressurised air P AIR is added to the top of the digester, in which a chips level CH LEV is established above the liquid level LIQ LEV in the top of the digester. Excess liquid is drawn off with a strainer SC 2 and collected in a withdrawal space 51 before being led back via line 41 .
[0069] An advantage with the second embodiment, but also with the first embodiment, is that each pump may closed independently while the remaining pumps may continue pumping at optimal efficiency and without requiring modification of the feed system itself.
Third Embodiment
[0070] FIG. 9 shows an alternative embodiment for the feed system to a continuous digester without a top separator where each pump 12 a, 12 b pumps the chips suspension through a first section 13 a, 13 b of a transfer line to the top of the digester, and the first sections of the transfer lines from at least 2 pumps are combined at a merging point 16 to form a combined second section 13 ab of the transfer line before this second section is led towards the top of the digester. To maintain a constant flow rate, a supply line 15 is also connected to the merging point 16 . In this embodiment black liquor is taken from line 41 and may be pressurised with a pump 14 . However, because the black liquor has already reached a full digester pressure, the need to pressurise the liquor is limited. All other characterizing parts of the system correspond to the system shown in FIG. 2 .
Fourth Embodiment
[0071] FIG. 10 shows an alternative embodiment for the feed system to a continuous digester with a top separator where each pump 12 a, 12 b pumps the chips suspension through a first section 13 a, 13 b of a transfer line to the top of the digester, and the first sections of the transfer lines from at least 2 pumps are combined at a merging point 16 to form a combined second section 13 ab of the transfer line before this second section is led towards the top of the digester. To maintain a constant flow rate, a supply line 15 is also connected to the merging point 16 . In this embodiment black liquor is taken from line 40 and may be pressurised with a pump 14 . However, because the black liquor has already reached a full digester pressure, the need to pressurise the liquor is limited.
[0072] All other characterizing parts of the system correspond to the system shown in FIG. 1 .
[0073] FIG. 11 shows an example of how supply lines 15 a, 15 b that are used in both the third and the fourth embodiment may be connected to merging points 16 ′ in the case 4 pumps 12 a - 12 d are used. An advantage with this supply arrangement is that it is possible to guarantee optimal speed in the combined flow in the second section 13 ac/ 13 bd and in the combined flow in the final third section 13 abcd of the transfer line.
[0074] It is critical that the rate of the flow up to the digester is well over 1.5-2 m/s so that the chips in the flow do not sink down towards the feed flow and cause plugging of the transfer line. The flow in the transfer line should suitably be maintained between 4-7 m/s to make sure that the chips are transferred to the top of the digester.
[0075] If, for example, pump 12 a would be shut down due to repair or a desired capacity reduction, the flow in addition line 15 a may be increased so that the flow rate in the second section 13 ac is maintained.
[0076] In these combined line systems for transferring chips suspensions it is advantageous that the lines after the merging points 16 , 16 ′, 16 ″ have a flow cross section that is equal to or greater than the sum of the incoming lines, to avoid pressure loss in the transfer lines. Suitable equations for flow areas A may be:
[0000] A 13bd ≧( A 13d +A 13b ), and
[0000] A 13abcd ≧( A 13bd +A 13ac ).
[0000] In a transfer line where the first section has a diameter of for example 100 mm and an established flow rate of 5 m/s, a flow rate of 4.4 m/s is established if a second section that combines 2 lines with diameter 100 mm has a diameter of 150 mm. With a subsequent combination of 2 such lines with a diameter of 150 mm to a third section with a diameter of 250 mm, a flow rate of 3.18 m/s may be established. All these flow rates have a margin towards the critical lowest flow rate.
[0077] The supply lines 15 a, 15 b may also have connections directly after each pump outlet, so that the line between pump and merging point is kept flushed during the time that the pump is shut down or operated at a reduced capacity. The addition of extra fluid may also be combined with a further dilution of the chips suspension before the pumps, for example on the suction side of the pumps or in the bottom of vessel 3 .
[0078] FIG. 12 shows a cross-sectional view of a second embodiment of how lines 13 a - 13 d from the pumps may be combined to form one single transfer line 13 abcd. Here, the supply line 15 for dilution liquid provides a vertical part of the transfer line towards the top of the digester, and each line 13 a, 13 b, 13 c, 13 d from each pump is connected successively, one by one, to this vertical part of the transfer line at different heights. At each supply position, the chip flow is added in a conical part of a diameter increase in the transfer line. As is indicated by the dashed alternatives 13 b ALT / 13 d ALT , the connections from the pumps may instead be shifted from side to side on the transfer line.
[0079] FIG. 13 shows a cross-sectional view of a third embodiment of how lines 13 a - 13 d from the pumps may be combined to form one single transfer line 13 abcd. Here, the supply line 15 for dilution liquid provides a vertical part of the transfer line towards the top of the digester, and each line 13 a, 13 b, 13 c, 13 d from each pump is connected at the same height to this vertical part of the transfer line. Preferably the supply position for the chip flow is arranged in a conical part of a diameter increase in the transfer line and each connected line is oriented upwards and inclined at an angle in relation to the vertical orientation in the interval 20-70 degrees. The Figure shows only the connections 13 a, 13 b, 13 c, as connection 13 d is in the part that is cut away in this view.
[0080] The invention is not limited to the above mentioned embodiments. More variations are possible within the scope of the following claims. In the embodiments shown in FIGS. 2 and 9 , in some applications the strainer SC 1 and the return line 40 may for example be omitted, preferable for cooking of wood material with a higher bulk density, such as hardwood (HW), that for a corresponding production volume require less liquid during transfer.
[0081] In the case where a raw wood material that is easy to impregnate and neutralise is used, for example raw wood material such as pin chips or wood chips with very thin dimensions and a quick impregnation time, vessel 3 may in extreme cases be a simple spout with a diameter essentially corresponding to the bucket formed outlet 10 in the bottom of the vessel.
[0082] If the chips fed into the vessel 3 are already well steamed, the liquid level LIQ LEV may be established above a chips level CH LEV .
[0083] In the embodiments shown, an alkali pre-treatment was used in vessel 3 , but it is also possible to use a process where this pre-treatment comprises acid pre-hydrolysis.
[0084] There is a substantial difference between pumping chips suspensions/slurries compared to pumping water-like liquids. In general, handbooks in pumping provide advice and instructions for pumping water-like fluids. However, the special circumstances of pumping slurries with a high content of solid matter must always be given special attention.
[0085] One difference, when pumping chip slurries, is that chips suspensions establish a volume of interlocked chips that create a flow-restriction, or a pressure drop through the chips, of the free liquid in the chips suspension/slurry through the slurrying vessel. It cannot, therefore, be assumed that a liquid head has the same impact upon the pumping inlets as in any general application where pumps are pumping pure liquid and the hydraulic system/volume transmits a full hydraulic pressure as a result of the liquid volume disposed above the pump inlets.
[0086] Another difference is that the chips in the chips suspension interlock, or have a tendency to interlock, to one another that creates a unitary interlocked volume of chips that moves as one “plug” flow. This unitary flow does not behave like a conventional liquid-like liquids do. It is difficult to break up the unitary plug-flow of interlocked chips into several partial flows which would require that the chip-plug flow behaves more like a liquid feeding each pump inlet with equal feeding volume tapped off from the chip plug flow.
[0087] When a hot liquid is added to a flow of chips suspension containing interlocked chips, such as adding hot black liquor via a pipe, it was surprisingly discovered that the hot liquid does not mix well or thoroughly with the chips suspension because hot streaks of black liquor was discovered in the transfer lines all the way up to the digester. It was also surprisingly discovered that the hot streaks of black liquor do not shift from one side to another inside the transfer line either but remained stable in the same position inside the transfer line.
[0088] It was also surprisingly discovered that by breaking up the chips plug, by using scraping arms of a stirrer close to the outlets at the pump inlets, the interlocking effect between chips in the chips suspension is sufficiently broken-up by continuous agitation from the stirrer so the feed of the chips slurry is unrestricted towards all the pump inlets which is important when many pump inlets are used because the distribution of the flow to the various pump inlets is more even. The breaking up of the interlocked chips also enhances the mixing of the hot liquor into the chips suspension which in turn reduces the hot streaks described above.
[0089] More particularly, the breaking up of the interlocked chips positively affects the pumping of the chips slurry from the multiple outlets of the vessel up to the top of the digester even if only one single pump per transfer line is used for the entire pump head. If the plug flows are not broken up, there is a high risk of pump cavitation due to the interlocking of the chips in each pump inlet and uneven flow between the pump inlets, as all multiple pump inlets establish a negative pressure in the pump inlets and hence into the bottom of the tower increasing the risk for cavitation in pumps.
[0090] In other words, when the chips in the chips slurry are interlocked, the static pressure at the bottom of the vessel does not generally change as linearly as it does in hydraulic systems by raising the liquid level as the liquid head experiences a pressure drop through the interlocked chip pile. Especially, if multiple single pumps, i.e. one single pump per transfer line, wherein the pumps are in parallel, are connected to the bottom of the vessel, all pumps induce a super-imposed negative pressure from each pump inlet that may cause cavitation.
[0091] However, it was surprisingly discovered that the static pressure created, while the stirrer breaks up the interlocked chip plug in the chips suspension at the bottom of the vessel, is high enough so that a single pump per transfer line can pump the chips slurry to the top of the digester kept at full digester pressure without cavitation of the pump (due to lack of sufficient or uneven feed of the chips slurry to each pump inlet). The breaking up of the interlocked chips makes the flow characteristics of the chips suspension to be more similar to that of the flow characteristics of conventional or water-like liquids.
[0092] While the present invention has been described in accordance with preferred compositions and embodiments, it is to be understood that certain substitutions and alterations may be made thereto without departing from the spirit and scope of the following claims.
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The feed system is for a continuous digester where at least two pumps are arranged in parallel at the bottom of a pre-treatment vessel and a stirrer is provided in direct connection to inlets to pumps. The system makes it possible to provide a feed system with an improved accessibility and operational reliability, and to operate the main part of the pumps at optimal efficiency even if the production capacity is reduced.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a non-provisional application which claims benefit under 35 USC §119(e) to U.S. Provisional Application Ser. No. 61/405,497 filed Oct. 21, 2010, entitled “Ice Worthy Jack-Up Drilling Unit,” and is a continuation-in-part application which claims benefit under 35 USC §120 to U.S. application Ser. No. 13/277,791 filed Oct. 20, 2011, entitled “Ice Worthy Jack-Up Drilling Unit” both of which are incorporated herein in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
None.
FIELD OF THE INVENTION
This invention relates to mobile offshore drilling units, often called “jack-up” drilling units or rigs that are used in shallow water, typically less than 400 feet, for drilling for hydrocarbons.
BACKGROUND OF THE INVENTION
In the never-ending search for hydrocarbons, many oil and gas reservoirs have been discovered over the last one hundred and fifty years. Many technologies have been developed to find new reservoirs and resources and most areas of the world have been scoured looking for new discoveries. Few expect that any large, undiscovered resources remain to be found near populated areas and in places that would be easily accessed. Instead, new large reserves are being found in more challenging and difficult to reach areas.
One promising area is in the offshore Arctic. However, the Arctic is remote and cold where ice on the water creates considerable challenges for prospecting for and producing hydrocarbons. Over the years, it has generally been regarded that six unprofitable wells must be drilled for every profitable well. If this is actually true, one must hope that the unprofitable wells will not be expensive to drill. However, in the Arctic, little, if anything, is inexpensive.
Currently, in the shallow waters of cold weather places like the Arctic, a jack-up or mobile offshore drilling unit (MODU) can be used for about 45-90 days in the short, open-water summer season. Predicting when the drilling season starts and ends is a game of chance and many efforts are undertaken to determine when the jack-up may be safely towed to the drilling location and drilling may be started. Once started, there is considerable urgency to complete the well to avoid having to disconnect and retreat in the event of ice incursion before the well is complete. Even during the few weeks of open water, ice floes present a significant hazard to jack-up drilling rigs where the drilling rig is on location and legs of the jack-up drilling rig are exposed and quite vulnerable to damage.
Jack-up rigs are mobile, self-elevating, offshore drilling and workover platforms equipped with legs that are arranged to be lowered to the sea floor and then to lift the hull out of the water. Jack-up rigs typically include the drilling and/or workover equipment, leg jacking system, crew quarters, loading and unloading facilities, storage areas for bulk and liquid materials, helicopter landing deck and other related facilities and equipment.
A jack-up rig is designed to be towed to the drilling site and jacked-up out of the water so that the wave action of the sea only impacts the legs which have a fairly small cross section and thus allows the wave action to pass by without imparting significant movement to the jack-up rig. However, the legs of a jack-up provide little defense against ice floe collisions and an ice floe of any notable size is capable of causing structural damage to one or more legs and/or pushing the rig off location. If this type of event were to happen before the drilling operations were suspended and suitable secure and abandon had been completed, a hydrocarbon leak would possibly occur. Even a small risk of such a leak is completely unacceptable in the oil and gas industry, to the regulators and to the public.
Thus, once it is determined that a potentially profitable well has been drilled during this short season, a very large, gravity based production system, or similar structure may be brought in and set on the sea floor for the long process of drilling and producing the hydrocarbons. These gravity based structures are very large and very expensive, but are built to withstand the ice forces year around.
BRIEF SUMMARY OF THE DISCLOSURE
The invention more particularly relates to an ice worthy jack up rig for drilling for hydrocarbons in potential ice conditions in offshore areas including a flotation hull having a relatively flat deck at the upper portion thereof. The flotation hull further includes an ice bending shape along the lower portion thereof and extending around the periphery of the hull where the ice bending shape extends from an area of the hull near the level of the deck and extends downwardly near the bottom of the hull along with an ice deflecting portion extending around the perimeter of the bottom of the hull to direct ice around the hull and not under the hull. The rig includes at least three legs that are positioned within the perimeter of the bottom of the hull wherein the legs are arranged to be lifted up off the seafloor so that the rig may be towed through shallow water and also extend to the sea floor and extend further to lift the hull partially or fully out of the water. A jack up device is associated with each leg to both lift the leg from the sea bottom so that the ice worthy jack up rig may float by the buoyancy of the hull and push the legs down to the seafloor and push the hull partially up and out of the water when ice floes threaten the rig and fully out of the water when ice is not present. A gas agitation system is provided to agitate the water near the legs and reduce issues with ice near the legs.
The invention further relates to a method for drilling wells in ice prone waters. The method includes providing a flotation hull having a relatively flat deck at the upper portion thereof and an ice bending shape along the lower portion thereof where the ice bending shape extends from an area of the hull near the level of the deck and extends downwardly near the bottom of the hull and an ice deflecting portion extending around the perimeter of the bottom of the hull to direct ice around the hull and not under the hull. At least three legs are positioned within the perimeter of the bottom of the hull. Each leg is jacked down in a manner that feet on the bottom of the legs engages the sea floor and lifts the hull up and fully out of the water when ice is not threatening the rig while the rig is drilling a well on a drill site. The hull is further lowered into the water into an ice defensive configuration so that the ice bending shape extends above and below the sea surface to bend ice that comes against the rig to cause the ice to submerge under the water and endure bending forces that break the ice where the ice flows past the rig. The method further includes agitating the water near the legs to reduce issues with ice near the legs.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present invention and benefits thereof may be acquired by referring to the follow description taken in conjunction with the accompanying drawings in which:
FIG. 1 is an elevation view of a first embodiment of the present invention where the drilling rig is floating in the water and available to be towed to a well drilling site;
FIG. 2 is an elevation view of the first embodiment of the present invention where the drilling rig is jacked up out of the water for open water drilling through a moon pool;
FIG. 3 is an elevation view of the first embodiment of the present invention where the drilling rig is partially lowered into the ice/water interface, but still supported by its legs, in a defensive configuration for drilling during potential ice conditions; and
FIG. 4 is an enlarged fragmentary elevation view showing one end of the first embodiment of the present invention in the FIG. 3 configuration with ice moving against the rig.
DETAILED DESCRIPTION
Turning now to the detailed description of the preferred arrangement or arrangements of the present invention, it should be understood that the inventive features and concepts may be manifested in other arrangements and that the scope of the invention is not limited to the embodiments described or illustrated. The scope of the invention is intended only to be limited by the scope of the claims that follow.
As shown in FIG. 1 , an ice worthy jack-up rig is generally indicated by the arrow 10 . In FIG. 1 , jack-up rig 10 is shown with its hull 20 floating in the sea and legs 25 in a lifted arrangement where much of the length of the legs 25 extend above the deck 21 of the hull 20 . On the deck 21 is derrick 30 which is used to drill wells. In the configuration shown in FIG. 1 , the jack-up rig 10 may be towed from one prospect field to another and to and from shore bases for maintenance and other shore service.
When the jack-up rig 10 is towed to a drilling site in generally shallow water, the legs 25 are lowered through the openings 27 in hull 20 until the feet 26 at the bottom ends of the legs 25 engage the seafloor 15 as shown in FIG. 2 . In a preferred embodiment, the feet 26 are connected to spud cans 28 to secure the rig 10 to the seafloor. Once the feet 26 engage the seafloor 15 , jacking rigs within openings 27 push the legs 25 down and therefore, the hull 20 is lifted out of the water. With the hull 20 fully jacked-up and out of the water, any wave action and heavy seas more easily break past the legs 25 as compared to the effect of waves against a large buoyant object like the hull 20 . Well drilling operations may commence in the ordinary course while there is no ice in the area. The ice-worthy jack-up drilling rig 10 is designed to resist ice floes by assuming an ice defensive, hull-in-water configuration as shown in FIG. 3 . In FIG. 3 , ice tends to dampen waves and rough seas, so the sea surface 12 appears less threatening, however, the hazards of the marine environment have only altered, and not lessened.
When the ice-worthy jack-up rig 10 assumes its ice defensive, hull-in-water configuration, the hull 20 is lowered into the water to contact same, but not to the extent that the hull 20 would begin to float. A significant portion of the weight of the rig 10 preferably remains on the legs 25 to hold the position of the rig 10 on the drill site against any pressure an ice flow might bring. The rig 10 is lowered so that inwardly sloped, ice-bending surface 41 bridges the sea surface 12 or ice/water interface to engage any floating ice that may come upon the rig 10 .
The sloped ice-bending surface 41 runs from shoulder 42 , which is at the edge of the deck 26 , down to neckline 44 . Ice deflector 45 extends downward from neckline 44 . Thus, when an ice floe, such as shown at 51 comes to the rig 10 , the ice-bending surface 41 causes the leading edge of the ice floe 51 to submerge under the sea surface 12 and apply a significant bending force that breaks large ice floes into smaller, less damaging, less hazardous bits of ice. For example, it is conceivable that an ice floe being hundreds of feet and maybe miles across could come toward the rig 10 . If the ice floe is broken into bits that are less than twenty feet in the longest dimension, such bits are able to pass around the rig 10 with much less concern.
In FIGS. 2 , 3 and 4 , the present invention offers an additional ice defensive aspect where air blower 35 is arranged to blow air down through hoses to the spud cans 28 . The spud cans 28 include holes or diffusers to release air bubbles to agitate the water around the legs 25 . The agitated water is stirred to prevent ice from forming on the legs and creates a natural flow away from the legs. With the gas agitation system, it may be practical to maintain the rig 10 in the configuration shown in FIG. 2 when ice first becomes a concern rather than immediately begin the involved process of transitioning the rig 10 from the configuration shown in FIG. 2 to the defensive, hull-in-water configuration shown in FIG. 3 . This may be helpful if weather forecasts suggest possible ice conditions for a period of time followed by storms and heavy seas (in which the out of the water configuration shown in FIG. 2 is preferred).
Ice has substantial compressive strength being in the range of 4 to 12 MPa, but is much weaker against bending with typical flexure strength in the range of 0.3 to 0.5 MPa. As shown, the force of the ice floe 51 moving along the sea surface 12 causes the leading edge to slide under the sea surface 12 and caused section 52 to break off. With the ice floe 51 broken into smaller floes, such as section 52 and bit 53 , the smaller sections tend to float past and around the rig 10 without applying the impacts or forces of a large floe. It is preferred that ice not be forced under the flat of bottom of the hull 20 and the ice deflector 45 turns ice to flow around the side of the hull 20 . If the ice is really thick, the ice deflector 45 is arranged to extend downwardly at a steeper angle than ice-bending surface 41 and will increase the bending forces on the ice floe. At the ice deflector 45 , an ice deflector is positioned to extend down from the flat of bottom of the hull 20 . In an optional arrangement, the turn of the bilge is the flat of bottom at the bottom end of the ice deflector 45 .
To additionally resist the forces that an ice floe may impose on the rig 10 , the feet 26 of the legs may be arranged to connect to cans 28 set in the sea floor so that when an ice floe comes against the ice-bending surface 41 , the legs 25 actually hold the hull 20 down and force the bending of the ice floe and resist the lifting force of the ice floe which, in an extreme case, may lift the near side of the rig 10 and push the rig over on its side by using the feet 26 on the opposite side of the rig 10 as the fulcrum or pivot. The cans in the sea floor are known for other applications and the feet 26 would include appropriate connections to attach and release from the cans, as desired.
It should probably be noted that shifting from a conventional open water drilling configuration as shown in FIG. 2 to a hull-in-water, ice defensive configuration shown in FIG. 3 may require considerable planning and accommodation depending on what aspect of drilling is ongoing at the time. While some equipment can accommodate shifting of the height of the deck 21 , other equipment may require disconnections or reconfiguration to adapt to a new height off the sea floor 15 .
The ice-worthy jack-up drill rig 10 is designed to operate like a conventional jack-up rig in open water, but is also designed to settle to the water in an ice defensive position and then re-acquire the conventional stance or configuration when wave action becomes a concern. It is the shape of the hull 20 (as well as its strength) that provides ice bending and breaking capabilities.
The hull 20 preferably has a faceted or multisided shape that provides the advantages of a circular or oval shape, and may be less expensive to construct. The plates that make up the hull would likely be formed of flat sheets and so that the entire structure comprises segments of flat material such as steel would likely require less complication. The ice-breaking surface would preferably extend at least about five meters above the water level, recognizing that water levels shift up and down with tides and storms and perhaps other influences. The height above the water level accommodates ice floes that are quite thick or having ridges that extend well above the sea surface 12 , but since the height of the shoulder 42 is well above the sea surface 12 , the tall ice floes will be forced down as they come into contact with the rig 10 . At the same time, the deck 21 at the top of the hull 20 should be far enough above the water line so that waves are not able to wash across the deck. As such, the deck 25 is preferred to be at least 7 to 8 meters above the sea surface 12 . Conversely, the neckline 42 is preferred to be at least 4 to 8 meters below the sea surface 12 to adequately bend the ice floes to break them up into more harmless bits. Thus, the hull 20 is preferably in the range of 5-16 meters in height from the flat of bottom to the deck 20 , more preferably 8-16 meters or 11-16 meters.
It should also be noted that the legs 25 and the openings 27 through which they are connected to the hull 20 are within the perimeter of the ice deflector 45 so that the ice floes are less likely to contact the legs while the rig 10 is in its defensive ice condition configuration as shown in FIG. 3 and sometimes called hull-in-water configuration. Moreover, the rig 10 does not have to handle every ice floe threat to significantly add value to oil and gas companies. If rig 10 can extend the drilling season by as little as a month, that would be a fifty percent improvement in some ice prone areas and therefore provide a very real cost saving benefit to the industry.
In closing, it should be noted that the discussion of any reference is not an admission that it is prior art to the present invention, especially any reference that may have a publication date after the priority date of this application. At the same time, each and every claim below is hereby incorporated into this detailed description or specification as an additional embodiment of the present invention.
Although the systems and processes described herein have been described in detail, it should be understood that various changes, substitutions, and alterations can be made without departing from the spirit and scope of the invention as defined by the following claims. Those skilled in the art may be able to study the preferred embodiments and identify other ways to practice the invention that are not exactly as described herein. It is the intent of the inventors that variations and equivalents of the invention are within the scope of the claims, while the description, abstract and drawings are not to be used to limit the scope of the invention. The invention is specifically intended to be as broad as the claims below and their equivalents.
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An ice worthy jack-up rig that may extend the drilling season in shallow water off shore Arctic or ice prone locations. The rig would work like a conventional jack-up rig while in open water with the hull jacked up out of the water. However, in the event of ice conditions, the legs are held in place by cans embedded in the sea floor to resist lateral movement of the rig and the hull is lowered into the water into an ice defensive configuration. The hull is specifically shaped with an ice-bending surface to bend and break up ice that comes in contact with the hull while in the ice defensive configuration.
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BACKGROUND OF THE INVENTION
The invention concerns a compact minirelay with a box-like housing for the excitation winding, the yoke and the armature, together with the switch and contact springs, the connections whereof pass tightly through the walls of the housing, and a snap-on cover that may be placed on the housing over its open side.
In known minature relays the connections are passed through the side walls of the housing. The connections further display bends at their internal ends to which the excitation winding connects and the switch springs or stationary switching contacts are fastened. In order to obtain the necessary tightness and to secure the contacts in their passage through the material of the housing, they are sealed in by injection molding. It has been found that this method of the application of the connections requires an expensive effort in production technology.
SUMMARY OF THE INVENTION
This problem is solved according to the invention by designing the housing in the form of a pan open on one side and of plate parts or the like, securely mounted externally on two opposite side walls of said pan, the connections of the switching and contact springs being arranged securely and tightly in the common interfaces of the side walls and the plate parts, together with the connections of the excitation winding. The pan consists conveniently of a flat bottom part and molded integral circumferential side walls. To secure the connections in the housing, therefore only simple insertion processes and an adhesive bonding or welding process, respectively, for the plate parts, are required. It is obvious that through the choice of side walls and plate parts of arbitrary thickness, adequate mechanical and electrical safety conditions may be provided and a compact design may be achieved.
The layout of the relay is such that the connections may be inserted in a positively locked manner in recesses provided in the side walls and/or the plate parts, wherein the connections are held securely against shifting by means of projections, protrusions or the like provided integrally on the side walls and engaging holes in said connections.
In a further development, the plate parts are placed at least in sections so as to project over the open side of the pan and the projecting sections utilized for the securing in place of the yoke and the armature retaining spring.
It is further provided that the plate parts and the side walls of the pan extending transversely to said plate parts at their ends facing away from the bottom part have a circumferential seam to receive a snap-on cover, which in the case of relays with several sets of springs may have a molded-on shoulder or several shoulder sections, projecting into the the spaced between the sets of springs as an electrically separating element. The shoulder or shoulder sections make it possible to maintain air or leakage distances of predetermined magnitude.
In a still further embodiment of the compact minirelay, it is provided that the connections may also be arranged without sliding and tightly in the interface between two plate parts solidly bonded to each other and securely fastened to at least one side wall of the pan. The plate parts thus form a single structural unit with the connections, said structural unit being applicable as such to the pan. For this purpose, independent plate parts that may be joined together by adhesive bonding or welding, or a single injection molded part accepting the connections in molded passages, may be provided.
Conveniently, in one plate of the pairs of plate parts, recesses for the positive acceptance of the connections are provided, possibly together with integrally shaped projections or the like, which secure the connections in place, while ribs or other protuberances in the interface of the plate parts and on the lateral surface facing the pan provide a tight and solid bond by means of fusion welding.
According to a further embodiment of the compact minirelay, the plate-like bodies carrying the connections are arranged fixedly on the legs and the shoulder part of a U-shaped molded part. The magnet system amy then be inserted freely from above or by way of the open sides in the U-shaped pan part and a circumferentially closed pan may be obtained by fixedly securing the plate bodies carrying the connections. The application of the bodies may be facilitated by securing them interlockingly to the edge surfaces of the legs and/or the shoulder part of the U-shaped molding and fastening them by welding or adhesive bonding, especially by ultrasonic means. In order to form the interlocking parts, the legs and/or the shoulder and the plate bodies, respectively, may be provided with projections and corresponding recesses in their common interfaces.
Further, the plate bodies may have recesses in their sides facing each other for the support and immobilizing of the yoke and the armature retaining spring, whereby the yoke and the armature retaining spring engage by means of widenings, shoulders or cuts. The plate bodies may be utilized further by providing them at intervals at their end away from the shoulder part with steps forming a seam for the support of the cover, whereby the snap-on cover may be secured to the plate bodies by means of integrally molded locking bodies. The steps have an additional centering effect on the cover, which further simplifies the assembly.
Finally, measures for the simple manufacture of the connections and their bonding to the side walls and/or the plate bodies, and their further development into switching or contact elements are taken, whereby the connections are cut together and simultaneously from a flat metal strip, while retaining certain connecting strips, then welded to stationary contacts and a switching spring with switching contacts, cut free of the connecting strips, bent at their ends facing the solid contacts and the switching spring and freed of the remaining connecting strips, to be arranged subsequently in the form of a single piece cut part in or on, respectively, the side walls of the pan or the plate parts or plate bodies and rendered independent by cutting away any remaining connecting strips. These manufacturing steps lend themselves to the automation of the production of the compact minirelay.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is demonstrated with the aid of examples of embodiment in the drawing, wherein:
FIG. 1 si a sectional view of a compact minirelay taken on the line 1--1 of FIG. 2;
FIG. 2 is a longitudinal section of a compact minirelay;
FIG. 3 is a plan view of a compact minirelay without the snap-on cover;
FIG. 4 is a partial sectional view taken on line IV--IV of FIG. 2, enlarged;
FIG. 5 is a partial sectional view of a housing;
FIG. 6 is a fragmentary view of a plate body in a side elevation;
FIG. 7 is a partial sectional view of a different housing for a relay;
FIG. 8 is an exploded view of the pan of a compact minirelay;
FIG. 9 is a perspective view of a cover;
FIG. 10 is a perspective and reduced view of a yoke;
FIG. 11 is a perspective and reduced view of an armature spring; and
FIG. 12 is a sectional view of a set of springs in a top view.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the figures, 1 signifies a pan, carrying solidly mounted by means of ultrasonic welding on its lateral walls 1' externally, the plate parts 2, forming together an essentially box-shaped housing for the excitation winding 3 with its core 3', the yoke 4 and the armature 5. Further, the housing comprises the connections 6, 7, 8 and 9 for the switching springs 6' and the contact springs 7' and 8' and the excitation winding 3. According to the invention, the connections 6, 7, 8, and 9 are arranged in common interfaces of the side walls 1' and the plate parts 2, which for this purpose engage in a positively locking manner the recesses 11 of the side walls 1' and of the plate parts 2 and are retained in said recesses by means of studs 10 molded onto the side walls 1'. The plate parts 2 have sections 12 protruding over the open side of the pan 1, which, as shown particularly in FIG. 1, extend over the yoke 4 and the armature retaining spring 13 and secure the latter in the housing. The sections 12 are further provided with locking grooves 14 or the like, wherein the snap-on cover 15 locks by means of its protrusions 16. The snap-on cover 15 is thereby inserted in a seam 17 arranged on the plate parts 2 and on the side walls 1" of the pan extending transversely to said plate parts.
The connections 6 to 9 are inserted initially in the recesses 11 of the side walls 1' to form the housing and then secured in place by the subsequent application and welding of the plate parts 2 to the side walls 1'. The connections 6 to 9 arranged in this manner safely restrict or prevent, respectively, the access of soldering and fluxing materials to the housing. The connections 6 to 8 are bent at their internal ends toward each other and carrying the switch springs 6' and the contact springs 7', 8'.
In the case of compact minirelays with two rows of laterally arranged switch and contact springs, the snap-on cover 15 is provided internally with a molded rib 18, which extends into the space between the springs 6', 7', 8' and the connections 8, respectively, and thus forms separate receiving chambers for them.
It is within the scope of the invention to have the plate parts 2 extending either over the entire height of the side walls 1' or over a portion of said height only.
In FIGS. 5 to 7, 1 again signifies a pan, with the plate parts 19 and 20 being secured to the side walls 1' thereof by welding or adhesive bonding, with the connections 6 to 9 being received and held between them. The plate parts 19, 20 are bonded together solidly and tightly be means of welding or adhesive bonding. At least one of the plate parts 19 or 20 has a prepared recess 21 within the area of the common interface, for the acceptance in a positively locking manner of the connections 6, 7, 8, 9.
The engagement of the protrusions 10 molded onto the plate part 19 in a recess 11 of the connections 6 to 9, the latter are secured without sliding between the plate parts 19, 20.
In the example of embodiment of FIGS. 8-11, the connections 9,6, 7 and 8 of the excitation winding and the spring sets 6', 7', 8' are arranged solidly by molding in the plate bodies 23, said plate bodies forming, according to FIG. 8, together with the U-shaped molded part 24, a pan for the housing of the excitation winding 3, the yoke 4, the armature 5 and the armature retaining spring 13. The two plate bodies 23 are placed for this purpose on the edge surfaces 25 of the molded part 25' and the legs 24", whereby protrusions or molded shoulders 26 engage as locking bodies the recesses 27 of the plate body 23, for the puspose of alignment and fixation, wherein the plate bodies are secured in place particularly by ultrasonic welding. The plate bodies 23 have external steps 28, which cooperate with the steps 29 in the legs 24" and perform a centering and support function when the cover 15 is placed on the housing. The steps 28, 29 form a seam 31, which receives the cover 15, while molded parts 32, acting as locking members, secure the cover 15.
The plate bodies 23 are provided with recesses 33 on their sides facing each other, which is the example shown are rectangular in shape and serve to receive shoulders 36 and cuts 27, respectively, found on the yoke 4 and the armature retaining spring 13. By means of the engagement of the shoulders 36 and the cuts 37, respectively, the yoke 4 and the armature retaining spring 13 are immobilized in the pan.
During the assembly of the compact minirelay formed in this manner, initially the excitation winding with the yoke and the armature retaining spring are inserted in the U-shaped molding from above or through one of the two open sides. The two plate bodies 23 are then applied to the molding 24, wherein the recesses 33 receive the shoulders 36 and the cuts 37, respectively of the yoke and the armature retaining spring, whereupon the plate bodies 23 are solidly bonded to the molding 24 by means of ultrasonic welding.
In FIG. 12, the numeral 38 identifies a metal strip, for example a thin strip of string metal, which may be uncoiled from a supply roll (not shown) or which may be present in the form of a small frame. By means of a cutting tool comprising the dies 39 to 54, initially the connections 6, 7, 8 and 9 and the connecting strips 55, 56, 57, 58, 55', 56', 57', 58', 59' and 55", 56", 57", 58" are cut out. Following the welding of a switch spring 6' carrying contacts to the connection 6 and of the stationary contacts 60 to the connections 7 and 8, the connections 6, 7, 8, 9 are freed of the connecting strips 55, 56, 57, 58 and the connections 6, 7, 8 bent along the bending lines 61, 62, 63, also the connecting strips 55', 56', 57',58', 59' cut away. The remaining cut part is then inserted in the housing 1 or the plate parts 19, 20 or the plate bodies 22, 23, respectively, and the connections 6, 7, 8, 9 cut away from the connecting strips 55", 56", 57", 58".
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A compact minirelay having a coil, armature and springs housed in a molded housing. Electrical connections for the relay extend through side walls of the housing along the interface between plate parts or between side walls and plate parts. The connections are seated in recesses at the interface and are interlocked with the housing parts which are then bonded together. A snap-on cover is provided.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application and the present invention claim under U.S. Patent Law, including under 35 U.S.C. § 120, the benefit of and priority from U.S. Application Ser. No. 60/900,047 filed Feb. 7, 2007 and Ser. No. 11/594,012 filed Nov. 7, 2006, both co-owned with the present invention and incorporated fully herein for all purposes.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is directed to underwater power fluid systems and recovery of expended power fluid from such systems.
[0004] 2. Description of Related Art
[0005] Deepwater power fluid systems provide pressurized working fluid for the control and operation of equipment, e.g. for blowout preventer operators; gate valves for the control of flow of oil or gas to the surface or to other subsea locations; hydraulically actuated connectors; and similar devices. The fluid to be pressurized is typically an oil based product or a water based product with added lubricity and corrosion protection, e.g., but not limited to hydraulic fluid. In certain prior art systems, once the power fluid has done its job in the operation of a device, it is exhausted into the water environment around the device.
[0006] U.S. Pat. Nos. 7,108,006; 6,202,753; 4,777,800; 4,649,704; and 3,677,001 are illustrative of various prior art subsea power fluid systems and are mentioned here not by way of limitation nor as exhaustive of the available prior art; and all said patents are incorporated fully herein for all purposes.
[0007] There has long been a need, recognized by the present inventor, for an effective method and system for preventing exhausted power fluids from polluting a body of water.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention, in certain aspects, discloses a fluid recovery system in which power fluid used by and exhausted from a subsea apparatus, e.g., but not limited to a blowout preventer operator, is recovered and pumped from beneath the water back to the surface.
[0009] In certain aspects, such a system has reserve capacity apparatus for receiving the exhausted power fluid so that a pump (or pumps) pumping the fluid is not overloaded or rendered inefficient.
[0010] In certain aspects, in such a system a negative internal pressure is maintained on a pump system (with a pump or pumps), e.g. with a line leading to the pump system maintained at a pressure lower than a pressure in an input line to a system providing reserve capacity so that the reserve capacity system remains evacuated of all power fluid and filled or substantially filled with water (e.g. seawater) exterior to the system. This insures that, in certain aspects, all power fluid to be pumped to the surface is indeed pumped to the surface. Optionally this is achievable using a switch that turns the pump(s) off when the reserve capacity system is empty of pushing fluid.
[0011] In certain aspects, a pumping system useful in embodiments of the present invention has both high pressure and low pressure protection, e.g. one or more relief valves (e.g. “cracking” check valves) so that the line leading to a pump system is not at too high a pressure, i.e., to protect a pump system enclosure or housing from undesirable pressures (either too high or too low).
[0012] In certain embodiments, two (or more) pumps are used to pump exhausted power fluid to the surface. The pumps' action is timed so that, when one pump is pumping fluid, the other pump is in the process of receiving fluid to be pumped. Thus fluid can be continuously pumped without the downtime associated with a single pump system's fluid reception by the single pump. In certain aspects, using more than one pump results in a reduced requirement for reserve capacity and/or provides a relatively constant flow rate of fluid to the surface. In certain aspects, pilot signals are provided from each pump to a valve assembly of the other pump so that only one pump at a time is pumping fluid to the surface.
[0013] In certain aspects, in system according to the present invention the pump or pumps are automatically shut off once all the exhausted fluid has been pumped to the surface.
[0014] In certain embodiments of the present invention, a pump or pumps (and, if present, a reserve capacity apparatus) are controlled by the pressure of exhausted power fluid and require no control or intervention by either subsea controls or devices or by surface controls or devices. This results in a simpler, less complex system. Upon complete evacuation of an amount of exhausted power fluid, the pump(s) stop.
[0015] In certain aspects by employing a reserve capacity apparatus in systems according to the present invention, the flow in a line or lines in which exhausted power fluid is pumped to the surface is minimized, reducing required discharge pressures and, thus reducing the power required to pump fluid to the surface. This reduced power requirement translates to a lower flow required on a pump system piston, i.e., the piston's bottom area can be reduced in size while the system still effectively pumps the fluid to the surface.
[0016] In certain aspects, in system according to the present invention, the pressure at which power fluid is supplied to an underwater device or apparatus is equalized to the pressure of the water on the underwater device or apparatus. Due to the difference in density between the power fluid and, e.g., seawater at depth, a density pressure differential occurs. Without pressure equalization, seawater could flow into the system, e.g. via check valves, resulting in the pumping of seawater with power fluid to the surface. In one aspect a relief valve in line from the pump system to the surface provides for the equalization of pressure due to the density differential.
[0017] Accordingly, the present invention includes features and advantages which are believed to enable it to advance subsea power fluid evacuation. Characteristics and advantages of the present invention described above and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments and referring to the accompanying drawings.
[0018] Certain embodiments of this invention are not limited to any particular individual feature disclosed here, but include combinations of them distinguished from the prior art in their structures, functions, and/or results achieved. Features of the invention have been broadly described so that the detailed descriptions that follow may be better understood, and in order that the contributions of this invention to the arts may be better appreciated. There are, of course, additional aspects of the invention described below and which may be included in the subject matter of the claims to this invention. Those skilled in the art who have the benefit of this invention, its teachings, and suggestions will appreciate that the conceptions of this disclosure may be used as a creative basis for designing other structures, methods and systems for carrying out and practicing the present invention. The claims of this invention are to be read to include any legally equivalent devices or methods which do not depart from the spirit and scope of the present invention.
[0019] What follows are some of, but not all, the objects of this invention. In addition to the specific objects stated below for at least certain preferred embodiments of the invention, there are other objects and purposes which will be readily apparent to one of skill in this art who has the benefit of this invention's teachings and disclosures.
[0020] It is, therefore, an object of at least certain preferred embodiments of the present invention to provide:
[0021] New, useful, unique, efficient, non-obvious fluid recovery systems for underwater power fluid systems; Such systems with reserve capacity apparatus; Such systems with high pressure and low pressure protection;
[0022] Such systems with multiple pumps (two, three, four, or more) for providing continuous pumping of recovered fluid;
[0023] Such systems with pumps with pistons having an internal compensation apparatus to facilitate piston movement and/or to assist in maintaining a negative pressure in a piston housing;
[0024] Such systems with two pumps in which only one pump at time is allowed to pump fluid to the surface;
[0025] Such systems with automatic pump shut-off; and
[0026] Such systems with power-fluid/water pressure equalization.
[0027] The present invention recognizes and addresses the problems and needs in this area and provides a solution to those problems and a satisfactory meeting of those needs in its various possible embodiments and equivalents thereof. To one of skill in this art who has the benefits of this invention's realizations, teachings, disclosures, and suggestions, other purposes and advantages will be appreciated from the following description of certain preferred embodiments, given for the purpose of disclosure, when taken in conjunction with the accompanying drawings. The detail in these descriptions is not intended to thwart this patent's object to claim this invention no matter how others may later attempt to disguise it by variations in form, changes, or additions of further improvements.
[0028] The Abstract that is part hereof is to enable the U.S. Patent and Trademark Office and the public generally, and scientists, engineers, researchers, and practitioners in the art who are not familiar with patent terms or legal terms of phraseology to determine quickly from a cursory inspection or review the nature and general area of the disclosure of this invention. The Abstract is neither intended to define the invention, which is done by the claims, nor is it intended to be limiting of the scope of the invention or of the claims in any way.
[0029] It will be understood that the various embodiments of the present invention may include one, some, or all of the disclosed, described, and/or enumerated improvements and/or technical advantages and/or elements in claims to this invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0030] A more particular description of embodiments of the invention briefly summarized above may be had by references to the embodiments which are shown in the drawings which form a part of this specification. These drawings illustrate certain preferred embodiments and are not to be used to improperly limit the scope of the invention which may have other equally effective or equivalent embodiments.
[0031] FIG. 1 is a schematic view of a power fluid system according to the present invention with a fluid recovery system according to the present invention.
[0032] FIG. 2A is a perspective view of a system according to the present invention.
[0033] FIG. 2B is a rear perspective view of the system of FIG. 2A .
[0034] FIG. 2C is a top view of the system of FIG. 2A .
[0035] FIG. 3A is a perspective view of part of the system of FIG. 2A .
[0036] FIG. 3B is a side view of the part shown in FIG. 3A .
[0037] FIG. 4A is a cross-section view of the part shown in FIG. 3A .
[0038] FIG. 4B is an enlargement of a portion of the part shown in FIG. 4A .
[0039] FIG. 4C is an enlargement of a portion of the part shown in FIG. 4A .
[0040] FIG. 4D is an enlargement of a portion of the part shown in FIG. 4A .
[0041] FIG. 5 is a cutaway perspective view of a valve according to the present invention used in systems according to the present invention.
[0042] FIG. 6A is a perspective view of a reserve capacity apparatus according to the present invention.
[0043] FIG. 6B is a cross-section view of the apparatus of FIG. 6A .
[0044] FIG. 7 illustrates schematically a system according to the present invention for equalizing pressure between power fluid and seawater.
[0045] FIG. 8 is a schematic view of a system according to the present invention.
[0046] FIG. 8A is an enlargement in cross-section of part of a pump of a system according to the present invention, e.g., a pump as in FIG. 4A , 8 , or 9 A.
[0047] FIG. 8B is a cross-section view of a compensator piston of the pump of FIG. 8A .
[0048] FIG. 9A illustrates a step in a method according to the present invention.
[0049] FIG. 9B illustrates positions of various parts in a step as in FIG. 9A .
[0050] FIG. 9C is an enlargement of a portion of FIG. 9B .
[0051] FIG. 9D is an enlargement of a portion of FIG. 9B .
[0052] FIG. 9E is an enlargement of a portion of FIG. 9B .
[0053] FIG. 9F is an enlargement of a portion of FIG. 9B .
[0054] FIG. 10A illustrates a step in a method according to the present invention.
[0055] FIG. 10B illustrates positions of various parts in a step as in FIG. 10A .
[0056] FIG. 10C is an enlargement of a portion of FIG. 10B .
[0057] FIG. 10D is an enlargement of a portion of FIG. 10B .
[0058] FIG. 10E is an enlargement of a portion of FIG. 10B .
[0059] FIG. 10F is an enlargement of a portion of FIG. 10B .
[0060] FIG. 11A illustrates a step in a method according to the present invention.
[0061] FIG. 11B illustrates positions of various parts in a step as in FIG. 11A .
[0062] FIG. 11C is an enlargement of a portion of FIG. 11B .
[0063] FIG. 11D is an enlargement of a portion of FIG. 11B .
[0064] FIG. 11E is an enlargement of a portion of FIG. 11B .
[0065] FIG. 11F is an enlargement of a portion of FIG. 11B .
[0066] FIG. 12A illustrates a step in a method according to the present invention.
[0067] FIG. 12B illustrates positions of various parts in a step as in FIG. 12A .
[0068] FIG. 12C is an enlargement of a portion of FIG. 12B .
[0069] FIG. 12D is an enlargement of a portion of FIG. 12B .
[0070] FIG. 12E is an enlargement of a portion of FIG. 12B .
[0071] FIG. 12F is an enlargement of a portion of FIG. 12B .
[0072] Presently preferred embodiments of the invention are shown in the above-identified figures and described in detail below. It should be understood that the appended drawings and description herein are of preferred embodiments and are not intended to limit the invention. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention. In showing and describing the preferred embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
[0073] As used herein and throughout all the various portions (and headings) of this patent, the terms “invention”, “present invention” and variations thereof mean one or more embodiment. Accordingly, the subject or topic of each such reference is not automatically or necessarily part of, or required by, any particular description merely because of such reference.
DETAILED DESCRIPTION OF THE INVENTION
[0074] FIG. 1 shows a system S according to the present invention in which power fluid from an hydraulic power unit is provided to a subsea apparatus, e.g., but not limited to, a blowout preventer operator (“BOP OPERATOR”). Hydraulic power fluid is pumped from a reservoir (“TANK”) by a pump (“PUMP”) through a check valve (“CHECK VALVE”) to a bank of accumulator containers at the surface (“ACCUMULATOR SYSTEM”). This fluid is then provided beneath a water level L through a check valve (“CHECK VALVE”), then optionally, to an accumulator system, e.g. with one or more depth compensated containers or bottles (“ACCUMULATOR SYSTEM”) (e.g. a conventional bladder or piston accumulator or with depth compensated bottles as disclosed in U.S. application Ser. No. 11/594,012 filed Nov. 7, 2006 and co-owned with the present invention). A control valve (“DIRECTIONAL CONTROL VALVE”) selectively provides the power fluid from the depth compensated accumulator containers to operate a subsea device or apparatus, e.g. the BOP operator shown. Fluid exhausted from the BOP operator either flows into the water (“VENT”) or to a fluid recovery system (“FLUID RECOVERY SYSTEM”) according to the present invention (any disclosed herein) with any pump or pumps disclosed herein. The power fluid is pumped to the surface, e.g. to a fluid reservoir (“TANK”) or to other containers and/or conditioning systems. The accumulator system may be any suitable accumulator system including, e.g., those disclosed in U.S. application Ser. No. 11/594,012 filed on Nov. 7, 2006.
[0075] FIGS. 2A-2C show a fluid recovery system 10 according to the present invention which has two reserve bottles 20 and 30 secured to a enclosure (or pod) 12 in which valves, etc. are located and to which are secured structural members 22 and 32 (which can serve as guide tubes for guide wires that allow the system to be retrieved). Two pump systems 40 and 50 , secured on the base 12 , receive power fluid from the reserve bottles 20 and 30 . The fluid (e.g., but not limited to, hydraulic fluid, e.g., but not limited to, from a device powered by the power fluid, e.g., but not limited to, an operator for a blowout preventer) is conveyed to the reserve bottles 20 and 30 through a line A (see also line a, FIG. 8 ). The system 10 has check valves X and Y (as in FIG. 8 ).
[0076] A typical hydraulic manifold box 14 houses hydraulic controls. Power fluid is pumped from the pump systems 40 and 50 to the surface in a return line B (see also line b, FIG. 8 ). Via a line C, (see also line C, FIG. 8 ) a constant flow of fluid under pressure is pumped from a surface system to the pump systems so that a negative internal pressure is maintained.
[0077] A suction/discharge manifold 80 houses the check valves X and Y and check valves M and N for the lines A and B (these check valves shown in dotted line in FIG. 2C ); e.g. like the valves P and Q, FIG. 8 ; the valve P which may be a check valve or as shown). Each pump system 40 , 50 has a corresponding valve system 41 , 51 (respectively) (see, e.g. the valves V 1 , V 2 , FIG. 9A and the valve system of FIG. 5 ).
[0078] FIGS. 6A and 6B show one possible embodiment of the reserve bottle 20 (the bottle 30 is like the bottle 20 ). The bottle 20 has an outer housing 22 in which is mounted an inflatable bladder 24 . Water exterior to the bottle 20 can enter the bladder 24 through a hole 26 in the housing 22 . Power fluid exhausted from a subsea apparatus or device enters the housing 22 through a hole 28 . As power fluid enters the housing 22 at a pressure greater than the pressure of the water exterior to the housing, water is exhausted from the bladder 24 out from the housing 22 .
[0079] Alternatively, the bladder 24 is used to contain exhausted power fluid and water is introduced around the bladder 24 . In certain particular embodiments, each bottle 20 and 30 can contain about 80 gallons of power fluid.
[0080] As shown in FIGS. 4A-4D , the pump systems 40 , 50 have valve systems 41 and 51 (respectively) including main bodies 42 , 52 with valves V 1 , V 2 (body 42 ) and valves V 3 , V 4 (body 52 ). The valve V 1 includes a mechanical actuator 43 and the valve V 4 includes a mechanical actuator 53 . As described in detail below, movement of pistons 44 , 54 (respectively) results in movement of actuators 45 , 55 (respectively) which in turn results in movement of the mechanical actuators 43 , 53 during a sequence of operation of the pump systems 40 , 50 . Optional springs 46 56 provide a “snap open” or “snap close”, feature for the valves V 1 , V 4 (respectively). As shown in FIG. 9A , e.g., the lines A, B, C (as in FIG. 2A and FIG. 8 ) are in communication with the pump systems 40 , 50 . When the piston 54 is pumped up, a pilot signal is sent from the valve system 51 (from the valve V 4 ) to the valve system 41 (to the valve V 2 ) which vents a pressure chamber CR around a main piston 44 (or vice-versa regarding the chamber CR around the piston 54 when the main piston 44 is pumped up) so that the piston 44 is not pumped up, i.e., so that both pistons do not pump fluid to the surface simultaneously. When a valve system's mechanical activator 45 or 55 is moved up (e.g. when a piston 44 or 54 pulls up on an activator 45 or 55 ), a line is opened by action of a valve V 1 or V 4 and a line is closed so that a chamber CR around a main piston 44 or 54 is vented in the line B to tank. When one of the activators 45 or 55 pushes down on an activator 43 or 53 , this chamber CR (one chamber CR around each of the pistons 44 , 54 ) fills with pressurized fluid pressurizing the chamber to push that piston up, pushing the fluid on the top that piston out of the pump into the line B back to the surface.
[0081] As shown in FIG. 5 the valve V 2 is hydraulically actuated for closing and actuated open by the force of springs 47 , 48 . As shown in FIG. 5 the valve V 2 is open by pilot pressure (e.g. from the outlet of the valve V 4 as seen in FIG. 12A ). The valve V 1 is mechanically actuated via the mechanical actuator 43 (both to open and to close the valve V 1 ). As shown in FIG. 5 the valve V 1 is open. The other valve systems herein, e.g. the valve system 51 and those of FIGS. 9A-12A , may be like the valve system 41 shown in FIG. 5 .
[0082] FIG. 7 illustrates the equalization of the pressure of power fluid in a line LN from a fluid recovery system FRS according to the present invention with the pressure of seawater at depth (e.g., but not limited to, at a depth of 10,000 feet). The power fluid (e.g. to power an apparatus 23 ) in this instance is slightly less dense than is the seawater, resulting in a pressure differential of about 120 psi. So that seawater is not sucked into the Line LN via a “Low Pressure Protect” check valve W and pumped to the surface, a relief valve VL is placed in the line LN between a reserve system 20 (with a bottle or bottles 21 , if any) and a surface reservoir (“Return tank”). For example, the relief valve VL is set at 120 psi (the pressure differential) and, if the pressure in the line LN drops below the setting of the valve VL (e.g. 120 psi) the relief valve VL closes the line LN to flow (e.g. until more power fluid is to be pumped to the surface by the system FRS in a line LE leading to the system FRS). The system FRS has a pump system PS (or pump systems) (e.g. like any pump system according to the present invention, e.g. like the pump systems 40 , 50 or those shown in FIGS. 8A , 9 A- 12 A). A check valve V (like the check valve X, above) provides high pressure protection. Check valves G and H (like the check valves P and Q, above) provide a check valve function on either side of a line LE to the system FRS.
[0083] FIG. 8A illustrates part of the interior structure of a pump system 40 (and of a pump system 50 ; and of the pumps in FIGS. 9A-12A ). A fluid recovery system with such a pump system (“PUMP SYSTEM”) is shown schematically in FIG. 8 . An embodiment of the system 10 (“POWER FLUID RECOVERY SYSTEM”) has a reserve capacity apparatus (as may any embodiment of the present invention) which equalizes pressure between the exterior water (e.g. sea water outside) and the hydraulic fluid returns, e.g., but not limited to (as is the case for any embodiment herein) bottles like the bottles 20 , 30 , FIG. 2A (“RESERVE CAPACITY BOTTLES”) which recover hydraulic fluid from a blowout preventer operator (“BOP OPERATOR”), flow to which is controlled by a control valve (“CONTROL VALVE”) which itself is controlled by a drive control (“VALVE DRIVE CONTROL”). The pump system (“PUMP SYSTEM”) (e.g. like the systems 40 , 50 ) with a valve system VS (like the systems 41 , 51 ) receives fluid from the blowout preventer operator (in a line A) and pumps it in a line B back to a surface reservoir (“TANK”). An optional relief valve (“RELIEF VALVE”) provides for equalization of pressure due to the density differential discussed above. The pump system may have any desired number of pumps (like those of the systems 40 , 50 ).
[0084] Check valves as indicated in the various lines provide a check valve function. The two check valves labeled X and Y provide high pressure protection (valve X) and low pressure protection (valve Y) (e.g. like the valves V and W, FIG. 7 ). Accumulator containers at the surface (“SURFACE BOTTLES”) serve as containers for fluid pumped from the tank; and optional subsea containers (“ACCUMULATOR SYSTEM”) provide an accumulator function at the level of the Power Fluid Recovery System.
[0085] As shown in FIG. 8A , via the line C, a constant flow of fluid under pressure is provided to the Pump System's pump which maintains the negative internal pressure in the pump as discussed above. Via the line A (like line A, FIG. 2A ), the pump receives fluid exhausted from the BOP operator and, via the line B (like line B, FIG. 2A ), the pump pumps the fluid back to the surface. The piston 44 movably disposed in the housing 44 h is movable (downwardly as shown in FIG. 8A ) in response to exhausted power fluid being introduced into the housing 44 h and the piston 44 is movable (upwardly as shown in FIG. 8A ) to pump the fluid into the line B and to the surface. In such movement, the piston 44 overcomes any friction drag due to a seal 45 that seals the piston/housing interface. As shown in FIGS. 9A-12A , the piston 44 is movable to contact and move a valve actuator of a valve system 41 or 51 .
[0086] The piston 44 has a central member 42 a with a hollow channel 42 b therein. Releasably secured to the housing 44 h is a compensator piston CP (shown in FIG. 8B ) with a hollow channel 49 a therethrough. Fluid under pressure flowing through the line C flows into, down, and through the compensator piston CP and up into the hollow channel 42 b . The pressure of this fluid pushes against the piston 44 pushing the piston 44 away from the top inner surface of the housing 44 h . The pressure in the line A is maintained less than the pressure of water exterior to the housing 44 h . The force applied to the main piston 44 through the compensator piston CP assists the main piston 44 in overcoming friction drag due to the seal 45 . The compensator piston CP is connected to the housing 44 h , e.g. with a threaded coupling 49 b . A snap ring 48 a holds a gland 48 b in place around the compensator piston CP. The gland 48 b includes a seal 48 c which seals the gland/housing interface. A seal 48 d on the interior of the gland seals the gland/compensator-piston interface.
[0087] In certain aspects, several interchangeable compensator pistons are provided with different effective diameters permitting fine tuning of the suction characteristics of the pump (“fine tuning”—referring to the ability to select the negative pressure level desired by selecting a particular compensator piston (so the line A is maintained at a negative pressure so the reserve capacity bottles remain fully evacuated of all power fluid and the bladders therein remain full of water (water from exterior to the bottles) until the BOP operator functions and power fluid used to operate the BOP operator which is exhausted from the BOP operator is to be pumped to the surface.
[0088] FIG. 8B shows the compensator piston CP. The compensator piston CP is secured to the housing 44 h with the threaded coupling 49 b . Since the piston CP is fixed to the housing 44 h , fluid entering in the line C and flows down through the piston CP and up into the space around the piston CP, resulting in a force pushing the piston 44 downward. Thus, as this piston tries to draw fluid in the pump via the check valve Q, a negative pressure is maintained in the return line A and movement of the piston 44 is facilitated.
[0089] FIGS. 9A-12F illustrate steps in methods according to the present invention using a fluid recovery system according to the present invention which has two pumps (e.g., like the pumps of the systems of FIGS. 2A , 3 A, 8 A). One pump is a “Left Pump” (with a “Left Piston”) and one pump is a “Right Pump” (with a “Right Piston”) (see FIG. 9A ).
[0090] The line labelled “FLUID RETURNS BACK TO SURFACE” is the line through which the pumps pump power fluid back to the surface and corresponds to line B, FIG. 8 and FIG. 8A . The line labelled “POD RETURNS” is the line through which the pumps receive exhausted fluid, corresponding to line A, FIG. 8 and FIG. 8A . In the line labelled “3000 PSI PRESSURE” fluid is supplied from the accumulator system, corresponding to the line C, FIG. 8A (of course the pressure in this line is not limited to 3000 psi and may, according to the present invention, be any suitable pressure).
[0091] As shown in FIGS. 9A , 10 A, 11 A and 12 A, systems according to the present invention may have a series of valves V 1 , V 2 , V 3 , V 4 (e.g. within a body like the body BY, FIG. 2A ) for controlling fluid flow to and from the pumps to effect efficient and continuous pumping of fluid from a powered downhole apparatus or device to the surface. In one aspect the valves V 1 -V 4 are as indicated in FIGS. 4A-4D . Valves V 1 and V 4 are mechanically operated by movement of the Left Piston and Right Piston moving corresponding mechanical valve actuators A 1 and A 2 (like the mechanical actuators 43 , 53 , FIG. 4A ).
[0092] FIG. 9A (“STEP 1 ”) illustrates fluid pressure from the line C pushing the Left Piston up to pump power fluid (previously supplied through line A) into the line B from above the Left Piston. The Left Piston has previously moved down, pushing the valve actuator A 1 down to activate the valve V 1 to allow fluid under pressure in the line C to enter below the Left Piston.
[0093] Also as shown in FIG. 9A , as the Left Piston is pumping fluid into the line B, the housing of the Right Piston is beginning to receive exhausted power fluid via the line A (through the check valve Q) which is flowing into the space above the Right Piston for eventual pumping to the surface. The Right Piston has previously moved the mechanical valve actuator A 2 to operate the valve V 4 to close the valve V 4 (so that no further power fluid enters below the Right Piston and the fluid from beneath the Right Piston is allowed to vent to the line A). In FIG. 9A , valve V 2 is opened by the spring force of its spring so that fluid under pressure is allowed to flow to the valve V 1 from the line C. Also, as shown in FIG. 9A , fluid under pressure in the line C flows to the compensator piston C 1 (like the compensator piston CP, FIG. 8B ) of the Left Pump and to the compensator piston C 2 (like the compensator piston CP, FIG. 8B ) of the Right Pump. Valve V 3 closes off flow from the line C to the Right Pump (thereby venting fluid to line A from the bottom of the Right Piston). The dotted line in FIG. 9A (and in subsequent figures) indicates a pilot line for providing a pilot signal to the valve V 3 to insure that fluid from the bottom of the Right Piston is vented to the line A regardless of the position of the valve V 4 (so that in certain positions, e.g. as in FIG. 9A , the Right Piston cannot pump exhausted power fluid to the surface; i.e., so that only one pump pumps exhausted power fluid to the surface at a time). “Mech SPM” refers to a mechanically actuated valve (e.g. V 1 , V 4 ) and “Hyd SPM” refers to an hydraulically actuated valve (e.g. V 2 , V 3 ). “Work Port” refers to a port from the chambers CR.
[0094] As shown in FIG. 10A (“STEP 2 ”) the Left Piston is in the process of pumping fluid to the surface and the Right Piston is in the process of moving the actuator A 2 down to actuate the valve V 4 (“firing”) to stop further power fluid “POD RETURNS” from flowing to the Right Piston. The valve V 2 is still permitting fluid under pressure to flow beneath the Left Piston as it continues to pump fluid to the surface and the valve V 3 is receiving the pilot signal which keeps the valve V 3 shifted to a closed position (as in FIG. 9A ) while fluid from the line C is provided to the bottom of the Left Piston. As shown in FIGS. 9A and 10A , no pressure from the line C is applied beneath the Right Piston so the Right Piston cannot go up when the Left Piston is going up. (Thus only one pump pumps power fluid to the surface at a time).
[0095] FIG. 11A illustrates the Left Piston approaching the upper limit of its travel, still pumping fluid into the line B, and almost at the point of pulling the mechanical actuator A 1 up to the required extent to activate the valve V 1 to shut off the flow of fluid under pressure in the line C to the space beneath the Left Piston. No exhausted fluid is flowing into the space above the Left Piston. The space above the Right Piston is filled with exhausted power fluid and the Right Piston as shown is static. The reserve capacity bottles (“Reserve Bottles”) are in the process of receiving more power fluid exhausted from the power-fluid-operated downhole device (e.g. a BOP operator). The space above the Left Piston will be substantially evacuated before any more exhausted power fluid is introduced above the Left Piston.
[0096] As shown in FIG. 11A , the valve V 2 is in the same position as in FIGS. 9A and 10A allowing fluid from the line C to go to the valve V 1 . The Right Piston, shown as static, is ready to pump fluid above it to the surface via the line B; and the Left Piston is in the process of finishing the pumping of fluid into the line B and of moving (“firing”) the valve V 1 .
[0097] As shown in FIG. 12A , exhausted power fluid is flowing into the space above the Left Piston while the Right Piston is moving up and pumping exhausted power fluid to the surface in line B. The valve V 1 has been activated to permit fluid from beneath the Left Piston allowing the Left Piston to move down so that the space above the Left Piston can receive exhausted power fluid to flow to the line A. The valve V 2 is insuring that fluid from the bottom of the Left Piston can flow to the line A. The valve V 4 has been activated to permit fluid under pressure from line C to flow into the space beneath the Right Piston to move it up to pump exhausted power fluid above the Right Piston to the surface in the line B. The pilot signal from the valve V 1 is vented to the line A, hence the valve V 3 is vented allowing the spring of the valve V 3 to shift the valve V 3 open allowing fluid through the line C to go to the valve V 4 and then to the space below the Right Piston.
[0098] In all of the steps, STEP 1 -STEP 4 , fluid under pressure from the line C is constantly applied to the compensator pistons C 1 and C 2 to assist in moving the Left and Right Pistons down when the spaces above them are receiving exhausted power fluid.
[0099] Accordingly, while preferred embodiments of this invention have been shown and described, many variations, modifications and/or changes of the system, apparatus and methods of the present invention, such as in the components, details of construction and operation, arrangement of parts and/or methods of use, are possible, contemplated by the patentee, within the scope of the invention, and may be made and used by one of ordinary skill in the art without departing from the spirit or teachings of the invention and scope of the invention. Thus, all matter herein set forth or shown in the accompanying drawings should be interpreted as illustrative and not limiting, and the scope of the invention is not limited to the embodiments described and shown herein.
[0100] The present invention, therefore, provides in at least certain embodiments, a method for recovering power fluid used to power a device under water and for pumping the recovered power fluid to a fluid container above a surface of the water, the method including: flowing fluid from a subsurface apparatus to a subsurface recovery system, the fluid initially provided to the subsurface apparatus to power the subsurface apparatus; and the subsurface recovery system including a pump system for selectively pumping recovered power fluid to a fluid container above a surface of the water; the pump system including at least one pump, and a valve system, the valve system controlling the at least one pump, and pumping recovered power fluid to the fluid container with the at least one pump. In such a method the at least one pump may have a main piston movably disposed in a main piston chamber in a main piston housing, the main piston housing having a flow channel therethrough in fluid communication with the main piston chamber for providing fluid under pressure from a surface fluid system into the main piston housing above the main piston, the method further including introducing fluid under pressure into the main piston chamber through the flow channel to maintain a pressure within the main piston housing less than a pressure of fluid exterior to the at least one pump.
[0101] The present invention, therefore, provides in at least certain embodiments, a method for recovering power fluid used to power a device under water and for pumping the recovered power fluid to a fluid container above a surface of the water, the method including: flowing fluid from a subsurface apparatus to a subsurface recovery system, the fluid initially provided to the subsurface apparatus to power the subsurface apparatus; and the subsurface recovery system including a pump system for selectively pumping recovered power fluid to a fluid container above a surface of the water, the pump system including a first pump, a second pump, and a valve system, the valve system controlling the first pump and the second pump to allow only one pump of the first pump and the second pump to pump recovered power fluid to the fluid container above the surface of the water, the method further including pumping recovered power fluid to the fluid container with only one pump at a time of the first pump and the second pump. Such a method may have one or some, in any possible combination, of the following: wherein the pump system includes pilot signal apparatus for supplying a pilot signal to the first pump and to the second pump signalling when one of the first pump and the second pump is pumping recovered power fluid to the fluid container so that the pump receiving said pilot signal is then prevented from pumping recovered power fluid to the fluid container, the method further including sending said pilot signal to one of the first pump or the second pump and then preventing said pump receiving said pilot signal from pumping recovered power fluid to the fluid container; continuously pumping recovered power fluid to the fluid container with the pump system using alternately the first pump then the second pump; wherein a definite amount of power fluid powers the subsurface apparatus, the method further including automatically shutting off the pump system when the definite amount of power fluid has been pumped by the pump system to the fluid container; wherein the recovered power fluid is re-used to power the subsurface apparatus; wherein each of the first pump and the second pump has a main piston and an associated mechanically-activated valve actuatable by contact by a corresponding main piston, the method further including moving a main piston of the first pump or of the second pump to contact a corresponding mechanically-actuated valve to close said valve allowing said main piston to move down so that a chamber in which said piston is movable can fill with recovered power fluid to be pumped to the fluid container; wherein each main piston of the first pump and the second pump has an activation member connected thereto for contacting a corresponding mechanically-activated valve and said activation member is spring loaded with a spring device to provide snap action for facilitating contact with and actuation of the mechanically-activated valve, the method further including facilitating actuation with said spring device of the mechanically-activated valves; wherein each pump has a main piston movably disposed in a main piston chamber in a main piston housing, each main piston housing having a flow channel therethrough in fluid communication with a main piston chamber for providing fluid under pressure from a surface fluid system above a main piston, the method further including introducing fluid under pressure into each main piston chamber through the flow channel to maintain a pressure within each main piston housing less than a pressure of fluid exterior to the pump system; wherein each of the first pump and the second pump has a main piston movably disposed in a main piston chamber in a main piston housing, each main piston having main a piston body with a central hollow member extending down within the main piston body, each of the first pump and the second pump having a compensation member connected to a main piston housing, the compensation member extendable into the central hollow member of the main piston body, the compensation member having a flow channel therethrough from top to bottom, said flow channel in fluid communication with a channel providing fluid under pressure from a surface fluid system, the method further including introducing fluid under pressure into the central hollow member of the main piston body through the flow channel of the compensation member to maintain a pressure within the main piston housing less than a pressure of fluid exterior to the pump; wherein force of said fluid under pressure flowed in the central hollow member of the main piston facilitates downward movement of the main piston, the method further including facilitating downward movement of the main piston with the force of fluid introduced into the central hollow member of the main piston and which flows therefrom into the main piston housing; wherein each of the first pump and the second pump includes a corresponding pump housing which receives recovered power fluid to be pumped to the surface, the method further including each of the first pump and the second pump commencing pumping recovered power fluid to the fluid container only upon complete filling of it corresponding pump housing with recovered power fluid; and/or while the first pump is pumping recovered power fluid to the fluid container, providing recovered power fluid to the second pump for the second pump, in turn, to pump to the fluid container.
[0102] The present invention, therefore, provides in at least certain embodiments, a method for recovering power fluid used to power a device under water and for pumping the recovered power fluid to a fluid container above a surface of the water, the method including: flowing fluid from a subsurface apparatus to a subsurface recovery system, the fluid initially provided to the subsurface apparatus to power the subsurface apparatus; and the subsurface recovery system including a pump system for selectively pumping recovered power fluid to a fluid container above a surface of the water, the pump system including a first pump, a second pump, and a valve system, the valve system controlling the first pump and the second pump to allow only one pump of the first pump and the second pump to pump recovered power fluid to the fluid container above the surface of the water, the method further including pumping recovered power fluid to the fluid container with only one pump at a time of the first pump and the second pump, wherein the pump system includes pilot signal apparatus for supplying a pilot signal to the first pump and to the second pump signalling when one of the first pump and the second pump is pumping recovered power fluid to the fluid container so that the pump receiving said pilot signal is then prevented from pumping recovered power fluid to the fluid container, the method further including sending said pilot signal to one of the first pump or the second pump and then preventing said pump receiving said pilot signal from pumping recovered power fluid to the fluid container, continuously pumping recovered power fluid to the fluid container with the pump system using alternately the first pump then the second pump, and while the first pump is pumping recovered power fluid to the fluid container, providing recovered power fluid to the second pump for the second pump, in turn, to pump to the fluid container.
[0103] The present invention, therefore, provides in at least certain embodiments, a system for recovering power fluid used to power a device under water and for pumping the recovered power fluid to a fluid container above a surface of the water, the system including: subsurface recovery system for receiving power fluid exhausted subsurface from a subsurface apparatus, the power fluid initially provided to the subsurface apparatus to power the subsurface apparatus; a pump system for selectively pumping recovered power fluid to a fluid container above a surface of the water, the pump system including at least one pump for pumping recovered power fluid to the fluid container, a valve system, and the valve system for controlling the at least one pump. Such a system may have one or some, in any possible combination, of the following: wherein the at least one pump is a first pump and a second pump, the valve system for controlling the first pump and the second pump to allow only one pump at a time of the first pump and the second pump to pump recovered power fluid to the fluid container above the surface of the water; the pump system including pilot signal apparatus for supplying a pilot signal to the first pump and to the second pump signalling when one of the first pump and the second pump is pumping recovered power fluid to the fluid container so that the pump receiving said pilot signal is then prevented from pumping recovered power fluid to the fluid container; the pump system for continuously pumping recovered power fluid to the fluid container; wherein a definite amount of power fluid powers the subsurface apparatus, the system further including the pump system including shut off apparatus for automatically shutting off the pump system when the definite amount of power fluid has been pumped by the pump system to the fluid container; wherein each of the first pump and the second pump has a main piston and an associated mechanically-activated valve actuatable by contact by a corresponding main piston so that moving a main piston of the first pump or of the second pump to contact a corresponding mechanically-activated valve to close said valve allows said main piston to move down so that a chamber in which said piston is movable can fill with recovered power fluid to be pumped to the fluid container; wherein each main piston of the first pump and the second pump has an activation member connected thereto for contacting a corresponding mechanically-activated valve and said activation member is spring loaded with a spring device to provide snap action for facilitating contact with and actuation of the mechanically-activated valve; wherein the at least one pump has a main piston movably disposed in a main piston chamber in a main piston housing, the main piston housing having a flow channel therethrough in fluid communication with the main piston chamber for providing fluid under pressure from a surface fluid system above the main piston so that introducing fluid under pressure into the main piston chamber through the flow channel maintains a pressure within the main piston housing less than a pressure of fluid exterior to the at least one pump; wherein each of the first pump and the second pump has a main piston movably disposed in a main piston chamber in a main piston housing, each main piston having a main piston body with a central hollow member extending down within the main piston body, each of the first pump and the second pump having a compensation member connected to a main piston housing, the compensation member extendable into the central hollow member of the main piston body, the compensation member having a flow channel therethrough from top to bottom, said flow channel in fluid communication with a channel providing fluid under pressure from a surface fluid system so that introducing fluid under pressure into the central hollow member of the main piston body through the flow channel of the compensation member maintains a pressure within the main piston housing less than a pressure of water exterior to the pump system; wherein force of said fluid under pressure flowed in the central hollow member of the main piston facilitates downward movement of the main piston; wherein each of the first pump and the second pump includes a corresponding pump housing which receives recovered power fluid to be pumped to the surface, each of the first pump and the second pump controlled so that said pump is able to commence pumping recovered power fluid to the fluid container only upon complete filling of a corresponding pump housing with recovered power fluid; and/or fluid provision apparatus for providing recovered power fluid to the second pump for the second pump while the first pump is pumping recovered power fluid to the fluid container.
[0104] In conclusion, therefore, it is seen that the present invention and the embodiments disclosed herein and those covered by the appended claims are well adapted to carry out the objectives and obtain the ends set forth. Certain changes can be made in the subject matter without departing from the spirit and the scope of this invention. It is realized that changes are possible within the scope of this invention and it is further intended that each element or step recited in any of the following claims is to be understood as referring to the step literally and/or to all equivalent elements or steps. The following claims are intended to cover the invention as broadly as legally possible in whatever form it may be utilized. The invention claimed herein is new and novel in accordance with 35 U.S.C. § 102 and satisfies the conditions for patentability in § 102. The invention claimed herein is not obvious in accordance with 35 U.S.C. § 103 and satisfies the conditions for patentability in § 103. This specification is in accordance with the requirements of 35 U.S.C. § 112. The inventors may rely on the Doctrine of Equivalents to determine and assess the scope of their invention and of the claims that follow as they may pertain to apparatus not materially departing from, but outside of, the literal scope of the invention as set forth in the following claims. All patents and applications identified herein are incorporated fully herein for all purposes. What follows are some of the claims for some of the embodiments and aspects of the present invention, but these claims are not necessarily meant to be a complete listing of nor exhaustive of every possible aspect and embodiment of the invention. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.
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Systems and methods for recovering power fluid used to power a device under water and for pumping the recovered power fluid to a fluid container above a surface of the water, the method in certain aspects including: flowing fluid from a subsurface apparatus to a subsurface recovery system, the fluid initially provided to the subsurface apparatus to power the subsurface apparatus; and the subsurface recovery system including a pump system for selectively pumping recovered power fluid to a fluid container above a surface of the water, the pump system having at least one pump and, in some aspects, a first pump, a second pump, and a valve system; the valve system controlling the first pump and the second pump to allow only one pump of the first pump and the second pump to pump recovered power fluid to the fluid container above the surface of the water; and pumping recovered power fluid to the fluid container with only one pump at a time. This abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims, 37 C.F.R. 1.72(b).
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BACKGROUND OF THE INVENTION
The invention concerns a machine for skiving or splitting nonmetallic planar workpieces, in particular plastic-coated paper-like workpieces, having a motor-driven moving knife, in particular a bell knife or hoop knife, whose cutting edge has a specific contour and moves continuously around a closed loop; and having a grinding device for grinding the knife.
A skiving machine of the aforesaid kind is known, for example, from DE 41 01 377.
Skiving machines are used, for example, in the shoe industry or pursemaking industry, to create a specific profile on the edges of cut sheets of leather, leather replacement materials, rubber, or plastic. A bell knife made of metallic material, which is cup-shaped and is equipped on its front circumferential edge with a cutting edge, is used for this purpose. The bell knife generally sits directly on the shaft of a high-speed, high-output electric motor, or on a spindle and is driven by a motor via a belt. Because the cutting edge of the bell knife made of metallic material is susceptible to wear, it is necessary to grind the cutting edge, from time to time or continuously, so as to sharpen it. Grinding devices that have corresponding deburring devices, as well as dressing devices for a grinding wheel of the grinding device, are known for this purpose.
A splitting machine is known, for example, from DE 38 15 130 A1.
This splitting machine is a hoop knife splitting machine that is equipped with a knife, in the form of an endless steel hoop, that runs over two belt pulleys, one of which is motor-driven. Since the circulating steel knife is subject to wear, a grinding device is provided with which the hoop knife is intermittently or continuously ground to sharpen it.
A feature common to both machines, i.e. skiving and splitting machines, is therefore the fact that they have a moving knife with a specific cutting edge contour that must be reground from time to time.
Since the contour of the cutting edge and the exact position of the cutting edge or cutting line is critical in terms of the skiving or splitting quality, the designs must be such that a flawless cutting edge contour is guaranteed despite the continuous or intermittent regrinding, and such that the position of the cutting edge or cutting line is exact and predetermined.
The field of application of such machines is gradually expanding, since skiving or splitting operations that earlier were performed principally on planar workpieces made of leather are now also being performed on other types of material.
Such workpieces include, for example, paper-like or board-like materials coated with plastic and/or aluminum foil.
Materials of this kind are used, for example, in the beverage industry. Beverage packages such as, for example, milk cartons or juice cartons are manufactured from plastic-coated board stocks of this kind.
Cut sheets of this kind can easily be coated on both sides with a plastic material that is approved for food contact, for example polyethylene. On the cut edges, however, the paper core material is exposed. In order to process these board materials into sealed beverage cartons, it has become known to equip the edges with, for example, a stepped cut by way of a skiving operation. This involves applying a corresponding stepped cut in the region of one edge of the cut sheet, on one side, using a bell knife of a skiving machine, so that a thinner portion of the board material remains on the rim which is then coated with plastic on only one side. This rim is then folded over itself, specifically over the uncoated side, thus resulting in an edge that is coated with plastic on its continuous peripheral edge as well. By heat-sealing several such folded-over edges to one another, it is then possible to construct a three-dimensional object, for example a parallelepiped or tetrahedron.
In processing such materials with a bell knife, it has been found that a deposit of contaminants, which is highly adherent and is made up predominantly of plastic coating material from the workpieces being processed, gradually accumulates in the region of the cutting edge. In the case of a skiving operation, for example, 560 meters per minute of edge material can be cut or skived.
Since the cutting edge contour of the knife is reground periodically or continuously, the grinding device encounters the adhering contaminants in the region of the contour and removes them as well.
Since these contaminants are made of sticky, viscous materials, they clog up the grinding wheel, so that it quickly becomes unusable. As a result, only relatively short service lives of one to two hours can be achieved, since the grinding device is completely clogged with the plastic materials after only a few grinding cycles.
Since the cutting edge of a bell knife is usually ground only on one side, only the contaminants adhering to that one side can be removed at all by the grinding wheel.
Similar impurity problems can also occur in splitting machines on hoop knives, since they have a similar cutting edge contour and similar problematic deposits can thus occur.
SUMMARY OF THE INVENTION
It is thus the object of the invention to provide a remedy here, and to improve a skiving or splitting machine of the kind cited initially in such a way that long service lives can be obtained for the knife and grinding device.
According to the present invention, the object is achieved in that a cleaning device which can be placed against the contour of the cutting edge, and with which the contaminants adhering to the cutting edge can be removed, is provided, the cleaning device being adaptable to the contour of the cutting edge.
The provision of a separate cleaning device has the considerable advantage that contaminants adhering to the cutting edge can be removed before the grinding device comes into engagement with the knife. This thus prevents the grinding device from quickly becoming clogged with the contaminants and requiring replacement.
The grinding device can then exclusively perform its grinding function, since it encounters a cleaned cutting edge; as a result, long service lives can be obtained for the grinding device, which then also results in long service lives for the knife.
Because the cleaning device is adaptable to the contour of the cutting edge, this contour is not adversely affected, i.e. its geometry is not changed and the cutting edge is cleaned exactly along its contour. This means that there are no remaining residues of contaminants that then are removed by the grinding device and would gradually clog it, which in turn would be detrimental to its service life.
Because the cleaning device is adaptable to the contour of the cutting edge, the grinding device is only just in engagement with the impurities on the cutting edge, and does not adversely affect the contour as such.
It has already been mentioned previously that the contour of the cutting edge is quite critical for the skiving or splitting quality. If residual contaminants were to remain behind, the grinding quality could be negatively influenced thereby, which is undesirable. In the case of thin knives, the geometry of the contour could be changed if the deposit were removed using large forces. The adaptability feature prevents this.
Very long service lives, and thus availabilities of up to 99.85%, can be achieved.
The object is thereby completely achieved.
In a further embodiment of the invention, the cleaning device is displaceable along the contour, transversely to the movement direction of the knife.
The advantage of this feature is that the cleaning device can be arranged and can work, in space-saving fashion, away from the actual working point of the knife on its edge and transversely to its movement direction.
In a further embodiment of the invention, the cleaning device cleans the cutting edge on both sides of its cutting portion.
The advantage of this feature is that the cutting edge is cleaned on both sides, thus continuously ensuring outstanding cutting quality.
If, for example, a knife is always reground only on one side, which is usual in the case of bell knives, the grinding device could in any case clean only one side, so that then when the aforementioned problematic materials are processed, the side opposite this reground side would gradually clog up with contaminants, which in turn would have a disadvantageous effect on grinding quality. During sharpening, a chip is detached from the material and is usually deflected and carried off via a chip deflector in the interior of the bell knife. If an increasingly thick deposit of contaminants then gradually builds up on the inner side of the bell knife, the chip can no longer be detached and carried off in precisely guided fashion.
In a further embodiment of the invention, the cleaning device has cleaning elements that can be guided back and forth along the contour transversely to the movement direction of the knife, and thereby detach contaminants adhering to the contour.
The advantage of this feature is that by way of the selection, number, and arrangement of the cleaning elements, flexible adaptation is possible to the local conditions of the skiving or splitting machine and to the type of contaminants, depending on which contaminant can best be removed by which cleaning element. The cleaning elements can then correspondingly be exchanged or replaced while the configuration of the cleaning device itself remains the same.
In a further embodiment of the invention, each cleaning element has an edge that peels off contaminants adhering to the contour.
This feature has the considerable advantage that the cleaning device operates as a peeling device, i.e. lifts off the contaminants, for example as chips, so that they are then carried off, without causing the cleaning elements of the cleaning device themselves once again to become gradually clogged or sticky.
The result can thus be, for example, that plastic material's adhering firmly to a metal knife are peeled off and carried away as chips.
This not only increases the service life of the knife and the grinding device, but also yields a particularly considerable increase in the service life of the cleaning device, so that the overall result is a long service life for all three of these operating devices. The machine is almost continuously available for operation.
In a further embodiment of the invention, a cleaning element sits at one end of a lever that is pivotable against spring force and that can be pressed by the force of the spring against the contour of the cutting edge.
The advantage of this feature is to ensure, with mechanically simple and robust means, not only that sufficient contact pressure is present to clean the cutting edge, but also that, because of the pivotability of the lever, the cleaning element can be guided exactly and easily along the contour of the cutting edge.
In a further embodiment of the invention, two pivotable levers, which can be placed against opposite sides of the cutting edge, are provided.
The advantage of this feature is that each lever can be guided on its side exactly along the respective contour of the cutting edge on that side, i.e. even if different contours are present, for example in the case of knives that are asymmetrical or are ground on only one side.
In a further embodiment of the invention, a control system is provided which effects placement of the cleaning device against the knife only a certain short distance behind the cutting portion.
The considerable advantage of this feature is to ensure that the cleaning device does not come into contact with the highly sensitive outermost cutting edge which, as already mentioned several times, is indeed critical in terms of skiving or splitting quality. This prevents the cleaning device from bumping against the edge and thereby deforming it. In any case, relatively few contaminants are present directly at the tip, since the latter engages into the solid material without yet lifting a chip. It is in the regions behind the tip, i.e. in a region in which the chip to be detached is already lifting up slightly, that substantially greater volumes of contaminants become deposited over time. The tip is in any case removed in a subsequent grinding operation, and usually the opposite side is also processed in a subsequent deburring operation, so that no continuously occurring accumulation of contaminants is observed directly in the region of the tip.
In a further embodiment of the invention, two two-armed levers that are pivotable about a common lever axis are provided, and a spring, which presses one end of each lever respectively against one side of the knife edge, acts between the axes.
The advantage of this feature is that the two sides of the cutting edges can be cleaned, in a manner adaptable to the respective contours of the cutting edge, by way of physically simple and compact features that are nevertheless independent of one another.
In a further embodiment of the invention, the cleaning device has a linear drive by way of which the cleaning device can be displaced back and forth along the contour transversely to the movement direction of the knife.
The advantage of this feature is that the cleaning device can be moved selectably, i.e. periodically, cyclically, or continuously, back and forth along the contour, specifically transversely to the movement direction of the knife; in the case of skiving machines in particular, this can be embodied in very space-saving fashion.
In the case of splitting machines with long hoop knife travel lengths, it would also be possible to place the cleaning device against the edge in the movement direction, if allowed by the circumstances in terms of space.
It is understood that the features mentioned above and those yet to be explained below can be used not only in the respective combinations indicated, but also in other combinations or in isolation, without leaving the context of the present invention.
SHORT DESCRIPTION OF THE DRAWINGS
The invention will be described and explained in more detail below with reference to a selected exemplary embodiment in conjunction with the appended drawings, in which:
FIG. 1 shows, in highly schematic fashion, a plan view of an exemplary embodiment of a skiving machine, only the bell knife, the grinding device, and the cleaning device according to the present invention being shown in order to simplify the representation;
FIG. 2 shows a side view, rotated 90° with respect to FIG. 1, of the skiving machine of FIG. 1 without the grinding device;
FIG. 3 shows a greatly enlarged portion of the representation of FIG. 1 with the cleaning device in an initial working state;
FIG. 4 shows a representation, corresponding to the one in FIG. 3, of a further operating position of the cleaning device; and
FIG. 5 shows an partial, even further enlarged, and highly schematic representation of the various working positions of the cleaning elements of the cleaning device shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1 through 5, a skiving machine 10 is labeled in its entirety with the reference number 10 .
Skiving machine 10 has a knife 12 that is configured as a bell knife 14 .
Bell knife 14 has on its exposed outer circular periphery a cutting edge 16 .
The outermost tip of cutting edge 16 forms a circular edge.
Cutting edge 16 has a specific contour 20 . Cutting edge 16 is ground down only from one side—in this case from outer side 22 —and therefore has on that side 22 a curved contour 24 that corresponds to the circumferential line of a grinding wheel 36 of a grinding device 34 , as shown in FIG. 1 . On inner side 26 , contour 20 of cutting edge 16 runs in a straight line. A chip deflector 28 , as known per se, is mounted in the interior of bell knife 14 , specifically on a retaining stem 30 that is joined to a drive (not shown here) for bell knife 14 .
The longitudinal center axis of retaining stem 30 is thus the drive or rotation axis 32 of the bell knife, as indicated by an arrow 33 .
The further usual components of a skiving machine, for example an advance roller arranged in the interior of the bell knife and a corresponding foot, are not shown here for the sake of clarity; reference is made in this context, for example, to the configuration of the aforesaid DE 41 01 377 A1.
A cleaning device 40 according to the present invention, arranged to the side and in front of bell knife 14 , is arranged in, skiving machine 10 .
Cleaning device 40 serves to remove contaminants 42 that have become deposited in the region of cutting edge 16 on both sides as deposit 44 and 46 (see especially FIGS. 3 through 5 ).
Cleaning device 40 has for this purpose a linear drive 48 that is constructed as a pneumatic cylinder 50 .
The corresponding connection and supply elements are not shown for the sake of clarity.
A piston rod 52 of pneumatic cylinder 50 carries a cleaning unit 54 .
Cleaning unit 54 has a first two-armed lever 56 and a second two-armed lever 58 .
The two levers 56 , 58 are pivotable about a common pivot pin 60 , so that its longitudinal center axis 62 represents the pivot axis of both levers 56 and 58 .
Arranged between the rear ends (which face toward pneumatic cylinder 50 ) of levers 56 and 58 is a compression spring 64 that pushes those two lever ends away from one another.
Cleaning elements 66 and 68 are arranged on the outer end of levers 56 and 58 at the end located opposite compression spring 64 , i.e. on the other side of pivot axis 62 .
Cleaning elements 66 , 68 are configured as roughly triangular plates that each have edges 71 and 73 extending in the circumferential direction of cutting edge 16 of bell knife 14 . The length of edges 71 , 72 is a few millimeters, as is evident from the side view of FIG. 2 .
Edges 71 , 72 are then slightly curved, corresponding to the radius of curvature of bell knife 14 .
Each cleaning element 66 , 68 is mounted immovably via a screw 67 on the outer end of the corresponding lever 56 , 58 .
A control system 70 , which serves to adjust the lifting travel of levers 56 , 58 , is provided; this is accomplished by way of two adjusting screws 74 and 76 that are attached to a stationary mount 78 .
The contour of levers 56 and 58 , and the adjusting screws 74 and 76 in engagement with them, are such that edges 71 and 73 of cleaning elements 66 and 68 are initially lifted slightly away from cutting edge 16 , as is evident in FIG. 1 . This position is apparent in the enlarged representation of FIG. 5 at the far left side. Actuation of linear drive 48 then causes cleaning elements 66 and 68 to be displaced to the right in the presentation of FIGS. 1 and 5, specifically until they have moved approximately 0.5 to 1 mm behind the outer cutting edge 18 . Levers 56 , 58 have now traveled over adjusting screws 74 and 76 of control system 70 to a point such that compression spring 64 presses the lever ends apart. Cleaning elements 66 and 68 are thereby pressed against the corresponding sides of cutting edge 16 . Edge 71 of cleaning element 66 is placed against side 26 , i.e. against the straight side of cutting edge 16 . Cleaning element 68 is correspondingly placed, via its edge 73 , against contour 24 of cutting edge 16 , curved in accordance with grinding wheel 36 . This position is visible in FIG. 3, and in FIG. 5 is the middle position of cleaning elements 66 and 68 .
When pneumatic cylinder 50 is then actuated again, edges 71 and 73 of cleaning elements 66 and 68 travel along the contour of cutting edge 16 and thereby remove contaminant 42 , i.e. the respective deposits 44 and 46 on either side of cutting edge 16 . This removal is accomplished in the manner of a chip, as is shown in FIG. 4 by chips 80 and 82 , which are then carried off to the side as indicated therein by arrows. The position of cleaning elements 66 and 68 in FIG. 4 corresponds to the right side of the schematic representation of FIG. 5 .
Because of the lever configuration, lever 58 can thus exactly follow the curved contour 24 of cutting edge 16 , and lever 56 correspondingly follows the contour on the other side in a straight line. This ensures that exact individual adaptation to the cutting contour is accomplished automatically, and that the contaminants can thus be removed precisely. Back-and-forth displacement of pneumatic cylinder 50 causes contaminants 42 to be removed from the rotating bell knife 14 over its entire circumference.
Flawless cleaning is thus possible, either continuously or intermittently depending on the operating mode.
After the cleaning device has been retracted, a grinding operation with subsequent deburring can then be performed.
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A machine for skiving or splitting nonmetallic planar workpieces, in particular plastic-coated paper-like workpieces, is disclosed. The machine has a motor-driven moving knife, in particular a bell knife or hoop knife, whose cutting edge moves around a closed loop and has a specific contour. A grinding device for grinding the knife is provided. In order to increase the service life, a cleaning device is provided, which can be displaced towards the cutting edge for removing contaminants adhering to the cutting edge.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a mobile communication system and a resource management method thereof, and more particularly to a mobile communication system and a resource management method thereof suitable for performing an inter-station handoff extending over a plurality of switching centers.
In the mobile communication system, the inter-station handoff is frequently performed because the number of switching centers has greatly increased with the increasing of subscribers and the enlarging of communication areas.
2. Description of the Related Art
In a conventional mobile communication system, a handoff is performed, which handoff involves switching a connection to different base stations one after another with movement of a mobile station. In particular, in a Code Division Multiple Access (CDMA) which is different from a Frequency-Division Multiple Access (FDMA), a mobile station can communicate with a plurality of base stations in the same frequency. For this reason, while communicating with a base station, the mobile station can communicate with a next (target) base station. Further, the mobile station carries out a soft diversity while maintaining communication with both of the above-mentioned base stations so as to perform a seamless handoff without a short transmission interruption, namely, a soft handoff.
Performing such a handoff may bring about a change in resources of a switching center. The resources are information about a connection of a mobile station which generates a call control and writes the call control into a memory in a call. The resources contain anchor information as fixed information and drift information as variable information corresponding to the anchor information of the mobile station. The handoff may bring about a change in the drift information, such that an abnormality is found, the abnormality being, for example, that a resource to be released is not released or has become an abnormal link.
In a conventional mobile communication system and resource management method thereof, as shown in FIG. 1, a communication between two mobile stations (MS) 21 , 22 is carried out through two base station systems (BSS) 12 , 14 which are connected to a switching system 10 . When a resource A (drift information of a calling side) Is found to be abnormal due to, for example, a long-duration call, a maintainer inputs a route trace command for the resource A to confirm normality of resources B, C and D which are in serial connection in the long-duration call. The route trace functions to trace resources of a call control generated in a calling connection and written into a memory, so as to confirm whether the call is correctly connected or not.
As shown in FIG. 2, in a case in which the resource A is detected as abnormal due to floating (the resource is not being effectively used), the maintainer inputs the route trace command for the abnormal resource A. When the resource A is detected as not being connected to any resource, a process of releasing the resource A is carried out.
According to movement of a mobile station, an inter-station handoff may extend over a plurality of switching centers.
In another conventional mobile communication system and resource management method thereof, as shown in FIG. 3, a communication between two mobile stations (MS) 21 , 22 is carried out through two base station systems (BSS) 12 , 15 which are connected respectively to two switching systems 10 , 11 . When a resource A (drift information of a calling side) is detected as abnormal due to, for example, a long-duration call, a maintainer inputs in the switching system 10 a route trace command for the abnormal resource A to confirm normality of resources B, C, D which are in serial connection. In the switching system 10 into which the route trace command has been inputted, the resource B can be detected. However, the route trace cannot be carried out in the switching system 11 . If the maintainer does not separately input the route trace command into the switching system 11 , normality of the resources C and D cannot be confirmed. Thus, normality of the resources A, B, C and D which have been used in the long-duration call cannot be confirmed automatically by one route trace command.
As shown in FIG. 4, in a case in which an abnormal resource is detected due to floating of the resource C in the switching system 11 , even though the maintainer inputs the route trace command into the switching system 10 , since the resources A and B are normally connected to each other in the switching system 10 , the resources A, B and C cannot be released.
SUMMARY OF THE INVENTION
It is a general object of the present invention to provide a mobile communication system and resource management method thereof, in which the above disadvantages are eliminated.
A more specific object of the present invention is to provide a mobile communication system and resource management method thereof, in which a route trace can be automatically carried out among a plurality of switching centers when a call control of a handoff extends over the switching centers.
The above object of the present invention is achieved by a mobile communication system for performing an inter-station handoff extending over a plurality of switching centers, the mobile communication system comprising: a route trace portion which actuates a route trace so as to trace resources of call control in a local station, an inter-station checking functional portion in which the resources are checked as to whether or not the resource becomes an inter-station resource by the inter-station handoff, and an inter-station communication portion which notifies a remote station to execute a route trace when the resource is the inter-station resource and receives a result of the route trace from the remote station.
Thus, the resource of the call control is route-traced in the local station and is checked as to whether the resource becomes the inter-station resource by the inter-station handoff. When the resource is the inter-station resource, the remote station is notified to execute a route trace and transmits a result of the route trace to the local station. Hence, when the resources of the call control are the inter-station resources, a route trace automatically extending over a plurality of switching centers can be automatically carried out.
The mobile communication system may further comprise a resource releasing portion which releases an abnormal resource detected by the route trace result.
Thus, since the abnormal resource detected by the route trace result is released, the abnormal resource can be automatically released in the local station.
The mobile communication system may be configured so that: the resource releasing portion notifies the remote station through the inter-station communication portion so as to release an abnormal resource detected by the route trace result from the remote station.
Thus, since the remote station is notified to release the abnormal resource detected by the route trace result from the remote station, the abnormal resource in the remote station can be automatically released in a case of inter-station call control.
The mobile communication system may further comprise a resource checking portion which checks the resource and a route trace actuating portion which actuates the route trace if the resource is checked as being abnormal.
Thus, since the resource is checked and the route trace is actuated if the resource is checked as being abnormal, when the abnormality is found, all of the abnormal resources in the local and remote stations can be automatically released.
Further, the above object of the present invention is achieved by a resource management method of the mobile communication system according to the present invention, comprising the steps of: a) actuating a route trace so as to trace resources of call control in a local station, b) checking whether or not each of the resources becomes an inter-station resource by the inter-station handoff; and c) notifying a remote station to execute a route trace when the resource is the inter-station resource and receiving a result of the route trace from the remote station.
Thus, the resource of the call control is route-traced in the local station and is checked as to whether the resource becomes the inter-station resource by the inter-station handoff. When the resource is the inter-station resource, the remote station is notified to execute a route trace and transmits a result of the route trace to the local station. Hence, when the resources of the call control are the inter-station resources, a route trace automatically extending over a plurality of switching centers can be automatically carried out.
The resource management method further comprises the step of d) releasing an abnormal resource detected by the route trace result.
Thus, since the abnormal resource detected by the route trace result is released, the abnormal resource can be automatically released in the local station.
The resource management method further comprises the step of e) signaling the remote station so as to release an abnormal resource detected by the route trace result from the remote station.
Thus, since the remote station is notified to release the abnormal resource detected by the route trace result from the remote station, the abnormal resource in the remote station can be automatically released in a case of inter-station call control.
The resource management method further comprises the step of f) checking whether or not the resource is abnormal and actuating a route trace in the local station if the resource is abnormal.
Thus, since the resource is checked and the route trace is actuated if the resource is checked as being abnormal, when abnormality is found, all of the abnormal resources in the local and remote stations can be automatically released.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the present invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings, in which:
FIG. 1 is a view showing a conventional mobile communication system and resource management method thereof;
FIG. 2 is a view showing the conventional mobile communication system and resource management method thereof;
FIG. 3 is a view showing another conventional mobile communication system and resource management method thereof;
FIG. 4 is a view showing the other conventional mobile communication system and resource management method thereof;
FIG. 5 is a block diagram showing an example of a CDMA mobile communication system in which an inter-station soft handoff is performed;
FIG. 6 is a block diagram showing an example of a route trace and resource management according to the present invention;
FIG. 7 is a block diagram showing an example of route trace control according to the present invention;
FIG. 8 is a block diagram showing an example of resource releasing control according to the present invention;
FIG. 9 is a block diagram showing a format of CCB information;
FIG. 10A is a view showing an example of a sequence of performing the inter-station route trace according to the present invention;
FIG. 10B is a view showing an example of a sequence of releasing a resource according to the present invention;
FIG. 11 is a block diagram showing an example of a format of a trace executing signal message and a trace result signal message according to the present invention;
FIG. 12 is a block diagram showing an example of a format of a resource releasing signal message according to the present invention;
FIG. 13 is a flowchart showing an example of a process of executing a resource management function A according to the present invention;
FIG. 14 is a flowchart showing an example of a process of executing a route trace function B according to the present invention;
FIG. 15 is a flowchart showing an example of a signal-receiving process of executing an inter-station resource management function C according to the present invention;
FIG. 16 is a flowchart showing an example of a signal-transmitting process of executing the inter-station resource management function C according to the present invention; and
FIG. 17 is a flowchart showing an example of a process of executing a resource releasing portion “c” of the resource management function A according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 5 shows a block diagram of an example of a CDMA mobile communication system in which an inter-station soft handoff is performed. In FIG. 5, the CDMA mobile communication system comprises mobile switching centers (MSC) 20 1 , 20 2 and a base station system (BSS). The base station system consists of base station controllers (BSC) 24 1 , 24 2 , 24 3 and 24 4 , base terminal stations (BTS) 26 1 , 26 2 , 26 3 and 26 4 which are controlled by the base station controllers (BSC) 24 1 , 24 2 , 24 3 and 24 4 respectively, and a mobile station 28 .
The mobile switching center (MSC) 20 1 ( 20 2 ) consists of a BSC interface switch (BSCI/FSW) 30 , a handoff control unit (HCU) 32 , and a switch 34 . The BSC interface switch (BSCI/FSW) 30 functions to connect the base station controllers (BSC) 24 1 , 24 2 ( 24 3 , 24 4 ) to the handoff control unit 32 . The handoff control unit (HCU) 32 functions to control a soft handoff. The switch 34 functions to connect the handoff control unit (HCU) 32 to a public telecommunication network (PSTN) 36 .
The handoff control unit 32 consists of a FER detector/selector 38 , a vocoder 40 and a down link duplicator 42 . The FER detector/selector 38 functions to detect error probability of radio circuits between the mobile station 28 and the handoff control unit 32 so as to select a radio circuit with the lowest error probability. The vocoder 40 functions to perform speech (voice) coding and decoding. The down link duplicator 42 functions to duplicate downstream data. In a case in which a soft handoff is performed between the base terminal stations (BTS) 26 1 and 26 3 which are controlled by the mobile switching centers (MSC) 20 1 and 20 2 , the handoff is controlled by, for example, the handoff control unit 32 within the mobile switching center (MSC) 20 1 .
FIG. 6 shows a block diagram of an example of a route trace and resource management capabilities according to the present invention. In FIG. 6, CDMA switching systems 50 , 51 are equivalent to the mobile switching station 20 1 and 20 2 in FIG. 5 respectively. Each of the CDMA switching systems 50 , 51 comprises a resource management function A, a route trace function B and an inter-station resource management function C.
In the embodiment of the present invention, the CDMA switching system 50 is regarded as a local station and the CDMA switching system 51 is regarded as a remote station.
In the resource management function A of the local station 50 , a resource checking portion “a” checks resources of the local station 50 every given time (for example, 12 hours). When an abnormal resource is found in the local station 50 , the route trace function B is actuated by a route trace actuating portion “b” of the resource management function A. Then, the abnormal resource is released by a resource releasing portion “c” of the resource management function A according to a result of the route trace executed in the route trace function B.
The route trace actuating portion “b” of the resource management function A actuates the route trace function B and thereby a route trace processing portion “d” is actuated. The actuated route trace processing portion “d” executes a route trace by using call control information (CCB information) so as to confirm whether a call is in a correct connection as indicated by the call control information. The route trace function B judges that the resource in the local station 50 is abnormal if the call control information is interrupted on the way of the route trace, or is normal if the route trace is completed without the call control information being interrupted. If it is detected from the call control information in an inter-station checking functional portion “e” that the call extends over the two stations 50 , 51 by an inter-station handoff, the inter-station resource management function C is actuated by the inter-station checking functional portion “e”.
The inter-station resource management function C transmits a route trace executing signal message through an inter-station signal message transmitting/receiving portion “f” thereof to the remote station 51 of the inter-station handoff. The inter-station signal message transmitting/receiving portion “f” functions as an inter-station communication portion.
In the remote station 51 , the inter-station resource management function C receives the trace executing signal message from the local station 50 and actuates the route trace processing portion “d” of the route trace function B through an inter-station signal message transmitting/receiving portion “f”.
Further, in the remote station 51 , the route trace processing portion “d” executes a route trace by using the call control information so as to confirm whether or not the call is correctly connected in the remote station 51 as indicated by the call control information. The inter-station signal message transmitting/receiving portion “f” transmits a result of the route trace to the inter-station resource management function C of the local station 50 .
Then, in the local station 50 , the inter-station resource management function C notifies the result of the route trace executed in the remote station 51 to the route trace processing portion “d” of the route trace function B. The notification is about normality/abnormality of the resources and the call control information obtained from the route trace. An abnormal resource may be a resource which is in a floating state due to omission of release, or destruction of link information (address).
The route trace function B of the local station 50 transmits the results of the route traces automatically executed in the local and remote stations 50 , 51 to the resource management function A of the local station 50 . If an abnormal resource is detected in the local station 50 , the resource releasing portion “c” of the resource management function A releases the abnormal resource. If an abnormal resource is detected in the remote station 51 of the inter-station handoff, the abnormal resource of the remote station 51 is released such that the inter-station signal message transmitting/receiving portion “f” of the local station 50 actuates the resource releasing portion “c” of the resource management function A of the remote station 5 through the inter-station signal message transmitting/receiving portion “f” and the route trace processing portion “d” of the remote station 51 .
FIG. 7 shows a block diagram of an example of route trace control according to the present invention. In the local station 50 , the resource management function A checks resources therein. If an abnormal resource is detected in drift information of a calling side, the resource management function A actuates the route trace function B so as to trace call control information (CCB information) of the local station 50 .
The CCB information, as shown in FIG. 9, consists of a control portion, a common portion, a SCN supporting portion and an extension portion. The control portion contains identification numbers of anchor/drift and the like.
The common portion contains TI information (terminal number) of the call control information, path information (call connection number) and CR number information (CR is a call control information number). For example, the common portion may contain address information regarding from which address the TI information begins, etc.
The SCN supporting portion contains control information for deciding, from TI information of the extension portion, to which TI information the TI information is connected, or which call control information is used, in a case of executing a route trace from various information of the extension portion, for example, from the drift information to the anchor information.
The extension portion contains TI information of the call control information, the path information and CR number information. This information are basic information outputted by the route trace. In the route trace, a CCB information address of a link head of the extension portion is used to seek the next CCB information.
The call control information consists of anchor information as fixed information and drift information as variable information which are contained in both of a calling side and an accepting side of mobile stations. The route trace function B of calling-side drift information 52 uses a call control program 53 to seek trunk information from CCB resources 54 of the calling-side drift information 52 . The trunk information connects the calling-side drift information 52 and the calling-side anchor information 58 of an abnormal resource. Then from the trunk information, the route trace function B traces trunks 55 , 56 to seek a connection resource of the calling-side anchor information 58 .
Further, the route trace function B of the calling-side anchor information 58 uses the call control program 53 to seek inter-station trunk information from CCB resources 59 . The inter-station trunk information connects the calling-side anchor information 58 and accepting-side drift information 62 . Then from inter-station trunk information, the route trace function B traces inter-station trunks 60 , 61 to seek a connection resource of the accepting-side anchor information 62 of the remote station 51 . After that, the route trace function B actuates the inter-station resource management function C so as to transmit a trace executing signal message to the remote station 51 .
The route trace function B of the remote station 51 uses a call control program 63 to seek trunk information from CCB resources 64 of the accepting-side drift information 62 . The trunk information connects the accepting-side drift information 62 and accepting-side anchor information 68 . Then from the trunk information, the route trace function B traces trunks 65 , 66 to seek a connection resource of the accepting-side anchor information 68 .
Further, the route trace function B uses the call control program 63 to trace the accepting-side anchor information 68 from CCB resources 69 . The route trace function B of the remote station 51 actuates the inter-station resource management function C to transmit a trace result signal message to the local station 50 so as to notify the route trace function B of the local station 50 .
FIG. 8 shows a block diagram of an example of resource releasing control according to the present invention. In the CDMA switching system 50 which is regarded as the local station, the route trace function B notifies a route trace result to the resource management function A. If the route trace result indicates that an abnormal resource is found in the local station 50 , the resource management function A actuates the resource releasing portion “c” thereof to release the abnormal resource from CCB resources 71 of calling side resource information 70 .
Then, the resource management function A actuates the inter-station resource management function C to transmit a resource releasing signal message to the CDMA switching system 51 which is regarded as the remote station. Thus, the resource management function A of the remote station 51 actuates the resource releasing portion “c” thereof to release the abnormal resource from CCB resources 76 of accepting-side resource information 75 .
FIG. 10A shows an example of a sequence of executing the inter-station route trace according to the present invention. In a case in which a trace executing signal message indicates that an abnormal resource is detected by the resource checking portion “a” of the local station 50 and thereby the route trace function B is actuated, or, in a case in which a maintainer performs a route trace, inter-station call control is transmitted to the remote station 51 . Then, after the route trace is executed in the remote station 51 , a trace result signal message as an answer to the trace executing signal message is transmitted to the local station 50 .
FIG. 10B shows an example of a sequence of releasing an inter-station resource according to the present invention. When the trace result signal message from the remote station 51 is transmitted to the local station 50 , the local station 50 confirms the trace result. If the trace result shows that an abnormal resource is found in the local station 50 , the local station 50 releases the abnormal resource thereof and then transmits a resource releasing signal message to the remote station 51 so as to release the abnormal resource in the remote station 51 .
FIG. 11 shows a block diagram of an example of a format of a trace execution signal message and a trace result signal message according to the present invention. An SCCP message portion (SCCP: Signaling Connection Control Part) contains various information such as DTFLG (data field), CLGSSN (subsystem number of calling party), CLGLG (calling party length), BMTYP (message type), BTRID (transaction ID), BMSLG (message length), BDSC (sidcribution subsystem NO), and the like. The BMTYP contains a code showing inter-station trace messages including a trace executing signal message and a trace result signal message. DTFLG˜BDSC are information for seeking a position of BMTYP.
A TCAP message portion (TCAP: Transaction Capabilities Application Part) contains a package type identifier, a total message length, a transaction ID identifier, a parameter set length, and a parameter set. The parameter set functions to respectively set a trunk number or resource information of a trunk location number, a trace result effective in a trace result signal message, and trace output information generated when a route trace effective in the trace result signal message is normally completed.
FIG. 12 shows a block diagram of an example of a format of a resource release signal message according to the present invention. A SCCP message portion contains various information such as DTFLG, CLGSSN, CLGLG, BMTYP (message type), BTRID, BMSLG, BDSC, and the like. The BMTYP contains a code showing a resource release message. A TCAP message portion contains a package type identifier, a total message length, a transaction ID identifier, a parameter set length, and a parameter set. The parameter set functions to respectively set a trunk number of resource to be released, or resource information of a trunk location number.
FIG. 13 shows a flowchart of an example of a process of executing resource management function A according to the present invention. In Step 10 , all of resource information of the local station 50 is monitored, and in Step 11 , it is judged whether the resource information is normal or not. If an abnormal resource is found in the local station 50 , the process goes to Step 14 , and if no abnormal resource is found in the local station 50 , the process goes to Step 16 .
In Step 14 , a route trace is actuated and then the process goes to Step 16 to judge whether a result of the route trace is abnormal or not. If the trace result is normal, the process ends. If the trace result is abnormal, the process goes to Step 18 to actuate a resource releasing process and then goes to the end.
FIG. 14 show a flowchart of an example of a process of executing the route trace function B according to the present invention. In Step 20 , a route trace is executed in the local station 50 . In Step 22 it is judged whether call control extends over two stations. If the call control is extending over the two stations, the process goes to Step 24 in which the inter-station resource management function C is actuated to transmit a trace executing signal message to the remote station 51 of the two stations and then goes to Step 26 . If the call control is not extending over the two stations, the process goes directly to Step 26 .
In Step 26 , it is judged whether a result of the route trace is normal or not. If the trace result is normal, the process goes to Step 28 in which an autonomic message including the trace result and normality is outputted. If the trace result is abnormal, the process goes to Step 30 in which an autonomic message including the trace result and abnormality is outputted.
FIG. 15 shows a flowchart of an example of a signal-receiving process of executing the inter-station resource management function C according to the present invention. In Step 32 , it is monitored whether a trace executing signal message is transmitted from the remote station. In Step 34 it is judged whether the trace executing signal message has been transmitted or not, and if the message has been received, the process goes to Step 36 from Step 34 . In Step 36 , a route trace of the local station is executed and then the process goes to Step 38 . In Step 38 , a trace result is transmitted to a trace-request source by a trace result signal message, and thus the process ends.
FIG. 16 shows a flowchart of an example of a signal-transmitting process of executing the inter-station resource management function C according to the present invention. In Step 40 , a trace resource of a trace executing signal message or trace result signal message, or resource releasing information, is set to be a signal message. In Step 42 the signal message is transmitted to the remote station 51 , and thus the process ends.
FIG. 17 shows a flowchart of an example of a process of executing the resource releasing portion “c” of the resource management function A according to the present invention. In Step 44 , a resource indicated by the resource releasing information is released and thus the process ends.
The above-mentioned examples of the present invention are directed to the use of the type of CDMA which performs soft handoffs. However, the present invention is not limited to the type of CDMA and is also suitable to the type of FDMA which only performs a handoff and the like.
The present invention is not limited to the specifically disclosed examples, and variations and modifications may be made without departing from the scope of the present invention.
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A mobile communication system includes a route trace unit for actuating a route trace to trace resources of call control in a local station, an inter-station checking unit for checking whether or not the resource becomes an inter-station resource by the inter-station handoff, and an inter-station communication unit for notifying a remote station to actuate a route trace when the resource is the inter-station resource and receiving a result of the route trace from the remote station. Accordingly, when the resources of the call control are the inter-station resources, the route trace automatically extending over a plurality of switching centers can be carried out automatically.
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This is a division, of application Ser. No. 860,240, filed May 6, 1986, now U.S. Pat. No. 4,801,877.
FIELD OF THE INVENTION
This invention relates generally to the field of testing rotors of dynamoelectric machines, such as electric motors and generators, and more particularly to a method and apparatus for testing squirrel cage rotors for induction motors to obtain the resistance, reactance, and effective electrical skew of the rotor to permit identification of rotor defects.
BACKGROUND OF THE INVENTION
Squirrel cage rotors for modern induction motors typically include a core comprised of a stack of steel laminations and an aluminum squirrel cage conductor arrangement, usually formed as a die casting. Manufacturing techniques have been perfected to the point where these rotors are mass produced with a high probability of uniformity and high quality. There are, however, a number of possibilities for deficiencies, including porosity or impurities in the aluminum casting and open circuits in the squirrel cage conducting bars which can affect the electrical resistance of the rotor, poor insulation between the squirrel cage conductors and the iron core which can produce undesired variations in the effective skew, and various other manufacturing defects. Thus it is desirable to test dynamoelectric machine rotors economically and reliably to detect such defects.
Because quality problems are generally infrequent, it is not economical to perform expensive tests on every individual rotor. However, since hidden defects do occur, in order to maintain a high degree of quality control there is a need to perform low cost tests on each rotor before it is assembled with a stator to form a complete machine. Further, it can be desirable to obtain information on the resistance, reactance and effective skew of the rotors for evaluation of defects, manufacturing processes and quality control.
A number of prior art methods have been developed in an attempt to test squirrel cage rotors. Some, such as that disclosed in U.S. Pat. No. 2,844,794, assigned to the assignee of the present invention, require the use of the dynamoelectric machine stator core, while others use destructive testing techniques. One non-destructive prior art technique for testing rotors independent of the stator is disclosed in U.S. Pat. No. 3,861,025, assigned to the assignee of the present invention. This technique involves rotating the rotor in a static magnetic field and evaluating the waveform of the resulting induced voltages displayed on an oscilloscope. This technique requires extensive operator training to interpret the oscilloscope display, and has inherent limitations on the results that can be achieved. Another prior art testing technique utilizes a stator fixture excited by a fixed AC current into which the rotor is placed and manually rotated to obtain a peak power measurement (i.e. power into the rotor) using a pick-up coil. By using the current measurement, the impedance of the rotor can be obtained, but separate resistance, reactance and skew information can not be determined.
It is accordingly an object of the present invention to provide a novel and improved method and apparatus for non-destructive testing of dynamoelectric machine rotors.
It is another object of the invention to provide a novel, economical, and reliable method and apparatus for non-destructive measurement of the resistance and reactance of dynamoelectric machine rotors.
It is yet another object of the invention to provide a novel, economical and reliable method and apparatus for non-destructive measurement of the effective skew of dynamoelectric machine rotors.
It is yet another object of the invention to provide a novel, economical, and reliable method and apparatus for non-destructive testing of dynamoelectric machine rotors which provides automatic pass/fail determinations.
It is still another object of the invention to provide a novel, economical, and reliable method and apparatus for non-destructive testing of dynamoelectric machine rotors including the measurement of resistance, reactance and skew and a detailed statistical comparison and evaluation of the measurement results, as well as automatic identification of defective rotors.
SUMMARY OF THE INVENTION
Briefly, according to preferred embodiments of the invention, a test apparatus and method is provided for testing dynamoelectric machine rotors. The apparatus comprises a test head for accepting and causing relative angular movement between the rotor and test head and includes exciting means for magnetizing the rotor during such angular movement in response to an alternating current. Voltage sensing means is provided for generating a voltage signal responsive to the magnetic flux variations generated by the rotor in response to the magnetization by the exciting means. Current sensing means is provided for sensing the magnitude of the alternating current utilized to magnetize the rotor and for generating a current signal representative thereof. Processing means is provided for determining the resistance and reactance of the rotor responsive to the voltage signal and current signal.
In addition skew sensing means may be provided for sensing the effective electrical skew of the rotor and for generating an effective skew signal responsive thereto. The processing means is usable for determining an effective electrical skew of the rotor responsive to the effective skew signal.
The subject matter of the invention is particularly pointed out and distinctly claimed in the claims at the concluding portion of this specification. The invention itself, 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 conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic front view illustrating a specific embodiment of a dynamoelectric machine rotor test apparatus for testing squirrel cage rotors in accordance with the invention.
FIG. 2 is a cut-away perspective view illustrating a specific embodiment of a typical squirrel cage rotor.
FIG. 3 is a detailed block diagram illustrating a specific embodiment of the dynamoelectric machine rotor test apparatus for testing squirrel cage rotors in accordance with the invention.
FIG. 4 is a cut-away perspective view illustrating the core configuration of a specific embodiment of the test head of the test apparatus illustrated in FIG. 3.
FIG. 5 is a cut-away diagrammatic view illustrating the structure of a specific embodiment of the test head of test apparatus illustrated in FIG. 3.
FIG. 6 is a cross sectional view illustrating the skew winding portion of a specific embodiment of the test head of the test apparatus illustrated in FIG. 3.
FIG. 7 is a diagrammatic view illustrating the structure of a specific embodiment of the test head of the test apparatus illustrated in FIG. 3.
FIG. 8 is a diagrammatic view illustrating a laid open structure of a specific embodiment of the test head of the test apparatus illustrated in FIG. 3.
FIG. 9 is a diagrammatic view illustrating a specific embodiment of the test fixture structure of the test apparatus illustrated in FIG. 1 with the test fixture in the rotor extended position.
FIG. 10 is a diagrammatic view illustrating a specific embodiment of the test head and mechanical structure of the test apparatus illustrated in FIG. 1 with the test head in the rotor retracted position.
FIG. 11 is an expanded diagrammatic view illustrating a specific embodiment of the test head and rotor clutch mechanism illustrated in FIG. 9 in the rotor extended position.
FIG. 12 is an expanded view of a portion of the rotor clutch mechanism illustrated in FIG. 11.
FIG. 13 is an expanded diagrammatic view illustrating a specific embodiment of the test head and rotor clutch mechanism illustrated in FIG. 10 in the rotor retracted position.
FIG. 14 is an expanded view of a portion of the rotor clutch mechanism illustrated in FIG. 13.
FIG. 15A is a flow diagram illustrating the program flow for one embodiment of the data processor of FIG. 3.
FIG. 15B is a flow diagram illustrating the program flow for one embodiment of the control processor of FIG. 3B.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a general diagrammatic front view illustrating a preferred embodiment of the dynamoelectric machine rotor test apparatus 20 according to the invention. The test apparatus 20 is a dual test fixture embodiment having two test fixtures 22, 24. Other embodiments utilizing one fixture or more than two fixtures will be apparent to those skilled in the art in view of the disclosure provided hereinafter. The two test fixtures 22, 24 each respectively comprise a test head 26, 28 and a hydraulically driven retraction and drive mechanism 36, 38. The retraction and drive mechanism 36, 38 functions to retract and rotate the rotor within the test head in response to activation of a start button 32, 34 associated with the respective test fixtures 22, 24. The test fixtures 22, 24 are mounted, as shown, in a test stand 30 to provide convenient access by an operator.
Each test fixture 22, 24 is coupled to a data acquisition, processing and control system 40 mounted in a rack 42 as shown. The system 40 comprises data acquisition and processing circuitry in a drawer 51, coupled to a terminal 44, and to a printer (e.g., an Epson RX-80) contained in a drawer 53, and coupled to a power supply 54. The terminal 44 comprises a display 46 (e.g., a Computerwise, Inc., Transterm Model TM-71 LCD Display) for displaying test results, control information, and other data, and a keyboard 48, (e.g., a Computerwise, Inc. Transterm Model TM-71 16-key, alpha/numeric keyboard) for entry of data and control information. The printer permits the printing of results and other data, while the power supply 54 provides electrical power for all of the electrical elements of the apparatus 20.
The single common data acquisition, processing and control system 40 controls testing and acquires data from each test head 22, 24 independently. In response to initiation of a test on a respective fixture 22, 24 by a operator, the system 40 automatically performs the rotor test on the respective test fixture. Thus, once the test sequence is initiated by the operator, the system 40 controls the rotation of the rotor within the fixture, the acquisition of data via the fixture, and the processing of the acquired data without further operator intervention.
A typical squirrel cage rotor suitable for testing by the apparatus 20 is illustrated in FIG. 2. The rotor 60 includes a cylindrical core 62 formed of a stack of laminations made of a magnetic material such as iron. The rotor core 62 includes a center opening 65 which runs axially through the center of the rotor 60 and which is intended to be mounted on the rotor shaft (not shown). The rotor core 62 also includes a circumferential series of nearly axial slots 64 near the outer diameter of the rotor 60. These slots may be disposed in a skewed or inclined relationship with respect to the longitudinal axis of the rotor. The squirrel cage windings are provided by an aluminum casting 66 disposed in and about the rotor core 62 comprising conductive bars 67 which fill the slots 64 and conductive end rings 68, 69 integral with the conductive bars.
This structure will have inherent resistance and reactance characteristics which are highly dependent on the proper construction of the rotor such as proper formation of the conductive bars in the slots 64. In addition, the skew characteristics of the rotor are largely determined by the angle of incline (i.e. skew) of the conductive bars off of the true longitudinal axis. However, variations of the properties of the magnetic material, the aluminum casting, the iron to aluminum insulation, etc. will produce variations in the effective electrical skew (i.e., the skew as measured by its effects on the electromagnetic field in the air gap).
The test heads 26, 28 of the test fixtures 22, 24 have a unique construction which may best be understood by reference to FIGS. 4-8. The test heads 26, 28 comprise a structure utilizing a core of magnetic material 200 very similar to a conventional dynamoelectric machine stator as illustrated in FIG. 4. This core is formed in the conventional manner of a stack of laminations of magnetic material such as iron, shaped to provide a plurality of slots which permit a set of windings to be arranged in the slots as illustrated in FIG. 5.
FIG. 5 is a diagrammatic illustration of the structure of a test head 26 (also see FIG. 7). The test head includes a set of primary windings 210 which form at least one pair of poles 212, 214 as illustrated in FIG. 7. These primary windings form the exciting current carrying winding for the test head 26 which, when an alternating current is supplied during a rotor test, creates an alternating magnetic field in a center cylindrical cavity 220. For testing, the rotor is positioned within the center cavity 220 and rotated, thereby inducing voltages in the rotor. This results in induced currents in the rotor and consequently generation of magnetic flux by the rotor which is sensed by the pick-up coil 106. The pick-up coil 106 comprise a set of coil windings in which is generated a voltage representative of the voltage induced in the rotor. These coils are, in the illustrated embodiment, composed of a multiple turn loop (any number of turns may be used), as shown, coupled in series to provide the voltage signal. In the preferred embodiment, these voltage pick-up coils 106 are wound over the primary coils 102.
The test head 26 also includes a skew pick-up coil 110 located at one end of the test head structure 26. This skew pick-up coil 110 is positioned in quadrature with the poles 212, 214 and at the end of the core 200 to sense flux build-up at the end of the rotor due to the skew characteristics of the rotor. In the illustrated embodiment, the skew pick-up is composed of two multiple turn loops coupled in series, as shown, although other coupling configurations and any number of turns (N) may be used. The skew pick-up coils 110, in the illustrated embodiment, are positioned within a groove 222 near the end of the core 200, as may best be understood by reference to FIG. 6.
For a further understanding of the structure of the coils of the test head 26, reference may be made to FIG. 8 which shows a diagrammatic view of the test head 26 laid flat. The primary windings 102 are shown forming two poles 212, 214 with the voltage pick-up coils 106 wound in some of the slots among the primary coil windings 102. The skew pick-up coil 110 is shown in quadrature relationship to the primary windings at one end of the core 200.
Referring now to FIG. 3, there is shown a detailed block diagram illustrating a specific embodiment of the dynamoelectric machine rotor test apparatus 20. Each test head 26, 28 includes an excitation means 102, 104 composed of the set of current carrying windings which produce an alternating magnetic field when energized by an alternating current of predetermined magnitude (e.g., 60 hz at 2.4 amps in the illustrated embodiment) coupled from the power supply 54, as shown. The magnetic field produced will magnetize a rotor rotated within the field producing magnetic flux which is dependent upon the rotor characteristics.
Each head 26, 28 also includes the voltage sensing pick-up coil 106, 108 responsive to the rotor induced magnetic flux which produces a voltage signal representative of the voltage induced in the rotor. The skew sensing pick-up coil 110, 112 is also located in the test head 26, 28 which produces an effective skew signal responsive to flux build-up at the end of the rotor due to the rotor's effective skew. Each of these sense signals is coupled to a sample and hold circuit 120, as shown (e.g., a Burr-Brown ADSHC-85). A current sensor 114 (e.g., a conventional current transformer), coupled as shown to the supply 54, senses the current provided to energize the test heads 26, 28 and couples a current sense signal to the sample and hold circuit 120.
Also coupled to the power supply 54 is a phase lock loop 122 (e.g., a National CD4046) which generates timing pulses which are phase locked to the exciting alternating current supplied to the test head windings 102, 104. In the illustrated embodiment, there are 32 pulses generated for each cycle of the exciting alternating current such that each pulse is generated at the same phase of the cycle for each succeeding cycle. These phase locked timing pulses are coupled, as shown, to the sample and hold circuit 120 to synchronize the sampling of the sense signals coupled from the voltage pick-up 106, the skew pick-up 110, and the current sensor 114. The phase locked timing signals are also coupled to a data processor 140 via a conductor 127, as shown.
The sample and hold circuit 120 and the phase locked loop circuit 122 are part of an analog to digital system 130 which also includes an analog multiplexor 124 (e.g., an Analog Devices AD7506) and an analog to digital converter 126 (e.g., Analog Devices ADC1131 high speed, 14 bit converter) configured as shown. The analog to digital system 130 is a subsystem of the data acquisition and processing circuit 50. The data acquisition and processing circuit 50 controls the acquisition of the test data and processes the data to produce useful test results as well as rotor pass/fail determinations. The data acquisition and processing circuit 50 also includes the data processor to 140 (e.g., an Intel 86/14 microcomputer) and a control processor 150 (e.g., an Intel 86/35 microcomputer) as shown. This multi-computer system provides highly efficient data acquisition and processing, although other configurations (e.g., a single microcomputer system) may also be used.
During a rotor test, the sample and hold circuit 120 simultaneously samples each of the sense signals each time a timing pulse from the phase locked loop 122 occurs. Simultaneous sampling of current and voltage sense signals permits calculation of a power value (W) (note: simultaneous sampling of the skew signal is not needed to permit the calculation of a power value). These samples, taken by the sample and hold circuit 120 are coupled to an analog multiplexer circuit 124, as shown. The analog multiplexer 124 multiplexes the samples sequentially, under the control of the data processor 140, to an analog to digital converter 126. The analog to digital converter digitizes the samples and couples the digitized samples to the data processor 140. The digitized samples coupled to the data processor 140 are processed to reduce the data to usable form.
In the illustrated embodiment, the processor 140 acquires 32 samples in a cycle of the exciting alternating current (i.e., at 60 hz, one sample every 520 microseconds), then ignores samples for the next five cycles, and samples again for 32 samples. (The flow of program control for the processor 140 may be more fully understood by reference to the flow chart 260 illustrated in FIG. 15A in conjunction with the following description). This pattern is continued for a total of forty sampling cycles of 32 samples each to complete one rotor test sampling sequence in four seconds. Once the data is acquired for each sample cycle, the processor 140 multiplies each current sample by the corresponding voltage sample to obtain a power value W (where W is power into the rotor). The 32 samples of the voltage signal, current signal, skew signal, and power value are then processed to obtain four test values which are a mean power value (W), and a root means square (rms) value for the voltage (V), current (I), and skew (SK) signals. This process is repeated 40 times, once for each sample cycle, thereby obtaining 40 sets of the four test values.
These forty sets of test values are coupled from the data processor 140 to the control processor 150 at the end of a rotor test sequence. (The flow of program control for the control processor 150 may be more fully understood by reference to the flow chart 270 illustrated in FIG. 15B in conjunction with the following description). The control processor 150 then determines a mean resistance (R), reactance (X), and effective skew (ESK) for the rotor from the 40 test values, as well as the range of the 40 values for the resistance (referred to as dissymmetry, DS) and the effective skew (referred to as skew dissymmetry, DSK).
Each resistance value (R) is determined by the formula
R=W/I.sup.2.
Each reactance value is determined by the formula
X=((VI).sup.2 -W.sup.2)1/2)/I.sup.2.
The effective skew is determined by the formula
ESK=SK/(I.sup.2 ×N)
where N=the number of turns of the skew pick-up coil.
Once the resistance, reactance, and effective skew values have been determined, the data is scanned to determine the maximum and minimum resistance and effective skew values. In addition, an average value of resistance, reactance, and effective skew is determined by summing the forty values for each and dividing by forty. These values are stored in internal memory within the data processor 140.
After all of the values have been calculated, the average value for resistance, reactance, and effective skew are each compared to predetermined maximum and minimum threshold values. In addition, the dissymmetry value is compared to a predetermined maximum. The maximum and minimum values may be entered through the key board 48 by the operator prior to the beginning of a test run. If the calculated values for the rotor are within the predetermined maximum and minimum threshold value, then the rotor is passed as a good rotor. However, if the rotor has any value outside of the predetermined limits, a fail (reject) indication is provided to the operator by means of an indicator such as a light or audible signal (not shown) to indicate a defective rotor. The reject signals to activate the fail indicators are generated on outputs 162 and 164, as shown.
In addition to the calculated values, additional statistical information is also determined and stored on a Winchester magnetic disk 55 coupled to the control processor 150, as shown. Among the types of data stored on the Winchester disk 55 are totals of the number of passed rotors, the number of fail rotors including how many failed for each threshold, running sums of each of the calculated values, and running sums of the squares of each of the values. This data permits the determination of statistical information over numerous tests of a test run, including such information as averages and standard deviation. All the calculated values of resistance, reactance, effective skew, dissymmetry, and skew dissymmetry for each test are displayed on the display 46 at the end of a test. In addition, the printer 52 may be used to print the results of a test as well as the statistical data. The printer 52 is activated by the operator via commands from the keyboard 48.
The control processor 150 also controls the sequence of events that occur during a test. Various input and output signals are coupled between the control processor 150 and an opto-isolator 160 (e.g., an opto-22) via a bus 166, as shown. The opto-isolator provides a control interface to the test fixtures 22, 24. The start switches 32, 34 are coupled to the opto-isolator 160 which couples the start signal to the processor in response to activation of one (i.e., Right (R) or Left (L)) of the start switches 32, 34. In response, the control processor 150 couples a control signal through the opto-isolator 160 to the appropriate retraction and drive mechanism 36, 38 (described in greater detail hereinafter with reference to FIGS. 9-14) which activates the mechanism 36, 38 thereby starting the rotor test. The retraction and drive mechanism 36, 38, in response to activation, retracts a rotor placed on a test head 26, 28. When the rotor is fully retracted such that it is in place for testing, a position sensor 170, 172 (e.g., a conventional limit switch) generates a position signal which is coupled through the opto-isolator 160 to the control processor 150 via conductors 174, 176. In response to the position signal, the control processor 150 generates a drive signal which is coupled through the opto-isolator 160 to the drive motors 180, 182 via the conductors 184, 186. This drive signal activates the motor 180, 182 to rotate the rotor.
In the illustrated embodiment, the rotor is rotated at a rate of 1 revolution in four seconds, and is rotated one full rotation for a complete test sequence (i.e., rotation for four seconds). During the four second test sequence, the data acquisition and processing system 50 acquires the desired data after which three seconds are utilized for the data to be processed. The use of the two fixture system permits the operator to set up a rotor on the unused fixture during this seven second test sequence. Thus, the dual fixture system allows more efficient testing by reducing delays due to the operator set up time. It also increases the cost effectiveness of the apparatus because both fixtures can be controlled with a single processing system.
During operation, a test is initiated by an operator by placing a rotor to be tested onto the test head, for example, head 26. The operator then initiates the test sequence by activating the start button 32, which signals the control processor 150 to activate the retraction mechanism thereby retracting the rotor to the test position. Once fully retracted the position sensor 170 generates a signal coupled to the control processor 150 which causes the control processor 150 to generate the motor activation signal, which activates the motor 180 to rotate the rotor. The rotor is rotated at a rate of one rotation in four seconds, and one complete test sequence is completed in one rotation. During the four second rotation period the voltage sensor 106, skew sensor 110, and current sensor 114 are sampled by the sample and hold circuit 120.
The sample and hold circuit 120 is timed synchronously with the exciting alternating current applied to the coils 102 by timing signals from the phase lock loop circuit 122. During this test sequence, 32 samples are taken during one cycle of the alternating current exciting signal, and one set of samples are taken every sixth cycle producing a total of forty sets of data. This data is coupled to the data processor 140 which does the initial processing of the data and couples the results to the control processor 150. The control processor 150 then performs the final processing, calculating resistance, reactance, skew, dissymmetry and skew dissymmetry. These values are displayed on the display 46 and may be printed on the printer 52 in response to commands entered through the keyboard 58. Information to permit statistical analysis over a series of tests is then stored on a Winchester disk 55.
Referring now to FIG. 9, there is shown a detailed diagrammatic view illustrating a specific embodiment of the test fixture structure 22 on which a rotor 60 has been placed in the extended position. During operation, the rotor 60 is retracted to the test position as illustrated in FIG. 10. The test fixture 22 comprises the test head 26 and the retraction and drive mechanism 36. Located coaxially at the center of the center cavity 220 of the test head 26 is a spindle 230 over which the rotor 60 may be placed, as shown.
The spindle 230 comprises a shaft 234 having an upper cylindrical cap 232 with a greater diameter than the shaft 234, and an annular ring 236 at the lower end through which the shaft 230 is slidably positioned, as shown. The annular ring 236 is mounted on a cylindrical mount 238 which is coupled by a spring loaded coupling to a shaft 240. The shaft 240 is slidably mounted in an aperture in the test stand 30 as shown. The shaft 230 is threadedly coupled to the shaft 240 and the shaft 240 is coupled to a drive motor 280 which rotates the rotor 60 when the motor is activated. This shaft-motor assembly is mounted on a bracket 242 which slidably engages a slide shaft 244. The bracket 242 is connected to a shaft 246 of a hydraulic cylinder 250 which is powered by an external source (not shown).
In the extended position, the rotor 60 extends above the test head 26 when the entire retraction and drive mechanism 36 is in its upper-most position as shown in FIG. 9. When activated, the hydraulic cylinder 250 retracts the shaft 246 lowering the retraction and drive mechanism 36 to the position shown in FIG. 10. This lowers the rotor to the retracted position within the central cavity 220 of the test head 26. The rotor is then rotated by the drive motor 180 which is activated when a position sensor (see FIG. 3) detects that the mechanism 36 is in the retracted position.
The rotor 60 is tightly held in position during rotation by a clutch mechanism more readily understood by reference to FIGS. 11-14. FIG. 11 is an expanded view of the top portion of the test fixture 22 in the extended position. The spindle 230, as illustrated in FIG. 11, comprises a set of annular sleeves 252 slidably positioned around a shaft 234, as shown. Between each sleeve 252 is an o-ring 254. These elements are held in place by the annular ring 236 and the cap 232. In the extended position, the o-rings are not compressed, and therefore do not extend in the radial direction beyond the edges of the annular sleeves 252, as illustrated in FIG. 12. Thus, the rotor 60 can easily slide over the spindle 230. However, when in the retracted position, as illustrated in FIG. 13, the annular ring 236 is pushed up against the annular sleeves 252 due to the movement of the shaft 234 downward. This compresses the o-rings 254 causing them to extend radially beyond the edge of the annular sleeves 252 contacting the inner surface of the rotor center cavity as illustrated by FIG. 14. As a result, the rotor 60 is securely held in place by the frictional force exerted on the rotor 60 by the extended o-rings 254. Thus, the rotor can be easily mounted on the spindle 230 when in the extended position but the rotor is securely held when in the retracted position.
Preferred embodiments of the novel method and apparatus for testing dynamoelectric machine rotors have been described for the purpose of illustrating the manner in which the invention may be made and used. It should be understood, however, that implementation of other variations and modifications of the invention in its various aspects will be apparent to those skilled in the art, and that the invention is not limited by the specific embodiments described. It is therefore contemplated to cover any and all modifications, variations or equivalents that fall within the true spirit and scope of the basic underlying principles disclosed and claimed herein.
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A method and apparatus for testing dynamoelectric machine rotors, particularly squirrel cage rotors for induction motors, to obtain resistance, reactance, and effective skew values to permit identification of rotor defects. The rotor is rotated in an alternating magnetic field and pick-up coils are used to sense the voltage generated in the rotor by sensing the magnetic flux generated by magnetization of the rotor during rotation. Current sensing is used to determine the current used in magnetizing the rotor and a separate skew pick-up coil is utilized to detect effective electrical skew. These signals are processed to determine whether the rotor meets predetermined pass/fail criteria, to provide detailed statistical data and to generate a failure indication responsive to one of the values falling outside respective predetermined limits.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional Patent Application No. 62/142,276, filed Apr. 2, 2015, which is incorporated by reference into the present application.
TECHNICAL FIELD
[0002] The present invention relates to the field of lock devices, and more particularly to magnetic lock devices.
BACKGROUND
[0003] Usually, cylinder locks require the use of a bitted key adapted to push pins when the key is inserted within the cylinder in order to line the pins up to a shear line and allow the core of the cylinder to rotate freely. Such cylinder locks may be vulnerable to many forms of vandalism, attacks, and/or lock picking, such as the insertion of glue or other contaminants, or the use of lock picking tools to determine when the pins are in an unlocked position.
[0004] In order to overcome the vulnerability of such cylinder locks, a protective device may be used. For example, such a magnetic protective device may comprise a sliding plate to cover the cylinder lock completely and a magnetic key to unlock the protective cover. However, such a protective device requires the user to carry the magnetic key for locking/unlocking the protective device and accessing the cylinder lock in addition to the key for locking/unlocking the cylinder lock.
[0005] Therefore, there is a need for an improved lock system.
SUMMARY
[0006] In accordance with a first broad aspect, there is provided a lock device comprising: a lock frame extending along a longitudinal axis, defining a cavity, and having at least one frame recess on an internal wall thereof; a lock body having a longitudinal wall extending along the longitudinal axis and a key-receiving face, the lock body defining a chamber and the longitudinal wall comprising at least one aperture therethrough, each one of the at least one aperture facing a respective one of the at least one frame recess, the lock body being moveable within the cavity of the lock frame between a first body position and an second body position; a translation pin movably inserted within the chamber; at least one active pin each positioned within a respective aperture of the lock body and movable between an insertion position in which the active pin abuts against a respective frame recess of the lock frame and prevent the lock body from moving within the cavity, and a retracted position in which the active pin is away from the frame recess and allows the lock body to move within the cavity; at least one magnetic body each positioned within the chamber of the lock body and movable between a first pin position in which the translation pin is prevented from moving and a second pin position in which the translation pin is allowed to move; and an actuator body secured to the lock body to move from a locked position when the lock body is in the first body position and an unlocked position when the lock body is in the second body position, wherein upon positioning a magnetic key adjacent to the key-receiving face, the at least one magnetic body moves from the first pin position to the second pin position to allow the translation pin to move within the chamber and upon rotating the magnetic key, the active pins move from the insertion position to the retracted position, thereby allowing the lock body to move from the first body position to the second body position and the actuator to move from the locked position to the unlocked position.
[0007] In one embodiment, the lock body is slidable within the lock frame.
[0008] In another embodiment, the lock body is rotatable within the lock frame.
[0009] In one embodiment, the lock frame and the lock body each have a cylindrical shape.
[0010] In one embodiment, the at least one frame recess each have a semi-cylindrical shape.
[0011] In one embodiment, the at least one magnetic body are each rotatably secured to the lock body, the first and second body positions corresponding to a first angular position and a second angular position, respectively.
[0012] In one embodiment, the at least one magnetic body each comprise a non-magnetic cylinder rotatably secured to the lock body and the lock frame.
[0013] In one embodiment, the at least one magnetic body comprises a magnet-receiving recess and a magnet secured therein.
[0014] In one embodiment, the non-magnetic cylinder comprises two conical ends, a first one of the two conical ends being received in a first conical recess within the lock frame and a second one of the two conical ends being received in a second conical recess within the lock body for rotatably securing the non-magnetic cylinder to the lock body and the lock frame.
[0015] In one embodiment, the non-magnetic cylinder comprises a recess on an external face for receiving at least a section of the translation pin thereon.
[0016] In one embodiment, the lock device further comprises a thread extending circumferentially along a section of the lock frame.
[0017] In one embodiment, the at least one frame recess comprise two frame recesses each corresponding to a respective one of the locked and unlocked positions.
[0018] In one embodiment, the at least one active pin are each provided with rounded ends.
[0019] In one embodiment, the actuator body comprises a cam.
[0020] According to another aspect, there is provided a lock system comprising the lock device and a magnetic key.
[0021] In one embodiment, the magnetic key comprises at least one key magnet each positioned within the magnetic key so as to substantially face a respective one of the at least one magnetic body when the magnetic key is positioned adjacent to the key-receiving face.
[0022] In one embodiment, the magnetic key and the key-receiving face of the lock body are so that a motion of the magnetic key triggers a motion of the lock body within the lock frame.
BRIEF DESCRIPTION OF THE FIGURES
[0023] Further features and advantages of the present invention will become apparent from the following detailed description, taken in combination with the appended drawings, in which:
[0024] FIG. 1 is a perspective view of a lock system comprising a magnetic cylinder lock and a magnetic key and operating in rotation, in accordance with an embodiment;
[0025] FIG. 2 is an exploded view of the magnetic cylinder lock of FIG. 1 , the magnetic cylinder lock comprising at least a cylinder frame, a cylinder body, magnetic bodies, and a cylinder cap, in accordance with an embodiment;
[0026] FIG. 3 is a top view of the cylinder frame of FIG. 2 ;
[0027] FIG. 4 is a cross-sectional view of the magnetic cylinder lock of FIG. 2 in a locked position, in accordance with an embodiment;
[0028] FIG. 5 is a cross-sectional view of the cylinder cap of FIG. 2 , in accordance with an embodiment;
[0029] FIG. 6 is a cross-sectional view of the magnetic cylinder lock of FIG. 2 in an unlocked position, in accordance with an embodiment;
[0030] FIG. 7 is a perspective view of one of the magnetic bodies of FIG. 2 , in accordance with an embodiment;
[0031] FIG. 8 is a front view of the magnetic body of FIG. 7 ;
[0032] FIG. 9 illustrates the relative positioning between magnetic bodies of FIG. 2 when the magnetic cylinder lock is in a locked position;
[0033] FIG. 10 is a perspective view of the magnetic key of FIG. 1 , in accordance with an embodiment;
[0034] FIG. 11 is an exploded view of the magnetic key of FIG. 10 ;
[0035] FIG. 12 illustrates the relative positioning of magnets within the magnetic key of FIG. 10 ;
[0036] FIG. 13 illustrates the relative positioning between magnetic bodies of FIG. 2 when the magnetic cylinder lock is in an unlocked position, in accordance with an embodiment;
[0037] FIG. 14 illustrates a magnetic operating in translation when in a first locked position, in accordance with an embodiment; and
[0038] FIG. 15 illustrates the magnetic lock of FIG. 14 when in a second locked position.
[0039] It will be noted that throughout the appended drawings, like features are identified by like reference numerals.
DETAILED DESCRIPTION
[0040] FIG. 1 illustrates one embodiment of a magnetic lock system 10 comprising a magnetic lock device or lock 12 and a magnetic key 14 for locking and unlocking the magnetic lock device 12 . The lock device 12 is securable to an element or object to be locked/unlocked such as a door, a cabinet, or the like. By abutting the magnetic key 14 on the magnetic lock device 12 and rotating the magnetic key 14 according to a respective rotation direction, the magnetic lock device 12 may be locked or unlocked.
[0041] FIG. 2 presents an exploded view of the magnetic lock device 12 which comprises at least a tubular cylinder frame 20 , a cylinder body 22 , a cylinder cap 24 , three magnetic bodies 26 , and a cam 28 .
[0042] The tubular frame 20 extends along a longitudinal axis between a first end 30 and a second end 32 and defines a cylindrical internal cavity 34 which also extends between the first and second ends 30 and 32 . The external longitudinal face 36 that extends between the first and second ends 30 and 32 comprises two threaded sections 38 and 40 spaced apart by two non-threaded sections. The tubular frame 20 further comprises a rim 42 that extends outwardly and radially from the second end 32 . The tubular frame 20 is adapted to be inserted into a hole present in the element to be locked/unlocked, such as a door or a cabinet, until the rim 42 abuts the surface of the element to be locked/unlocked. The two planar sections located between the threaded sections 38 and 40 are used for adequately orienting the tubular frame 20 relative to the element to which it is to be secured. A nut is then screwed on the tubular frame 20 for securing the tubular frame 20 to the element. In one embodiment, the two planar sections may be omitted so that a single threaded section extends around the circumference of the tubular frame 20 .
[0043] As illustrated in FIG. 3 , the internal wall 44 of the internal cavity 34 of the tubular frame 20 is provided with four recesses 46 which are located at four different angular positions along the perimeter of the wall 44 . In the illustrated embodiment, the recesses 46 are positioned at the following angular positions: 0, 90, 180, and 270 degrees. It should be understood that the illustrated angular positions for the recesses 46 are exemplary only and that other configurations are possible. Similarly and as described below, the number of recesses 46 may vary as long as the internal wall 44 comprises at least one recess 46 defining a locking position for the magnetic lock system 10 .
[0044] The cylinder body 22 comprises a tubular section 50 extending between a first end 52 and a second end 54 along the longitudinal axis. A cylindrical section 56 extends outwardly and longitudinally from the second end 54 of the tubular section 50 and a square hollow section 58 extends outwardly and longitudinally from the first end 52 of the tubular section 50 . The wall or face 60 of the cylindrical section 56 that is opposite to the second end 54 of the tubular section 50 comprises three conical recesses 62 .
[0045] As illustrated in FIG. 4 , the cylinder body 22 further defines a cylindrical cavity 64 that longitudinally extends through the tubular section 50 and the square section 58 and partially through the cylindrical section 56 . The face 60 further comprises a hole 66 extending therethrough and emerging in the cavity 64 . In the illustrated embodiment, the hole 66 is centered on the face 60 and the conical recesses 62 are positioned at different angular positions about the central hole 66 .
[0046] It should be noted that in the illustrated embodiment the cylindrical section 56 has an external diameter that is less than that of the tubular section 50 .
[0047] As illustrated in FIG. 5 , the cylinder cap 24 comprises a cylinder section 70 that extends along the longitudinal axis between a first end 72 and a second end 74 . The cylinder section 70 defines a cavity 76 that extends from the first end 72 towards the second end 74 . The cavity 76 comprises a cylindrical cavity section 78 that extends from the first end 72 towards the second end 74 up to a wall 77 , three cylindrical chamber sections 80 that extends from the cylindrical cavity section 78 towards the second end 74 , a central recess section 81 centrally extending from the cylindrical cavity section 78 along a portion of the length of the cylindrical chamber sections 80 , and three conical recesses 82 each extending from a respective cylindrical chamber section 80 towards the second end 74 . The cylindrical cavity section 78 is sized and shaped to receive the cylindrical section 56 of the cylinder body 22 therein. In one embodiment, the diameter of the cylindrical section 56 substantially correspond to that of the cylindrical cavity section 78 so that the cylindrical section 56 be snuggingly received in the cylindrical cavity section 78 . The three cylindrical chamber sections 80 are positioned about the central recess section 81 and they are connected with the central recess section 81 to form a single cavity.
[0048] The cylinder cap 24 further comprises a rim 84 that extends radially and outwardly from the second end 74 of the cylinder section 70 . A key-receiving recess 86 also extends from the second end 74 of the cylinder cap 24 towards the first end 72 . It should be noted that the key-receiving recess 86 is shaped and sized for receiving the magnetic key 14 .
[0049] Referring back to FIG. 2 , the cylinder lock device 12 further comprises three magnetic bodies 26 which each include a respective cylindrical disk 90 and a respective magnet 92 . Each cylindrical disk 90 extends along the longitudinal axis between a first end 94 and a second end 96 as illustrated in FIGS. 7 and 8 . A first conical protrusion 98 extends outwardly from the first end 94 and a second conical protrusion 100 extends outwardly from the second end 96 . The first conical protrusion 98 of each cylindrical disk 90 is shaped and sized to be received within a respective conical recess 62 of the tubular section 50 . The second conical protrusion 100 of the each cylindrical disk 90 is shaped and sized to be received within a respective conical recess 82 of the cylinder cap 24 . Furthermore, each cylindrical disk 90 is sized and shaped to be received in a respective cylindrical chamber section 80 of the cylinder cap 24 .
[0050] Each cylindrical disk 90 is further provided with a magnet-receiving hole 102 sized and shaped to receive a respective magnet 92 . In the illustrated embodiment, both the magnet 92 and the magnet-receiving hole 102 have a cylindrical shape. The person skilled in the art will understand that other shapes for the magnet 92 and the magnet-receiving hole 102 are possible as long as the magnet 92 may be received within the magnet-receiving hole 102 . Each cylindrical disk 90 is further provided with a semi-cylindrical recess 104 that extends from the first end towards the second end 96 and from the longitudinal wall 106 of the cylindrical disk 90 .
[0051] Referring back to FIG. 2 , the cylinder lock device 12 further comprises two active pins 110 . Each active pin 110 is made of a cylinder provided with rounded ends. The longitudinal wall of the tubular section 50 of the cylinder body 22 comprises two holes 112 extending therethrough and each hole 112 is adapted to receive a respective active pin 110 . Each hole 112 is sized and shaped to slidably receive a respective active pin 110 therein. The position of the holes 112 along the length of the tubular section 50 is chosen so that the holes 112 may face a respective recess 46 on the internal wall 44 of the tubular frame 20 when the cylinder body 22 is inserted into the cavity 34 of the cylinder frame 20 .
[0052] The cylinder lock device 12 also comprises a translation pin 120 that includes a cylindrical portion 122 extending along the longitudinal axis between a first end 124 and a second end 126 , and a head section 128 protruding from the second end 126 . The head section 128 has a hemi-spherical shape of which the diameter is greater than that of the cylindrical portion 122 . It should be understood that the head section 128 may be provided with a shape other than a hemi-spherical shape. For example, the head section 122 may be provided with a conical shape, a pyramidal shape, or the like. Similarly, while the present description refers to a pin portion 122 having a cylindrical shape, it should be understood that the portion 122 may have another shape such as a square cross-sectional shape, a rectangular cross-sectional shape, etc.
[0053] The head section 128 is sized and shaped so as to be translationally received within the cavity 64 of the tubular section 50 while the end 124 of the translation pin 120 is sized and shaped to be translationally received within the hole 66 of the cylindrical section 56 . In one embodiment, the curvature of the end 124 is substantially equal to the curvature of the semi-cylindrical recess 104 .
[0054] In one embodiment, a spring 130 is also provided to be positioned about the cylindrical portion 122 of the translation pin 120 .
[0055] When assembling the cylinder lock device 12 , a magnet 92 is inserted into the magnet-receiving hole 102 of each cylindrical disk 90 , thereby forming the magnetic bodies 26 . It should be understood that adhesive may be used to fixedly secure the magnets 92 in their respective magnet-receiving hole 102 . Then the magnetic bodies 26 are each inserted into a respective cylindrical chamber section 80 of the cylinder cap 24 so that the conical protrusion 100 be received into a respective recess 82 of the cylinder cap 24 .
[0056] Then the cylindrical section 56 of the cylinder body 22 is inserted into the cylindrical cavity section 78 of the cylinder cap 24 so that the conical protrusion 98 of each magnetic body 26 be received into a respective conical recesses 62 of the cylindrical section 56 . The cylinder cap 24 is then secured to the cylinder body 22 using a securing pin 140 which is inserted through a hole 142 present in the longitudinal wall of the cylinder section 70 and through a hole 144 present in the external wall of the cylindrical section 56 . While the present description refers to the use of a securing pin 140 for securing together the cylinder cap 24 and the cylinder body 22 , the person skilled in the art will understand that other securing means may be used. For example, a screw may be used. In another embodiment, the holes 142 and 144 may be omitted and an adhesive may be used to secure together the cylinder cap 24 and the cylinder body 22 .
[0057] Once the cylindrical section 56 is inserted into the cylindrical cavity section 78 , the magnetic bodies 26 may each rotate within their respective chamber section 80 . Since the magnets 92 of the magnetic bodies 26 attract one another, the magnetic bodies 26 rotate within their respective chamber section 80 under the attraction force generated between the magnets 92 . The magnetic bodies 26 are then positioned in an inactive position, as illustrated in FIG. 4 . For at least one given magnetic body 26 , the relative position between the recess 104 and the hole 102 is chosen so that the recess 104 does not face the center of the cylindrical cavity section 78 when the magnetic bodies are in the inactive position. As a result, the end face 94 of the given magnetic body 26 obstructs at least partially the hole 66 present in the face 60 of the cylindrical section 56 when the magnetic bodies 26 are in the inactive position.
[0058] Once the cylinder cap 24 and the cylinder body 22 are secured together, the spring 130 is positioned about the cylindrical portion 122 of the translation pin 120 and the translation pin 120 is inserted into the cavity 64 of the cylinder body 22 so that the end 124 of the translation pin 120 faces the hole 66 of the cylindrical section 56 . The active pins 110 are inserted into their respective hole 112 so that they emerge within the cavity 64 of the cylinder body 22 and that the head section 128 of the translation pin 120 be located between the portion of the active pins emerging within the cavity 64 and the cylindrical section 56 .
[0059] The assembly comprising the cylinder body 22 having the cylinder cap 24 secured thereto, having the active pins 110 inserted into their respective hole 112 , and having the translation pin 120 inserted into the cavity 64 is inserted into the tubular frame 20 until the rim 84 of the cylinder cap 24 abuts against the rim 42 of the tubular frame 20 . The assembly is then rotated until the holes 112 of the tubular section 50 each face a respective recess 46 present on the internal face of the tubular frame 20 . Since it is positioned in compression, the spring 130 exerts a pressure force on the head section 128 of the translation pin 120 which in turn exerts a force on the active pins 110 . As a result of the force exerted by the head section 128 , the active pins 110 each translate within their respective hole 112 and their respective recess 46 until their rounded end abuts the internal wall 44 of the cylinder frame 20 within the recess 46 . The tubular section 50 , and therefore the assembly are then prevented from rotating within the cavity 34 of the cylinder frame 20 .
[0060] The cam 28 is then secured to the square section 58 of the cylinder body 22 . The cam 28 is provided with a square aperture 150 being sized and shaped to snuggingly receive the square section 58 . The square section 58 is then inserted into the square aperture 150 of the cam 28 and a securing means such as bolt 152 is used to fixedly secure the cam 28 to the cylinder body 22 so that a rotation of the cylinder body 22 within the cylinder frame 20 triggers a rotation of the cam 28 . The bolt 152 may be screwed within the cavity 64 of the cylinder body 22 . It should be understood that any adequate method for fixedly securing the cam 28 to the cylinder body 22 may be used. For example, adhesive may be used for fixedly securing the cam 28 to the cylinder body 22 . While the present description refers to a square shape for the section 56 and the aperture 150 , it should be understood that other shapes may be envisioned as long as the section 56 fits into the aperture 150 and a rotation of the section 56 triggers a rotation of the cam 28 . For example, the section 56 and the aperture 150 may each have a triangular shape.
[0061] In one embodiment, a stop plate 154 is inserted between the cam 28 and the cylindrical section 50 . As known in the art, the stop plate 154 is adapted to limit the rotation of the cylinder body 22 to a desired angle such as 90 degrees or 180 degrees.
[0062] As described above, the lock system 10 further comprises a magnetic key 14 which is illustrated in FIGS. 10-12 .
[0063] The magnetic key 14 comprises three key magnets each corresponding to a respective magnet 92 of a corresponding magnetic body 26 . When the key 14 is positioned within the key-receiving recess 86 , each key magnet attracts its corresponding magnet 92 . The position of each key magnet within the key 14 is chosen as a function of the relative position between the hole 102 and the recess 104 of its respective magnetic body 26 so that, when the key 14 is received within the key-receiving recess 86 , each key magnet attracts its respective magnet 92 and rotates its respective magnetic body 26 up to an active position. FIG. 13 illustrates the magnetic bodies 26 positioned in the active position when the magnetic key 14 is positioned in the key-receiving recess of the cylinder cap 24 .
[0064] In one embodiment, the key 14 comprises a finger-receiving portion 160 which allows a user to hold the key 14 , and a lock-abutting portion 162 adapted to be inserted into the key-receiving recess 86 . In one embodiment, the lock-abutting 162 comprises a plate 164 insertable into a recess located (not shown) in the finger-receiving portion 160 . The plate 164 comprises three insert-receiving recesses 166 each for receiving a respective insert plate 168 . Each insert plate is provided with a magnet-receiving recess 172 for receiving a respective key magnet 170 .
[0065] The position of the insert-receiving recesses 166 within the plate 164 and the position of the magnet-receiving recesses 172 within the insert-receiving recesses 166 are chosen so that each magnet key 170 attracts its respective magnet 92 and rotates its respective magnetic body 26 up to an active position.
[0066] In one embodiment, the magnetic key 14 and/or the cylinder cap 24 is adapted to adequately orient the key 14 so that each key magnet be adequately positioned relative to its corresponding magnetic body 26 when the key 14 is inserted into the key-receiving recess 86 . For example, the key 14 and the cylinder cap 24 may each be provided with a respective reference mark and the magnetic key is inserted into the key-receiving recess so that the two reference marks face one another. In another example, the magnetic key may be provided with a recess or a notch and the cylinder cap 24 may be provided with a corresponding protrusion adapted to fit into the notch. In this case, the magnetic key 14 is positioned within the key-receiving recess 86 so that the protrusion of the cylinder cap 24 be inserted into the notch of the key 14 in order to adequately position the key magnet relative to their respective magnetic body 26 . In a further example, the magnetic key 24 and the key-receiving recess 86 may be provided with a matching asymmetric shape such as a scalenus triangular shape in order to adequately position the key magnet relative to their respective magnetic body 26 when the magnetic key 14 is inserted into the key-receiving recess 86 .
[0067] Referring back to FIG. 4 , the magnetic key 14 is away from the key-receiving recess 86 and the magnetic bodies 26 are in the inactive position. When the magnetic bodies 26 are in the inactive position, at least one magnetic body 26 obstructs the aperture 66 of the cylindrical section 56 , thereby preventing the translation pin 120 from entering into the cylindrical cavity section 78 , as illustrated in FIG. 9 . The compression spring 130 exerts a compression force on the head section 128 of the translation pin 120 which in turn maintains the active pins 110 into their respective recess 46 . The cam 28 is then prevented from any rotation and is in a first position, e.g. the locked position.
[0068] If a user tries to rotate the cylinder cap 24 without inserting the magnetic key 14 within the key-receiving recess 86 , the magnetic bodies which obstruct the aperture 66 prevent the translation pin 120 from entering into the cylindrical cavity section 78 . Since the translation pin 120 cannot translate into the cylindrical cavity section 78 , the head section 128 of the translation pin 120 prevents any translation of active pins 110 towards the center of the cavity 64 and the active pins 110 remain positioned within their respective recess 46 , thereby preventing any rotation of the cylinder body 22 within the cavity 34 of the cylinder frame 20 .
[0069] When the magnetic key 14 is inserted into the key-receiving recess 86 , the key magnets each attract their respective magnet 92 . The magnetic attraction force between the key magnets and their respective magnet 92 triggers a rotation of the respective magnetic bodies 26 and brings the magnetic bodies 26 in the active position. When the magnetic bodies 26 are positioned in the active position, the recesses 104 of the magnetic bodies 26 each face the central recess section 81 and form together with the central recess section 81 a pin-receiving cavity 180 sized and shaped to receive the end 120 of the translation pin 120 , as illustrated in FIGS. 6 and 13 .
[0070] A rotation of the magnetic key 14 triggers a rotation of the cylinder body 22 relative to the cylinder frame 20 since the cylinder body and the cylinder cap 24 are fixedly secured together. The rotation of the cylinder body 22 relative to the cylinder frame 20 creates a translation force exerted by each recess 46 on its respective active pin 110 . As a result of the translation force, the active pins translate within their respective hole 112 towards the center of the cavity 64 and exert a force on the head section 128 of the translation pin 120 . As a result of the force exerted on the head section 128 by the active pins 110 , the spring 130 is compressed and the translation pin 120 translate towards the cylinder cap 24 so that its end 124 enters the cavity formed by the recesses 104 . The cylinder body 22 may then freely rotate within the cylinder frame 20 .
[0071] In one embodiment, the magnetic key 14 is rotated until each hole 112 faces another recess 46 . When the holes 112 face their respective other recess 46 and the rotation of the magnetic key is stopped, the compression force exerted by the spring 130 on the head section 128 of the translation pin 120 pushes the active pins 110 into their respective other recess 46 , thereby preventing a rotation of the cylinder body 22 within the cylinder frame 20 . The cam 28 is then in a second position, e.g. the unlocked position.
[0072] The cam 28 may be brought back in the first position by rotating the magnetic key in the opposite direction until the holes 112 face the next recess 46 and the spring 130 pushes the active pins 110 in their respective next recess 46 .
[0073] While the present description refers to a frame 20 having a tubular shape, it should be understood the frame 20 may have a shape other than tubular as long as it comprises the cylindrical cavity 34 in which the cylinder body 22 may rotate.
[0074] It should be understood that the number of active pins 110 and the number of holes 112 may vary as long as the magnetic lock device 12 comprises at least one active pin 110 and at least one hole 112 .
[0075] Similarly the number of recess 46 may vary as long as the magnetic lock device 12 comprises at least one recess 46 for each active pin 110 .
[0076] While the active pins 110 have rounded ends, it should be understood the shape of the ends of the active pins may vary. For example, the ends of the active pins 110 may be provided with a conical shape. In another embodiment, they may be flat.
[0077] While they have a hemi-spherical shape, it should be understood that the recesses 46 may be provided with any other adequate shape as long as the walls of the recesses 46 are inclined so as to allow the active pins to slide thereon.
[0078] While the present description refers to the protrusions 100 and 98 for the cylindrical bodies 90 and to corresponding recesses 62 and 82 to allow the rotation of the cylindrical bodies, it should be understood that any adequate rotatable connection may be used. For example, the cylindrical bodies may be rotatably secured to the cylinder body 22 and/or the cylinder cap 24 via a rotation shaft.
[0079] While the present description refers to recesses 104 having the shape of a portion of cylinder, it should be understood that the recesses 104 may be provided with any adequate shape as long as the cavity that they form in connection with the central recess 81 is shaped and sized to receive the translation pin 120 .
[0080] The relative position between the recess 104 and the magnet 92 for each magnetic body 26 and/or the relative position between each key magnet and its respective magnetic body 26 may be varied to create multiple locking combinations. It should be understood that the position of the key magnets 170 within the magnetic key 14 is then chosen as a function of the position of the magnets 92 . It should also be understood that the orientation of the magnets 92 and therefore that of the key magnets 170 may be varied to increase the number of possible locking combinations. It should further be understood that the key magnets 170 have a magnetic force that is adapted to attract their respective magnet 92 and rotate their respective magnetic body 26 .
[0081] The person skilled in the art will understand that the number of magnetic bodies 26 may vary as long as the magnetic lock device 12 comprises at least one magnetic body 26 . Increasing the number of magnetic body 26 allows increasing the number of possible locking combinations.
[0082] In an embodiment in which the magnetic lock device 12 comprises a single magnetic body 26 , the cylinder cap 26 may comprise a reference magnet or a piece of ferrous material for attracting the magnet 92 when the magnetic key 14 is away from the cylinder cap 24 and rotating the magnetic body 26 in the inactive position.
[0083] While the cylindrical bodies 90 are rotatable in the illustrated embodiment, the person skilled in the art will understand that the cylindrical bodies 90 may be slidably secured within the cylinder cap 24 . For example, they may slide along a radial direction to allow movement of the translation pin 120 . In another example, they may slide along the longitudinal axis to allow movement of the translation pin 120 .
[0084] In one embodiment, the cam 28 may be replaced by an electrical conductor element adapted to create an electrical contact between electrical terminals of an electric circuit in order to close the electrical circuit. In this case, the lock is a switch lock.
[0085] It should be understood that the recess 86 may be omitted. For example, the end 74 of the cylinder section 70 may have a knob shape comprising a substantially flat portion for receiving the magnetic key.
[0086] While the present description refers to the cylinder body 22 and the cylinder cap 24 as being separate pieces, the person skilled in the art would understand that the cylinder body 22 and the cylinder cap 24 may be integral together to form a single piece.
[0087] While in the above-illustrated embodiment, the magnetic lock device 12 operates in rotation, the person skilled in the art will understand that the magnetic lock device may operate in translation, i.e. the cylinder body translates with respect to the cylinder frame. In this case, the cylinder cap 24 is pushed or pulled instead of being rotated once the magnetic key 14 has been inserted into the key-receiving recess 86 .
[0088] FIG. 14 illustrates one embodiment of a lock device 200 that operates in translation. The lock device 200 comprises a frame 202 , a lock body 204 which is slidably inserted into the frame 202 , and a lock cap 206 . The lock body 204 is similar to the cylinder body 22 and comprises holes for receiving active pins 110 and a cavity for receiving a translation pin 120 . A locking bolt 208 is secured to the lock body 204 instead of the cam 28 . The lock cap 206 is similar to the cylinder cap 24 and comprises a cavity for rotatably receive three cylindrical disk 90 which are rotatably secured to the lock body 204 and the lock cap 206 . The lock cap 206 comprises a key receiving face 210 on which a magnetic key such as key 14 is abutted for unlocking the lock device 200 . For each active pin 110 , the internal face of the frame 202 comprises a first pin-receiving recess 212 and a second pin-receiving recess 214 . The pin-receiving recesses 212 and 214 are located at the same angular position but at different positions along the length of the internal face of the frame 202 .
[0089] The lock device 200 illustrated at FIG. 14 is in a first locked position. In this position, the translation pin 120 exerts a pressure force on the active pins 110 which abut in their respective pin-receiving recess 214 , thereby preventing any translation of the lock body 204 within the frame 202 .
[0090] By abutting the magnetic key 14 on the face 210 of the lock cap 206 , the cylindrical bodies 90 rotate and create a cavity adapted to receive the end of the translation pin 120 . When a translation force is exerted on the lock cap 206 while the magnetic key is in physical contact with or is adjacent to the face 210 , the active pins 110 translate towards the center of the lock body 204 and exert a force of the translation pin 120 . As a result of this force, the translation pin 120 translate toward the lock cap 206 and the end of the translation pin 120 enters the cavity created by the alignment of the cylindrical bodies 90 , thereby allowing the active pins 110 to further move toward the center of the lock body 204 and the lock body 204 to move within the frame 202 . During the movement of the lock body 204 within the frame 202 , the spring 130 exerts a force on translation pin 120 which in turn exerts a force on the active pins 110 so that the active pins 110 are in physical contact with the internal wall of the frame 202 and slide thereon.
[0091] When they each face a respective first recess 212 , the active pins 110 enter their respective first recess 212 due to the force exerted by the spring 130 and the translation of the lock body 204 is then stopped. The lock device 200 is then in a second locked position. The translation of the lock body 204 from the first locked position to the second locked position allows moving the locking bolt from a first position to a second position. The locking bolt may be used as a switch for closing an electrical circuit for example.
[0092] It should be understood that the recesses 212 may be omitted. Similarly, one of the recesses 214 and one of the active pins 110 may be omitted
[0093] It should be understood that the above described cylinder lock device may be used as an actuator for different types of locking devices such as a cam lock, a door lock, a gate, a safe cabinet, a locker, or the like.
[0094] In one embodiment, an aim of the present cylinder lock system is to solve the double-layered protection system which requires carrying more keys, and furthermore to provide a solution that eliminates direct contact with the locking mechanism, such that a thief may not feel or listen his way around the locking pins, allowing him/her to achieve the unlocking of the cylinder.
[0095] Another object of the present cylinder lock system is to make picking of the lock extremely difficult even for an expert picker, and resistant to all existing picking methods.
[0096] Another goal is to provide a cylinder lock system that can be applied to common locks of the known type by making the new cylinder of a standard size, while maintaining enough locking combinations for each different application.
[0097] In one embodiment, the present cylinder lock system aims to provide a solution that is structurally simple and has relatively low manufacturing costs in order to make it affordable to end-users.
[0098] The embodiments of the invention described above are intended to be exemplary only. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.
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A lock device comprising: a lock frame defining a cavity and having at least one frame recess; a lock body having a key-receiving face and defining a chamber and the longitudinal wall comprising at least one aperture therethrough emerging in the chamber, each one of the at least one aperture facing a respective one of the at least one frame recess, the lock body being moveable within the cavity of the lock frame; a translation pin movably inserted within the chamber; an active pin positioned within an aperture of the lock body and movable between an insertion position and a retracted position; a moveable magnetic body positioned within the chamber to sequentially prevent and allow motion of the translation pin; and an actuator body movable between a locked position and an unlocked position.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a stator for an impact crusher for separation of compound materials, with an outer face of the casing wall and an inner face of the casing wall, which is plated with a plurality of plates with ribs, wherein the plates are designed as wear parts and are attached replaceably.
[0003] 2. Discussion of Related Art
[0004] Impact crushers are used in a variety of different technical fields, but herein only the use regarding the separation of compound materials is of interest. Such compound materials can be compounds of metal/metal, plastic/plastic, metal/plastic or mineral compounds with metals and/or plastics. Because the physical properties of the individual components of the compounds are different, such compound particles are separated in impact crushers and with each impulse different materials deform unequally elastically and unequally plastically and thereby separate. Typical compound materials, which are processed by the applicant are, for example, electronic waste and shredder waste of all kind, in particular from car recycling.
[0005] The use of impact crushers in this area is associated with enormous wear of the hammer tools as well as of the crusher walls. Accordingly the crusher walls, which are the inner casing wall of respective stators of such impact crushers, are plated with replaceable plates, which comprise ribs, on which particles of the compound materials to be delaminated impinge with high energy. As soon as the ribs are reduced to a certain minimum due to respective wear, the plates have to be replaced. Typically, such plates are made from steel plates and the ribs are formed by slotting machines or by milling. The back side of such plates are fitted to the actual casing wall of the stator.
[0006] From Great Britain Patent Reference GB-A-1397674 an impact crusher is known, the stator of which comprises a carrier plate on which a plurality of rib-shaped projections are welded, between which hammer tools are rotating pivotably supported on a rotor. The respective plate is attached to hydraulic-slide elements in order to adjust the plate according to the wear. After wearout of the projections, the entire adjustable base plate has to be replaced accordingly. This requires a relatively complex disassembly.
[0007] From PCT Patent Reference WO 00/53324 (BHS Sonthofen) another impact crusher is known, which represents the closest prior art. This stator of an impact mill serves for separation of compound materials and comprises an outer face of the casing wall as well as an inner face of the casing wall, which is plated with a plurality of plates with ribs, wherein the plates are designed as wear parts and are attached replaceably. This known solution intends to simply hook-in the plates tile-like at the upper edge of the stator casing wall. Accordingly, the plates have a continuous longitudinal rib with a hook-shaped cross section extending on the upper edge portion. This longitudinal rib engages in a ring groove formed on the stator wall. Along the periphery of the stator a plurality of such plates are hooked-in. The plates, which have a relatively high weight, are kept in position solely by gravity and are positioned abutting each other relatively tight. Normally, such plates are easy to replace but the mounting of these plates carries a potentially high risk. The peripheral speed in such impact crushers can be up to several hundreds km/h, which represents a high potential energy. If bigger parts get into the impact crusher, which accordingly are hard, because the shredder could not crush them, then these parts can be wedged in between the rotor and the stator. Although the hammer tools are typically supported pivotably, instantaneous acceleration forces occur, which can result in displacing of the plates or even in unhooking. After such an event a complete revision of the impact crusher is necessary.
SUMMARY OF THE INVENTION
[0008] It is one object of this invention to provide a stator of an impact crusher for separation of compound materials with a considerably higher safety, wherein at the same time the plates, which are wear parts, can be produced inexpensively.
[0009] This object can be achieved if the plates are metal cast plates having at least one transverse threaded bore and that the outer casing wall of the stator has passages, through which the fixing bolts with threads fitting into the threaded bore of the plates can be passed through and are visible from outside of the stator.
[0010] This unique mounting method is based on the consideration that inside the impact crusher an extremely high contamination occurs and thus a principally logical and easy screwing from inside is basically not realized.
[0011] The use of plates which are designed as metal cast plates is in particular inexpensive, but the precision of the cast results in an increase of the manufacturing cost. In order to be able to work with a decreased relative accuracy it is advantageous to provide the base of the plates with supporting strips projecting slightly from the base in order to qualify the supporting accuracy.
[0012] In order to achieve the required strength also with casted plates, such plates are provided advantageously with the features described in this specification and in the claims.
[0013] Further advantageous embodiments of the subject matter of this invention are discussed in this specification and in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The drawings show a preferred embodiment of this invention, wherein:
[0015] FIG. 1 shows a stator of an impact crusher according to this invention, in a perspective view;
[0016] FIG. 2 shows a plate for encasement of an inner face of the casing wall with respective fasteners on its own, in a perspective view;
[0017] FIG. 3 shows a mat suitable for attachment between a plate and the inner wall face of the stator, in a plan view;
[0018] FIG. 4 shows the same mat but in a side view;
[0019] FIG. 5 shows a single plate on its own, in a perspective view; and
[0020] FIG. 6 shows the same plate together with the fasteners, in a perspective exploded view.
DETAILED DESCRIPTION OF THE INVENTION
[0021] In FIG. 1 a general view of the inventive stator of an impact crusher is shown. The stator is denoted in general with element reference numeral 1 and has a casing wall 2 , which has an inner face 3 of the casing wall 2 and an outer face 4 of the casing wall 2 . The upper edge of the casing wall 2 has a circumferential collar 5 for mounting of a cover which is not shown. The lower edge of the casing wall has a mounting flange 7 , with which the stator 1 can be mounted on a chassis, also not shown. The fixing bores 8 in the collar 5 serve for fixation of the mentioned cover, while the fixing bores 9 fix the casing wall 2 of the stator to the chassis. While the material to be delaminated is fed through the cover, which is not shown, into the impact crusher, the delaminated material exits through a material discharge opening 6 in the lower region of the casing wall 2 . In case the impact crusher works in a reverse flow mode, an air flow is blown in through the material discharge opening 6 at the same time. The entire inner face 3 of the casing wall is plated with plates 10 . This view shows that the plates 10 comprise crusher ribs 13 extending parallel to a center axis of the stator as well as reinforcement ribs 17 , which are not as high as the crusher ribs 13 and which are perpendicular to the crusher ribs 13 . With respect to the further design of the plates 10 , reference is made to the further description of the figures.
[0022] FIG. 2 shows the plate 10 and its fasteners in the assembled condition on its own in a perspective view. The plate 10 is also shown on its own in FIG. 5 . The plate 10 comprises a lower base 11 , the thickness of which is relatively small with respect to the total thickness of the plate 10 . The plates 10 are wear parts and accordingly it is desirable that the usage volume is relatively high in relation to the total volume. This is achieved because the crusher ribs 13 in their height form a multiple of the thickness of the lower base 11 . The thickness of the base 11 need only be designed so that its strength is ensured. Also, the thickness of the base 11 is such that the fasteners are sufficiently stabilized in the plates 10 . In one design, reference is made to FIG. 5 .
[0023] In order to design the base 11 optimally thin, reinforcement ribs 17 are provided perpendicular to the longitudinal direction of the crusher ribs 13 . The reinforcement ribs 17 , however, are considerably smaller in their height than the height of the crusher ribs 13 . The crusher ribs 13 , the upper end faces of which define a plane, which represents the work face 12 , have varying extending rib walls. Extending perpendicular to the lower base 11 , first rib walls 14 are shown and on the other side second rib walls 15 extend inclined to the base 11 . The first rib walls extending perpendicular to the base 11 are arranged in the mounted condition so that the particles of compound materials accelerated in the rotational direction impinge on the perpendicular faces 14 . The inclined second rib walls 15 form retaining walls, so to speak, which are not directly subject to wear. The accelerated particles, which are accelerated virtually tangential by the hammer tools at the rotor, virtually impinge only at the outer end of the first rib walls 14 extending perpendicular to the base 11 . Accordingly, the crusher ribs 13 are decreasing in their height due to the abrasion and it is not the crusher ribs 13 that become thinner and thinner, as could be expected. So that the working gap between the hammer tools at the rotor and the crusher ribs 13 at the stator stays within a small tolerance range, the efficiency of the impact crusher is maintained, and the hammer tools at the rotor are attached radially movable outwards.
[0024] The mounting of the plates 10 is achieved with the fixing bolts 20 . Normally, each plate 10 is attached with two fixing bolts. The fixing bolt is in principle cylindrical and only the end has an outside thread tapered in the region of the thread 21 , so that at the transition between the cylindrical portion of the fixing bolt 20 and the threaded portion 21 a shoulder 22 is formed. In the screwed-in condition, the shoulder 22 rests on the lower surface of base 11 . The fixing bolts 20 are inserted through the casing wall 2 of the stator 1 . Accordingly, along the entire periphery of the casing wall 2 respective bores are provided regularly. The fixing bolts 20 have a slotted hole 23 penetrating the bolt diametrically. This slotted hole 23 extending in the longitudinal axis of the fixing bolt 20 is dimensioned so that a respective wedge-shaped cotter 25 is insertable therethrough in a positive and non-positive fit. For each fixing bolt 20 there is an associated spacer ring 24 . The thickness of the spacer rings is selected in a manner that in a correctly mounted condition the wedge-shaped cotter 25 pushed through the slotted hole 23 is pressing on the spacer ring 24 . The obtained contact pressure prevents loosening of the fixing bolts 20 . So that the wedge-shaped cotter 25 cannot fall out of the slotted hole 23 , the wedge-shaped cotter 25 can be secured by a locking pin 29 . The locking pin 29 is pushed through a transverse hole 27 in the cotter. The locking pin 29 itself can, for example, be connected with the spacer ring 24 , which also has a transverse bore 26 , through a connection element 28 . Thus, the locking pin cannot get lost. The connection element 28 can be, for example, a wire or metal wire rope.
[0025] The transverse threaded bore 18 can virtually be seen only in the view according to FIG. 1 . In FIG. 6 , the two bores are only schematically drawn in a dashed line to indicate, where these transverse threaded bores 18 are located.
[0026] Between the base 11 of the plates 10 and the inner face 3 of the casing wall, mats 30 are placed. The mats 30 can, for example, be made of a vulcanized rubber. The mats 30 comprise on a central longitudinal axis as many holes 31 as fixing bolts 20 are penetrating the same. The size of the mats 30 can be equal to the length and width of the base 11 of a plate or to an integer multiple of the edge lengths of the plates 10 . In the illustrated example, the mat 30 in the FIGS. 3 and 4 is designed corresponding to the width of a plate, and its length corresponds to the height of the casing wall 2 of the stator. Also within a stator, plates with different sizes can be used. However, the width of all plates is preferably designed identical, while their length is, for example, designed differently, so that as illustrated here, two or three rows on top of each other are sufficient. While plates with a large length are mounted with two fixing bolts 20 , plates with the half of the length are mounted to the casing wall 2 only with one single fixing bolt. The different plate lengths are required in order to obtain the necessary recess for the material discharge opening 6 without the need for special plates.
[0027] Preferably, the stator has an inner surface with a quadrangle cross section. This allows an at least approximately planar support of the plates 10 . The plates 10 made of steel cast have a planar base 11 . In addition, the plates 10 comprise supporting strips with a relatively small height at the base 11 . The formed supporting strips 16 may not be obligatory but they improve the support on the inner face 3 of the wall casing of the stator 1 because the same can exhibit casting unevenness. The linear support can be realized much simpler than a support with full contact. At the same time, in a preferred embodiment according to this invention, a mat 30 , as mentioned earlier, is placed between the inner face 3 of the casing wall and the base 11 of the plates. The mat not only serves as a compensation to obtain a fairly planar support but also effects at the same time a certain vibration dampening and thereby results in a reduction of sound emission. With the measures the vibrations are also reduced to the point that no loosening of the fixing bolts 20 takes place.
[0028] With the fixing bolts easily accessible from the exterior and their easy locking, the replacement of the plates on the inner face of the casing wall is possible with a considerably shorter downtime of the operation compared to options which provide a different mounting, while at the same time however the safety is very high. For replacement of the plates the cover, not shown here, is removed and thereafter the complete rotor is pulled out so that the plates are freely accessible.
[0029] The use of casted plates, which in principle are wear parts, is considerably less expensive than the previously used options, which are realized on machining centers in conventional mechanical engineering.
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A reliable, inexpensive option for the plates that function as wear parts and are mounted on an inner face of a casting wall of a stator. To achieve this the plates are designed as cast parts and are fixed to the inner face of the casting wall from an exterior of the stator. The plates are fixed by fixing bolts, which are screwed into the plates through the casting wall from the exterior. The plates have transverse threaded bores that correspond to the bolts. Respective spacer rings are pushed onto the fixing bolts secured by wedge-shaped cotters in both a positive and non-positive fit, and the wedge-shaped cotter pressing on the spacer rings that lie against the outer face of the casting wall. This invention is extremely economical and improves the operational safety in comparison to known options.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to decorative pocket handkerchiefs and handkerchief accessories for suit coats, jackets and sport coats, and more particularly, to a pocket handkerchief clip which is spring-biased to receive a folded pocket handkerchief or handkerchief accessory in displayed position at the top of the front coat pocket. The pocket handkerchief clip can be sized to fit substantially any pocket, and in a preferred embodiment, is supported by a lint pad which can be threadably mated with the clip to support the clip in the pocket and provide a means for removing lint from the coat, trousers or other article of clothing, as the need arises. A lint pad handle is also provided as an optional feature for supporting the lint pad, and in a preferred embodiment a thread knife is retractably or slidably mounted in the lint pad to remove loose threads from the jacket or other article of clothing.
2. Description of the Prior Art
Pocket handkerchiefs and other decorative handkerchief pieces or accessories for sport coats, suit coats and jackets are well known in the prior art. Depending upon the particular style in vogue at the time, handkerchiefs are folded in a variety of ways to project either an edge or one or more corners of the handkerchief from the top of the jacket or coat pocket in a decorative manner to enhance the appearance of a jacket, suit coat or sport coat. Thus, handkerchiefs of various size, shape and color, as well as shaped handkerchief accessories are frequently used in such a decorative way, and in some cases the handkerchiefs are simply placed at random in the pocket to project a portion of the handkerchief from the top of the pocket. One of the problems associated with the conventional use of handkerchiefs in such a decorative way in the pockets of jackets, suits and sport coats is the relatively small size of the handkerchief in comparison with the depth of the pocket in which it is placed. For example, if it is desired to project one or more corners of the handkerchief from the top of the pocket, regardless of the care with which the handkerchief is folded to achieve this goal, it sometimes slips down into the pocket and frequently will not stay in position without the assistance of pins or other fastening means. Furthermore, in the case of the shaped handkerchief decoration accessories which are frequently sewn or glued to paper or cardboard supports, the supports usually curl or bend with use, and are rendered unfit to support the projecting accessory, causing the decorative portion of the handkerchief accessory to slide into the pocket.
Consequently, it is very difficult to use a shaped handkerchief accessory or a conventional handkerchief in the pocket of a suit, sport coat or jacket without the necessity of using pins or other fasteners to prevent the projecting area of the handkerchief or shaped accessory from slipping into the pocket.
Accordingly, it is an object of this invention to provide a clip for insertion in the front pocket of a suit coat, jacket or sport coat and engaging and supporting a pocket decoration accessory in order to project a desired portion of the pocket handkerchief or decoration accessory from the top of the pocket as a decorative item.
Another object of the invention is to provide a new and improved spring-biased clip for receiving one edge or a portion of a pocket handkerchief or a pocket decoration accessory and insertion in the pocket of a suit coat, jacket or sport coat to support the handkerchief or accessory, and permit a desired portion of the handkerchief or accessory to project from the top of the pocket.
Still another object of the invention is to provide a pocket handkerchief clip which is characterized by a pair of cooperating frame members which can be opened against a bias by finger pressure to receive a pocket handkerchief or handkerchief accessory piece, and then positioned in the pocket of a jacket, suit coat or sport coat to support the pocket handkerchief or accessory and facilitate projecting a desired portion of the handkerchief or accessory from the pocket as a decorative piece.
Still another object of this invention is to provide a new and improved pocket handkerchief clip which is characterized by a shaped base frame and a cooperating clip frame joined by a length of shaped, tensioned wire to bias a handkerchief or handkerchief decoration accessory between the clip frame and the base frame, and a cooperating lint pad which is removably joined to the base frame to support the base frame when the base frame and the cooperating lint pad are placed in the pocket of a suit coat, jacket or sport coat to support the handkerchief or handkerchief accessory and permit a selected portion of the handkerchief or accessory to project from the top of the pocket as a decorative item to the suit coat, sport coat or jacket.
Yet another object of the invention is to provide a pocket handkerchief clip and lint pad combination for receiving a handkerchief or handkerchief decoration accessory and supporting the handkerchief or accessory in the pocket of a suit coat, jacket or sport coat, which clip is further characterized by a clip frame and a cooperating base frame joined by a tensioned, resilient wire member, and a lint pad which threadably mates with the clip to support the clip in the pocket of a sport coat, suit coat or jacket to facilitate projection of a desired portion of the handkerchief or handkerchief decoration accessory tip from the top of the pocket, the pocket handkerchief clip assembly further comprising a handle for attachment to the lint pad when the lint pad is removed from the clip in order to support the lint pad while the pad is used to remove lint from the clothing and a thread knife in the lint pad for removing loose threads from the clothing.
SUMMARY OF THE INVENTION
These and other objects of the invention are provided in a pocket handkerchief clip for engaging and supporting a folded decorative handkerchief or handkerchief accessory, which clip is characterized by a shaped clip frame and a cooperating base frame joined by a shaped, tensioned wire member to facilitate opening and closing of the clip frame with respect to the base frame by application of finger pressure, and a lint pad in threadable cooperation with the clip in order to support the clip in the pocket of a suit coat, sport coat or jacket to facilitate projection of a desired portion of the handkerchief or accessory tip from the top of the pocket and to prevent the handkerchief or accessory tip from sliding into the pocket responsive to movement of the wearer. In a preferred embodiment of the invention the lint pad contains a thread knife having a point and a blade located on a shank which is retractably or slidably mounted in the pad for removing loose threads from the jacket or coat, or other article of clothing.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be better understood by reference to the accompanying drawing, wherein:
FIG. 1 is a perspective view of a preferred embodiment of the pocket handkerchief of this invention;
FIG. 2 is a side elevation of the pocket handkerchief clip illustrated in FIG. 1, with a lint pad provided in cooperation with the clip;
FIG. 3 is a front elevation, partially in section, illustrating the base frame member of the pocket handkerchief clip, and a preferred technique of mounting the lint pad on the base frame;
FIG. 4 is a perspective view of a preferred lint pad and retractable thread-cutting knife;
FIG. 5 is a side elevation of the knife thread carried by the lint pad;
FIG. 6 is a front elevation, partially in section, of the lint pad and optional carrying handle; and
FIG. 7 is a front elevation, partially in section, of a typical suit coat, sport coat or jacket with a pocket handkerchief clip and lint pad assembly in position supporting a handkerchief or handkerchief decoration accessory.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1-3 of the drawing, in a preferred embodiment, the pocket handkerchief clip of this invention is generally illustrated by reference numeral 1, and includes a clip frame 2, which is characterized by a shaped base frame 3 and a cooperating pivot frame 9. The base frame 3 includes a base frame handle 4 extending downwardly from the base frame 3 and shaped to define a fulcrum 5, projecting inwardly of the base frame handle 4. A base frame notch 6, is provided adjacent and above the fulcrum 5 in base frame handle 4, in order to accommodate the base frame arm 13 of a tension wire 12, which is more particularly illustrated in FIG. 3 of the drawing. In a most preferred embodiment of the invention the base frame 3 is tapered from base frame handle 4 to define a base frame tip 7, which extends the entire length of the top edge of the base frame 3, as illustrated. The pivot frame 9 is shaped substantially as a mirror image of the base frame 3, and is provided with a pivot frame handle 10 extending downwardly from the pivot frame 9 and shaped to contact the base frame handle 4 at the fulcrum 5. A pivot frame notch 11 is provided in pivot frame handle 10 adjacent the base frame notch 6 in base frame handle 4, in order to further accommodate the base frame arm 13, as hereinafter described.
Referring now specifically to FIGS. 2 and 3 of the drawing, in another preferred embodiment of the invention the pocket handkerchief clip 1 is provided with a cooperating, removable lint pad 18, having a lint pad nipple 17, fitted with nipple threads 19, projecting from the top thereof. Lint pad nipple 17 is positioned for threadable engagement with internal threads [not illustrated] in the handle seat 8, which is secured inside the base frame handle 4, as illustrated in FIG. 3. Accordingly, when lint pad 18 is secured to the base frame handle 4 by means of lint pad nipple 17, the pocket handkerchief clip 1 and lint pad 18 are configured as illustrated in FIG. 2 of the drawing. As further illustrated in FIGS. 1 and 2 of the drawing, a pocket decoration accessory 25, consisting of a pair of accessory tips 26, is positioned between the base frame tip 7 and the pivot frame tip 16, in order to secure the pocket decoration accessory 25 in pocket handkerchief clip 1, as hereinafter described. In a typical embodiment of the invention the pocket decoration accessory 25 can be shaped from a cloth such as the material used to manufacture handkerchiefs, and in an alternative embodiment, a full-sized handkerchief can be folded and placed between the base frame tip 7 and pivot frame tip 16, as desired. However, for purposes of illustration, a pocket decoration accessory 25 which includes single and double decoration tips 26 is referred to in this application in nonexclusive particular, and the term "pocket decoration accessory 25" is used to describe either a handkerchief or a pocket decoration accessory of selected design.
Referring now to FIG. 3 of the drawing, in a most preferred embodiment of the invention the base frame 3 and pivot frame 9 are joined by a tension wire 12, which is fitted through a hollow tension cylinder 15, located in the base frame handle 4. Tension wire 12 is shaped to define an upward and rearwardly extending base frame arm 13, which extends around base frame handle 4 and engages the opposite side of base frame handle 4 from the tension cylinder 15. A clip frame arm 14 extends forwardly of, and around the pivot frame handle 10 of pivot frame 9, as illustrated in FIGS. 1 and 2, such that depression of the pivot frame handle 10 in the direction of the arrows illustrated in FIGS. 1 and 2 causes the base frame tip 7 and the pivot frame tip 16 to diverge as the pivot frame handle 10 pivots on fulcrum 5. This action facilitates the insertion of the pocket decoration accessory 25 between the base frame tip 7 and the pivot frame tip 16, with the bias in base frame arm 13 and clip frame arm 14 serving to press the base frame tip 7 and the pivot frame tip 16 together against the pocket decoration accessory 25 when pressure is released from the pivot frame handle 10. Tension wire 12 can be shaped from a wire stock which is suitably formed with spring tension to permit bending and return to the original configuration without exceeding the elastic limit.
Referring now to FIGS. 4 and 5 of the drawing, in another most preferred embodiment of the invention a thread knife 20 is adjustably and retractably mounted in the interior of the lint pad 18 with the point 21 and blade 22 extending upwardly inside the lint pad nipple 17, as particularly illustrated in FIG. 4. Accordingly, in this embodiment, the point 21 of the thread knife 20 can be grasped and pulled upwardly to extend the blade 22 and the point 21 from the interior of the lint pad 18 and the lint pad nipple 17 to expose the blade 22 and the point 21 and facilitate the isolation and cutting of loose threads from clothing such as the coat or trousers, in nonexclusive particular. Accordingly, since the shank 23 of the thread knife 20 is slidably or retractably engaged in a base [not illustrated] located inside the lint pad 18, the point 21 and blade 22 can be retracted inside the lint pad nipple 17 of lint pad 18 when it is desired to threadably engage the lint pad nipple 17 with the base frame handle 4 of the base frame 3.
Referring now to FIG. 6 of the drawing in yet another preferred embodiment of the invention the lint pad 18 is provided with a lint pad handle 24, which is provided with a handle seat 8 for receiving the nipple threads 19 of the lint pad nipple 17 and securing the lint pad 18 to the lint pad handle 24. In this manner the lint pad 18 can be easily and conveniently used to remove lint from various articles of clothing, as desired. It will be appreciated from a consideration of FIGS. 2 and 3 of the drawing that the lint pad 18 can also be used to remove lint from clothing while attached to the base frame 3, as an alternative feature of the invention.
Referring now to FIG. 7 of the drawing, when it is desired to use the pocket handkerchief clip 1 in cooperation with the lint pad 18 to support a pocket decoration accessory 25, the pocket decoration accessory 25 is initially positioned as desired in the clip frame 2, and the lint pad 18 is threadably connected to the base frame 3 by engaging the nipple threads 19 in lint pad nipple 17 with the internal threads [not illustrated] in the handle seat 8, which is embedded in the base frame handle 4 of base frame 3, as illustrated in FIG. 3. The lint pad 18 is thus securely attached to the base frame handle 4, as illustrated in FIG. 2. The entire pocket handkerchief clip 1 and lint pad 18 combination is then inserted in the pocket 27 of a coat 28, as illustrated in FIG. 7, to support the decoration tip 26 of pocket decoration accessory 25 in extended position from the top of the pocket 27. It will be appreciated by those skilled in the art that the lint pad nipple 17 of lint pad 18 can be threadably inserted in the handle seat 8 to a desired extent which permits the clip frame 2 to be concealed beneath the top edge of the pocket 27 in order to securely support the decoration tip 26 of pocket decoration accessory 25. Furthermore, when it is desired to remove lint from the coat 28 or other clothing, the pocket handkerchief clip 1 and lint pad 18 assembly can be removed from the pocket 27 and the lint pad 18 used to facilitate the removal of lint. If extensive lint removal is necessary, the lint pad 18 can be threadably removed from the base frame handle 4 of clip frame 2 and subsequently threadably inserted on lint pad handle 24, as illustrated in FIG. 6 to clean the garment or garments. Furthermore, in the event that loose threads need to be removed from the clothing, the lint pad 18 can be threadably removed from the clip frame 2 as heretofore described, the thread knife 20 extended from the interior of lint pad 18 and lint pad nipple 17, and the point 21 or the blade 22 used to remove the threads.
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A pocket handkerchief clip which is spring-biased to receive a folded handkerchief or a shaped handkerchief accessory, and is designed to fit into the front pocket of a suit coat, jacket or sport coat for displaying the handkerchief or handkerchief accessory at the top of the pocket. In a preferred embodiment the clip is attached to a lint-removing member or pad which serves to support the clip in the pocket, and the lint pad includes a retractable thread knife for removing loose threads from clothing.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a warhead with a tandem charge, including a fuze for sensing a target. A tandem charge includes a hollow charge which is fixed with respect to a housing, and with a smaller-caliber second-fired or follow-up charge being axially displaceable within a guide tube for the subsequent flight of the second-fired charge. Included are safety devices for the first and second-fired charges, providing for a firing delay for the second-fired charge.
2. Discussion of the Prior Art
A warhead with a tandem charge as set forth hereinabove is generally known from the disclosure of U.S. Pat. No. 4,803,928. In a housing there are arranged a target detector for either impact or proximity, an explosive charge operating on the principle of a hollow charge, a guide housing having an axially guided second-fired charge arranged therein, a propellent charge for the second-fired charge and a detonator for triggering of the hollow charge and of the second-fired charge. The guide housing for the second-fired charge together with the propellent charge thereof is pressure-resistant because of the high pressure exerted thereon by the propellent charge, and consequently possesses a comparatively large weight. This essentially signifies that the warhead is adapted for the destruction of aircraft runways by the explosive charge which produces a bore in the concrete slab of the runway, into which there penetrates the second-fired charge and then detonates therein.
Moreover, German Patent 26 29 280 discloses a warhead designed for deployment against aircraft which are disposed in shelters. That particular warhead incorporates a structure which, in principle, is similar to that disclosed in the above-mentioned U.S. Pat. No. 4,803,928. In that arrangement, however, the second-fired charge which is propelled by a propellent charge is in the form of a fragmentation projectile in order to increase the hitting probability thereof.
The above-mentioned known warheads are not suitable for use in combat areas and against shelters or dugouts which are protected behind barricades or barriers, since in fact the barriers which are constituted from heterogeneous materials are penetrated but, due to the high kinetic energy of the warhead, the latter is either not triggered or detonated too late.
It is readily obvious, that due to new and more stringent target criteria, represented by a barrier or barricade, it is necessary to correspondingly change the sensor device of the fuze. The foregoing then results in the unsatisfactory only partially successful condition that the barrier is admittedly penetrated by the hollow charge; however, the second-fired charge does not produce an effect by virtue of its delayed or post-acceleration.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to provide a projectile for effectively combatting an enemy located under cover; for example, such as a sniper when engaged in house-to-house combat, in respect to which the term cover signifies the walls of houses and buildings, barricades, and protective walls and barriers.
The invention attains its object in that the second-fired or follow-up charge of the tandem charge of the warhead is in the form of a fragmentation projectile adapted to be accelerated in the direction of flight in the absence of a separate propellent charge, solely due to its mass inertia upon impact of the warhead and notwithstanding the detonation of the hollow charge.
At a caliber of 90 mm for the warhead, the hollow charge blows a passage having a diameter of about 50 to 60 mm through a target. The fragmentation projectile passes through that passage into the target and detonates at about 0.5 to 2.5 meters behind the target with an extensive fragmentation effect in the adjoining affected area. The essential consideration is that, by virtue of its mass inertia, upon impact of the warhead against the target, the follow-up charge continues its forward movement almost unretarded by the detonation of the hollow charge. Consequently, there is no need to provide for a separate acceleration charge for the follow-up or second-fired charge. This feature, pursuant to the invention, renders it possible in a simple manner to place the follow-up charge in its intended area of action; in effect, without requiring the expenditure of additional mechanical or pyrotechnic equipment.
In accordance with a specific aspect, the warhead incorporates a piezo-fuze and contact sensor so as to be universally employed both against hard targets for example, masonry, and also against soft targets, such as sand bags or earthworks.
Delayed detonation of the follow-up charge is achieved in a simply manner through the intermediary of a time-delay detonator.
An inexpensive low-weight warhead is provide through the use of aluminum, whereby the warhead can be launched by either mechanized launching equipment and also manually from the shoulder by means of a bazooka.
An inexpensive insert or support for the hollow charge is formed of a flat or shallow cone of aluminum.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference may now be had to preferred embodiments of the invention, as illustrated in the drawings; in which:
FIG. 1 illustrates a longitudinal sectional view of a warhead;
FIG. 2 illustrates a bazooka equipped with the warhead of FIG. 1;
FIGS. 3, 4 and 5 illustrate successive physical phases in the striking of a target by the warhead.
DETAILED DESCRIPTION
A warhead 1 comprises an axially extendable fuze 2, a ballistic cover 3, a cylindrical casing 4 having a cone 5 at its tail end and a receiving case 6, a hollow charge 10 with a safety or safe-and-arm device 11, a second-fired or follow-up charge 20 with a guide tube 21 and support collar 22, and with an apertured plate 23 and a safety device 25 being integrated into the follow-up charge 20 at the tail end including a pyrotechnic time-delay detonator 28.
The fuze 2 is equipped with two sensors 30a and 30b, in a manner diagrametically illustrated in the drawings. One of the sensors is a piezo-sensor for hard targets; for example, such as masonry, and the other sensor is designed for non-hard or soft targets; for example, such as for sandbags, earth, wood or the like. In its transport condition, each sensor 30a, 30b is arranged in a retracted condition in the ballistic cover 3, as shown in FIG. 2. In a combat situation, the sensor is fixed in the extended operative position, as illustrated in FIG. 1. Furthermore, it is also possible to provide the warhead with a proximity fuze.
The hollow charge 10 incorporates a separate housing 12 which is fixedly connected to the casing 4 by means of a coupling ring 13. The safety device 11, an explosive charge 14 and a shallow conical insert or support 15 of aluminum are fixed within the housing 12 of the hollow charge.
The second-fired or follow-up charge 20 comprises a fragmentation casing 26 with an explosive 27 and the safety or safe-and-arm device 25.
As shown in FIG. 2, the warhead 1 which is illustrated in FIG. 1 is adapted to be designed as a bazooka grenade 30 which can be fired from a suitable launching support 29. The bazooka grenade 30 is equipped with a rocket drive assembly 31 and extendable guide vanes 32.
A further embodiment of a grenade 40, as shown in FIG. 3, comprises the warhead 1, including vanes 32 and rocket drive assembly 31.
Upon firing of the warhead 1 in conjunction with the grenade 40, the grenade is accelerated to a launching velocity of about 270 m/s. After a flying distance of five meters, the safety device 11 is armed so that the hollow charge 10 with the follow-up charge 20 is now ready for firing.
When the warhead 1 strikes a target 50, the fuze 2 transmits a firing pulse to the safety device 11. The latter device 11 triggers the hollow charge 10 by means of the explosive 14, resulting in deforming the insert 15 into a pointed member or spike (not shown). When the hollow charge 10 possesses a caliber of 90 mm, the pointed member or spike passes through the target 50 with a speed for the spike point of about 6000 m/sec.; and forms in the target a passage 51 which is about 50 to 60 mm in diameter. The follow-up charge 20 passes through the passage 51 into the target and detonates at location 52 at a distance of about 0.5 to 2.5 meters behind the target, with the generation of an intensive fragmentation effect in the surrounding area. For purposes of initiating the actuation of the follow-up charge 20, concurrently with the firing of the hollow charge 10, there is triggered the delay detonator 28 of the follow-up charge 20. The time-delay detonator 28 fires the follow-up charge 20 subsequently at about a 12 ms delay.
Upon the warhead 1 striking the target 50 at either a right angle or at an inclined angle, there are achieved the following penetrating performances or distances with a fragmentation action by the follow-up charge 20:
Concrete walls, penetrating distance: about 40 cm;
Brick walls, penetrating distance: about 50 cm;
Wood, penetrating distance: about 60 to 80 cm;
Sandbags, penetrating distance: about 50 to 70 cm.
In the case of the presence of wall or window openings, the effect in the target due to the detonation of the hollow charge is encountered in the room behind the wall.
The warhead 1 can be utilized under universal conditions, such as by being employed in conjunction with artillery ammunition or rockets; for example, in a guided anti-tank rocket, such as a MILAN.
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A warhead which may be integrated, for example, in a bazooka, is capable of shooting through a wall protecting an enemy. For that purpose, a tandem charge includes a hollow charge which produces in the wall a firing passage for a follow-up charge. The follow-up charge is in the form of a fragmentation projectile which produces fragments behind the wall.
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